A vacuum pressure impregnation process includes placing a room temperature coil/winding into a pressure vessel with a camera aimed at the coil/winding for inspection, and sealing the pressure vessel to draw a first vacuum level, maintained for a first duration. The coil/winding is flooded with resin and remotely monitored. A second vacuum level is maintained for a second duration while remotely monitoring. A first positive pressure level is applied for a third duration while remotely monitoring, before releasing and drawing a third vacuum level, maintained for a fourth duration while remotely monitoring. A second positive pressure level is applied for a fifth duration while remotely monitoring, before releasing pressure and removing the coil/winding from the pressure vessel.

A slot includes a coil housing portion having first and second side portions and a bottom portion. A first straight line connects first and second points which are boundaries between the bottom portion and the side portions. A slot opening has third and fourth points closest to the first and second side portions. A second straight line connects the first and third points. A third straight line connects the second and fourth points. A first region is surrounded by the first straight line and the bottom portion. A second region is surrounded by the second straight line and the first side portion, and is surrounded by the third straight line and the second side portion. A third region is surrounded by the three straight lines. Areas A1, A2 and A3 of the three regions and total cross-sectional areas S1, S2, S3 of coils therein satisfy (S1/A1)>(S2/A2)>(S3/A3).

A rotating electrical machine stator and a method for manufacturing a rotating electrical machine stator with high productivity. A rotating electrical machine stator includes a stator core having a slot; and a coil having a leg part including a held-in-slot part held in the slot and a portion extending from the held-in-slot part, and a resin foam is provided between an inner surface of the slot and an outer surface of the held-in-slot part facing the inner surface of the slot. The coil is formed by joining together a plurality of segment conductors each having a joint part, and a conductive joint material is disposed between a pair of joint parts facing each other in the slot.

An inter-phase insulating paper is inserted, using a guide jig, into slots formed in the inner circumferential surface of a stator core. The guide jig is disposed at a predetermined position on one end surface side of the stator core. The inter-phase insulating paper is inserted into the guide jig along the stator core central axis line. The guide jig deforms the inter-phase insulating paper to a predetermined shape when the inter-phase insulating paper passes through the inside of the guide jig. The guide jig inserts both side portions of the inter-phase insulating paper simultaneously into different two slots of the stator core along the stator core central axis line.

A routing structure of a conductive wire includes: a body portion; a guide portion fixed to the body portion and including a protruding portion protruding to an outside of the body portion; a conductive wire hooked on the protruding portion of the guide portion; and a first insulating portion disposed between the body portion and the guide portion and insulating the body portion and the guide portion.

Provided is a holding device usable when a stator is machined, the stator including a toric stator core, a plurality of coils (see FIG. 1) provided such that coil ends of the coils project from both ends of the stator core in its axial direction, and insulating paper disposed between the stator core and each of the coils. The holding device includes: a core fixture configured to fix the stator core; and a coil-end fixing portion configured to fix to-be-machined coil ends such that the coil-end fixing portion presses the to-be-machined coil ends from the inner side to the outer side in the radial direction of the stator core. A relative position in the axial direction between the stator core fixed by the core fixture and the to-be-machined coil ends fixed by the coil-end fixing portion is fixed.

Systems and methods for forming insulation on magnet wire are provided. An extruder that includes one or more rotating screws may receive a thermoset polymeric material and process the thermoset polymeric material to increase its pressure and temperature. An extrusion crosshead assembly in fluid communication with the extruder may receive the thermoset polymeric material and press extrude the thermoset polymeric material as insulation onto a magnet wire. A curing device may then cure the extruded insulation material.

A method for manufacturing an armature (1) includes: a coil disposing step involving using a thermally expandable resin (Q) that expands by application of heat, and disposing a coil (30) in a core (10) such that the thermally expandable resin (Q) before expansion is disposed between a slot-housed portion (31) and an inner surface of a slot (11); a resin disposing step involving, before or after the coil disposing step, using a thermally melting resin (P) that melts by application of heat, and disposing the thermally melting resin (P) before melting such that the thermally melting resin (P) comes into contact with coil end portions (32); and a heating step involving, after the coil disposing step and the resin disposing step, heating, expanding, and then curing the thermally expandable resin (Q), and heating, melting, and then curing the thermally melting resin (P).

In a method for insulating a coil winding of an active part of a rotating electric machine, the active part is impregnated with an insulating resin in a tub-like impregnation container by vacuum pressure impregnation. The active part is held in the impregnation container, after impregnation with the insulating resin, completely submerged in the insulating resin. The impregnation container together with the active part is introduced into a baking oven, and the active part is set in the insulating resin in rotation about a longitudinal axis of the active part. While the active part is rotating, the insulating resin is purged from the impregnation container and then the oven temperature is increased to a predetermined baking temperature which is maintained for a predetermined baking period. Rotation of the active part is terminated after expiration of the baking period.

The present invention relates to a method of insulating a motor, comprising: providing a impregnating resin; heating up the motor windings with electricity to 100-120° C., and potting the motor windings with the impregnating resin for 2-5 min at that temperature; heating up the motor windings with electricity to 140-160° C., and trickling the impregnating resin for 3-8 min for insulation; heating up the motor windings with electricity to 165-175° C., and curing for 15-45 min. The method of insulating a motor provided by the present invention has a higher resin filling level and a higher resin utilization rate, as well as faster curing speed.