A method for producing an active part (1) for a rotary electric machine (101), comprising the following steps: providing a core (2) for the active part (1) and shaped conductors (6) inserted into the core; joining together, in each case, two of the end areas (9) so that the two end areas (9) form a pair (10); and welding each pair (10) of the end areas (9) by means of a laser beam which is guided on the end areas (9) of the pair (10) along a first trajectory (13).

A method for producing an active part (1) for a rotary electric machine (101), comprising the following steps: providing a core (2) for the active part (1) and shaped conductors (6) inserted into the core; joining together, in each case, two of the end areas (9) so that the two end areas (9) form a pair (10); and welding each pair (10) of the end areas (9) by means of a laser beam which is guided on the end areas (9) of the pair (10) along a first trajectory (13).

The invention relates to a stator (2) comprising an annular body (4) having a side face (6) from which a plurality of radial teeth (8) extend, said teeth being angularly spaced in such a way as to define slots (10), and a plurality of conductive needles (15A, 15B), each conductive needle comprising two conductive segments (16A, 16B, 16C, 16D) connected by an elbow connector (18), the conductive segments being stacked one above the other in the slots (10) so as to form N layers which are parallel or substantially parallel to the side face (6) of the annular body. Each conductive needle (15A, 15B) comprises a conductive segment present in two separate slots, with one conductive segment present in a slot E in such a way as to occupy a layer (Ci) and another conductive segment present in a slot E+P in such a way as to occupy a layer (Ci+2), P being a pitch that is predetermined in a first direction of orientation.

The invention relates to a stator (2) comprising an annular body (4) having a side face (6) from which a plurality of radial teeth (8) extend, said teeth being angularly spaced in such a way as to define slots (10), and a plurality of conductive needles (15A, 15B), each conductive needle comprising two conductive segments (16A, 16B, 16C, 16D) connected by an elbow connector (18), the conductive segments being stacked one above the other in the slots (10) so as to form N layers which are parallel or substantially parallel to the side face (6) of the annular body. Each conductive needle (15A, 15B) comprises a conductive segment present in two separate slots, with one conductive segment present in a slot E in such a way as to occupy a layer (Ci) and another conductive segment present in a slot E+P in such a way as to occupy a layer (Ci+2), P being a pitch that is predetermined in a first direction of orientation.

Provided is a device for manufacturing a stator, the device including a winding jig configured to wind a coil and to manufacture a winding coil, and an insertion jig configured to receive the winding coil from the winding jig and to insert the winding coil into a stator core, wherein the winding jig comprises a body extending along a longitudinal direction (L1), a power supply unit configured to make the body revolve around a central shaft of the body, and a protrusion formed on a surface of the body.

Provided is a device for manufacturing a stator, the device including a winding jig configured to wind a coil and to manufacture a winding coil, and an insertion jig configured to receive the winding coil from the winding jig and to insert the winding coil into a stator core, wherein the winding jig comprises a body extending along a longitudinal direction (L1), a power supply unit configured to make the body revolve around a central shaft of the body, and a protrusion formed on a surface of the body.

Systems and methods for manufacturing stators for electric submersible pumps, where a stator core having an inner portion and an outer portion is formed. The inner portion has a plurality of teeth and outward-facing slots. Magnet wire coils are formed on the inner portion by holding the inner portion in a stationary position and using a linearly movable robotic arm to position the magnet wire in each slot while preventing the wire from sliding axially with respect to the stator and adjacent turns of the coil. After forming the magnet wire coils on the inner portion of the stator core, the outer portion of the stator core is press-fit onto the inner portion to close the slots. The magnet wire can thereby be positioned to maximize the fill factor of each slot and increase power density for a given temperature rise.

Systems and methods for manufacturing stators for electric submersible pumps, where a stator core having an inner portion and an outer portion is formed. The inner portion has a plurality of teeth and outward-facing slots. Magnet wire coils are formed on the inner portion by holding the inner portion in a stationary position and using a linearly movable robotic arm to position the magnet wire in each slot while preventing the wire from sliding axially with respect to the stator and adjacent turns of the coil. After forming the magnet wire coils on the inner portion of the stator core, the outer portion of the stator core is press-fit onto the inner portion to close the slots. The magnet wire can thereby be positioned to maximize the fill factor of each slot and increase power density for a given temperature rise.

A stator manufacturing apparatus includes an insertion tool that is insertable into a stator core and being configured to dispose a pair of side parts of a stator coil in two holding grooves. A pressing tool has plate-like pushers arranged to correspond to the positions of the holding grooves. The pressing tool pushes out the side parts of the stator coils and inserts the side parts into the corresponding slots. A pair of shaping tools face coil end parts of the stator coils. A plurality of slits through which the pushers are insertable are provided in a principal surface of each shaping tool. A shaping tool moving unit shapes the coil end parts by pressing the pair of shaping tools in an axial direction with the pushers inserted in each of the corresponding holding grooves.

A stator manufacturing apparatus includes an insertion tool that is insertable into a stator core and being configured to dispose a pair of side parts of a stator coil in two holding grooves. A pressing tool has plate-like pushers arranged to correspond to the positions of the holding grooves. The pressing tool pushes out the side parts of the stator coils and inserts the side parts into the corresponding slots. A pair of shaping tools face coil end parts of the stator coils. A plurality of slits through which the pushers are insertable are provided in a principal surface of each shaping tool. A shaping tool moving unit shapes the coil end parts by pressing the pair of shaping tools in an axial direction with the pushers inserted in each of the corresponding holding grooves.