An object of the present invention is to suppress reduction of insulation reliability between stator coils. A method of manufacturing a rotary electric machine according to the present invention is a method of manufacturing a stator including an insulating member intervening between a plurality of coil end portions each protruding from a stator core, the method including: a first step of disposing an interposed member to cover part of the insulating member between the plurality of coil end portions; and a second step of welding part of each of the plurality of coil end portions.

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.

A hollow portion is formed in a holding jig. A first projection protrudes from a first inner side wall of the hollow portion. As the holding jig rotates to twist and bend a leg portion of a conductor, the projection bites into the leg portion.

A bending apparatus (10) includes an upper first die (11), an upper second die (12), a lower die (13), a control unit (20), an upper first moving mechanism (21), an upper second moving mechanism (22), a lower moving mechanism (23), a holding die (31), and a moving and rotating mechanism (32). The lower die (13) is moved in an upper direction after the upper first die (11) and the upper second die (12) are moved to the front, whereby four coil segments (4) are bent. When the upper second die (12) is moved to a first withdrawal position in the rear direction after the four coil segments (4) are bent, a working space for the holding die (31) is ensured.

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 coil unit and a manufacturing method of the same are provided which simplify the connection structure at the end portion of a coil to reduce the size of a stator, and minimize the work environment (equipment and work regions) when mounting the coil on the stator, and make it possible to perform efficient mounting work. A terminals-welded coil unit includes a coil made of a first metal material, and a terminal made of a second metal material connected to an end portion of the coil. A welded portion between the end portion of the coil and the terminal is configured by pressure welding with end surfaces butted against each other.

An object is to provide a stator coil having a corner portion with less start points for partial discharge while reducing loss. A stator coil having a conductor bar includes, at a corner portion thereof: a first insulating layer covering an outer periphery of the conductor bar; an electric conductor having one end electrically connected to the conductor bar on a distal end side of the corner portion, and another end placed on an outer surface of the first insulating layer; a first conductive layer covering an outer periphery of the first insulating layer and the electric conductor located on the outer surface of the first insulating layer; a second insulating layer covering an outer periphery of the first conductive layer; and a second conductive layer covering an outer periphery of the second insulating layer.

A rotor coil for a revolving armature includes a strand coil that includes a part arranged in a core slot of the rotor and is composed of a plurality of element wires; and a solid coil welded to an end of the strand coil wherein the end of the strand coil and an end of the solid coil are welded by friction stir welding. A manufacturing method of a rotor coil includes the step of performing friction stir welding wherein the friction stir welding is performed for the butt joint with the end of the strand coil arranged in an advancing side defined by a rotation direction of a tool and with the solid coil arranged in a retreating side.

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.

An electric machine includes a stator core defining slots having radial layers that each include adjacent first and second pin positions. Pins are disposed in corresponding ones of the slots and are interconnected to form a winding path. The path occupies the first and second positions of each layer, and, for each of the corresponding slots, the pins are in a same layer.