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).

A method and apparatus for inserting an undulated coil assembly (90) in the hollow core (101) of a dynamoelectric machine, the coil having a planar configuration with adjacent superimposed linear portions (LI) extending parallel to each other and a plurality of turn portions (T) connecting the linear portions (LI), comprising positioning at least a first coil portion (90′) of the coil assembly around a support member (200); aligning a guide assembly (302,303,304) with respect to the end faces and the slots (102) of the core (101); engaging the superimposed linear portions (LI) along guide surfaces that form a passage (301) during the feeding along the guide assembly (302,303,304); feeding the first coil portion (90) from the support member (200) along the guide assembly (302,303,304) to change orientation of adjacent superimposed linear portions (LI) being fed and to insert the adjacent superimposed linear portions being fed in the slots (102); relatively moving the core (101) with respect to the guide assembly (302,303,304) to position the slots (102) for receiving the superimposed linear portions (LI). A hollow core of a dynamoelectric machine wound with an undulated coil assembly comprising superimposed linear portions positioned at different pitch distances (PT1,PT2) in two adjacent slots (102).

A stator winding includes a plurality of conductors including ducts. The ducts can be connected to a heat pipe or a conduit providing a coolant flow to directly cool the winding. The heat pipe can be connected to a heat exchanger that includes a coolant flow. The stator winding can be produced using additive manufacturing, with hollow ducts extending through leg sections and solid end sections. The heat exchanger can also be additively manufactured. A circuit for driving an electrical machine can be in thermal communication with the heat exchanger, such that the thermal system manages both the stators and the drive circuit.

A processing apparatus for a stator bar of a generator according to an embodiment of the present disclosure may allow a worker to safely and easily perform welding on both ends of a plurality of stator bars to be installed in the generator, thereby improving workability.

The cold pressure welding apparatus includes a first holding part capable of sandwiching a first flat conductor, a second holding part disposed opposite to the first holding part and capable of sandwiching a second flat conductor, and a drive part for moving the first holding part and the second holding part. The drive part can move the first holding part and the second holding part between a first direction separated position and a close position along a first direction. The drive part can move the first holding part and the second holding part between a second direction separated position and a sandwiching position along a second direction.

Certain aspects relate to a continuous winding formed from a conductor of rectangular cross-section, the winding having a compound bend in the crowns connecting successive linear segments where the compound bend does not stress the conductor insulation to its failure point. The compound bend can be formed by applying force to the conductor in a first direction, thereby shaping a first bend in the conductor to form a u-shaped conductor having a crown and two linear segments, where the crown includes a v-shaped bend and two straight segments on either side of the v-shaped bend that each connect to one of the linear segments. A second bend can be formed by applying force to the conductor in a second direction perpendicular to the first direction. The shape of the second bend can depend on the desired radius of the winding when circularly wound and positioned in a stator.

The invention relates to a stator for an electric machine, comprising a plurality of rod conductors and a plurality of interconnection pieces. The interconnection pieces each have a curved shape, in particular the shape of a C, extending in the radial direction and about the axis of rotation of the stator; in order to form respective interconnection planes along the axis of rotation, each group of interconnection pieces is arranged in the region of at least one short end of the rod conductors of the associated group of rod conductors that are to be electrically connected. The invention further relates to a connection component and an electric machine.

Generator stator bar having profile strip and process for manufacturing a generator stator bar are presented. The generator stator bar includes stator bar strands assembled together. The profile strip is placed on top side and bottom side surfaces of the stator bar strand assembly. The profile strip includes uncured strip consisting of uncured material. The profile strip includes pre-cured strip consisting of pre-cured material. The pre-cured strip includes cavities perforated through its thickness. The profile strip enables the generator stator bar to be manufactured by a single press and heat operation to achieve a rectangular geometry having round outer edges and to maintain orientations of stator bar strands parallel to the profile strip.

A method for producing a form-wound coil for fitting into a laminated stator core of a synchronous generator of a gearless wind turbine, comprising the steps of cutting out at least one first flat strip conductor from a metal sheet with a first slot-strip portion, for inserting into a first slot of the laminated core, cutting out at least one second flat strip conductor from a metal sheet with a second slot-strip portion, for inserting into a second slot of the laminated core, and angling away the first and/or second cut-out strip conductor in such a way as to create an angled-away winding head portion, for connecting the first and second slot-strip portions.

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.