A motor according to the present invention includes: a stator core that surrounds an outer circumference of a rotor, and that includes: a yoke portion; and a plurality of tooth portions in which tip portions protrude radially inward toward a central axis of the rotor from an inner circumferential surface of the yoke portion; a heat sink that is disposed so as to face a first end surface of the stator core in an axial direction of the stator core; a stator coil that includes phase coil portions that are configured using conducting wires that are mounted to the stator core; and a coil fixing member that is disposed on coil end portions of the phase coil portions, that fixes the coil end portions in a state of surface contact with the heatsink.

Described is a method for producing a stator, in particular for electric motors. In a first step, a plurality of flexible electrical conductors are combined to form a conductor bundle. In a second step, two end regions of the conductor bundle are pressed in such a way that a central region of the conductor bundle formed between the two end regions remains flexible. Also described is a corresponding stator.

In order to provide a rotary electric machine with a reduced size and improved weldability, the stator of a rotary electric machine has a segment coil formed by bending rectangular conductors, and a stator core having slots in which the segment coil is inserted. As for the weld parts formed at the tips of the lead parts of the segment coil which protrude from the end face of the stator core and are twisted together, at least one of the weld beads aligned in the radial direction of the stator is an oblong body that is long in the radial direction of the stator core, and the angle formed by the longitudinal direction of the oblong body and the axial direction of the stator core is less than 90 degrees in a core cross section that includes the central axis of the stator core.

A stator coil includes a plurality of flat wire-shaped coil pieces extending in a circumferential direction of a rotary electric machine at a position on an outer side of a stator core in an axial direction of the rotary electric machine. At the position on the outer side of the stator core in the axial direction, a distal end portion of one of the coil pieces, extending in a first direction in the circumferential direction, is joined with a distal end portion of another one of the coil pieces, extending in a second direction in the circumferential direction. The second direction in the circumferential direction is reverse to the first direction in the circumferential direction. An axially outer end face of the distal end portion of each coil piece is a circular arc face that is convex toward the outer side in the axial direction.

Method and station for the construction of a stator winding with rigid bars for a rotary electrical machine; an insulated wire of electrically conductor material and provided on the outside with an insulating layer is unwound from a coil. A final end of the insulated wire is bent in a U shape so as to create a bar having two legs connected to one another by a cusp. The insulated wire is transversely cut to separate the rigid bar from the remaining part of the wire; and the bar is inserted into a stator slot of a magnetic core of a stator. The electrical conductivity is measured between the core and the outer surface of the insulated wire by means of a first electrode electrically and permanently connected to the core of the insulated wire and a second electrode, which rubs against the outer surface of the insulated wire.

In an armature coil according to the present invention and, more particularly, in an armature coil including a plurality of coil conductors wound around a plurality of slots which are formed in a stator core and opened on the radially inner side, the circumferential width of the plurality of the coil conductors is formed in a substantially trapezoidal shape which gets narrower toward the radially inner side and the cross-sectional areas of the plurality of the coil conductors in the slot are each substantially the same and the circumferential width thereof is formed narrower as the coil conductor is arranged toward the radially inner side; and one coil conductor is formed in a convex shape and another coil conductor is formed in a concave shape along the convex shape.

A cutting, leveling, and welding device for a flat wire motor stator includes a material conveying line, a material transfer mechanism, a material conveying rotating disk, a tooling picking and placing mechanism, a pressing and fitting mechanism, a wire cutting mechanism, a welding mechanism, a locking mechanism, and a stator adjustment mechanism. The material conveying rotating disk is provided with working position holes arranged around the material conveying rotating disk, and the material conveying rotating disk is capable of rotating to drive a to-be-processed stator to rotate. The tooling picking and placing mechanism, pressing and fitting mechanism, wire cutting mechanism, and welding mechanism are arranged in sequence around and above the material conveying rotating disk and are corresponding to the working position holes. The to-be-processed stators on the material conveying line are continually conveyed to the material conveying rotating disk by using the material transfer mechanism.

A method and arrangement is disclosed herein for making a stator with 3D printed end turns. The stator includes a stator lamination stack with semi-closed slots. Straight I-pin wire segments are housed in the slots of the stator lam stack and form the in-slot segments of a stator winding arrangement. The end turns of the winding arrangement are provided by a conductive material that is 3D printed material at both axial ends of the straight I-pins. The end turns result in a winding arrangement with diamond coils that are inter-locked. The 3D printing of the end turns makes the winding arrangement possible, as the winding arrangement is configured such that it cannot be inserted into the lamination stack in a radial direction (i.e., via any slot openings at the inner diameter or outer diameter).

Provided are an insertion method and an insertion apparatus for efficiently and reliably inserting a plurality of coil elements aligned in a ring shape into respective slots of a stator core. In an insertion method of inserting, the insertion method includes a coil element alignment process S3 of forming an assembly body 50 by assembling the plurality of coil elements 40 in a ring shape in the state where the turn portions 42 alternately overlap each other, a supporting process S42 of supporting the assembly body 50 by using the turn portions 42, and an insertion process S45 of allowing the assembly body 50 and the stator core 60 to be close to each other and inserting the leg portions 41 of the coil elements 40 of the assembly body 50 into the slots 61.

A process and a system for welding rotor coils are presented. A plurality of rotor coils are arranged on a table of a machine. A welding tool welds the rotor coils on one end using a Friction Stir Welding process. Transition pieces are each arranged between the rotor coils to create a continuous welding path. A run-off tab is placed at an end of the welding path. The welding tool is changed to a milling tool after completion of the welding. The milling tool traces back along the welding path to separate the rotor coils. The milling tool may be changed to the welding tool to repeat the process for another end of the rotor coils. The process is completely automatic and controlled by a control unit.