The reliability of a rotating electrical machine is improved. A method for manufacturing a stator used in a rotating electrical machine includes: a first step of arranging a first segment coil and a second segment coil to face each other; a second step of processing the first segment coil to generate a bridge part that comes into contact with the second segment coil; and a third step of joining the bridge part and the second segment coil by laser welding.

The invention relates to a device for cutting to length conductor pieces, in particular hairpins, received in a stator core, including a receptacle for the stator core together with the conductor pieces received therein, the free ends of which protrude out of the stator core when in the received state, in particular in the direction of gravity, and a cutting unit which comprises cutting portions that are designed and arranged such that they can be moved toward one another in order to act in a cutting manner from two opposing sides on at least one conductor piece to be cut to length, and the longitudinal axis thereof, during a cutting process.

A welding method for welding grouped conductor ends of a component for an electrical machine by means of a welding device. In the method, a relative position of a first conductor end and a second conductor end of grouped conductor ends and then a first size parameter of a molten pool formed during welding are detected. Subsequently, a second size parameter of the molten pool formed during welding is detected. In a further method step, a value of the molten pool is determined from the first size parameter, the second size parameter and the relative position. Finally, a welding energy input is controlled depending on the determined value of the molten pool.

First-fourth slots may be provided in an inner circumferential surface of a stator core. A coil may include first-third segments conductor. Each of the conductors may include a U-shape. The first segment conductor may be inserted in the first slot and the second slot in a state where a coupling portion of the first segment conductor is located at a position facing a first end surface. The second segment conductor may be inserted in the second slot and the third slot in a state where a coupling portion of the second segment conductor may be located at a position facing a second end surface. The third segment conductor may be inserted in the third slot and the fourth slot in a state where a coupling portion of the third segment conductor may be located at a position facing the first end surface.

A stator may include a stator core and a coil. The stator core may include: a first portion; a second portion; and a first intermediate portion interposed between the first portion and the second portion in the axial direction. A first segment conductor and a second segment conductor may overly each other in a circumferential direction of the stator core hr a slot within an area of the first intermediate portion. A first side surface may include a first protrusion provided by the first intermediate portion protruding with respect to the first portion and the second portion. The first segment conductor and the second segment conductor may be held between the first protrusion and a second side surface such that the first, segment conductor and the second segment conductor are connected with each other.

A bent conductor segment (1a, 1b, 1c) for a stator winding of a stator of an electric machine is formed from a bent metal wire and has at least one first straight section (10a, 10b, 10c) with a first free end (11a, 11b, 11c) and a second free end (13a, 13b, 13c). One of the free ends (11a, 11b, 11c, 13a, 13b, 13c) of the conductor segment (1a, 1b, 1c) comprises a hard solder (2a, 2b, 2c) cohesively connected to said free end (11a, 11b, 11c, 13a, 13b, 13c).

Disclosed is a stator (2) comprising a stator body (25) having notches (21) formed between teeth (23), electrical conductors (22) being housed in the notches (21), at least one part of the electrical conductors being in the form of a U-shaped pin, each comprising first (22c) and second (22f) axially extending legs in the first (A) and second (R) notches, respectively, at least one of the first (22e) and second 22f) legs of the electrical conductors (22) extending out of the notches via an inclined welding portion, at least one part of the electrical conductors each having a welding portion, innermost with respect to the longitudinal axis of the stator, the innermost welding portions being inclined with the same inclination with respect to the plane perpendicular to the longitudinal axis of the stator.

The invention relates to an apparatus and a method for reshaping one or more conductor pieces arranged in a stator core, wherein a plurality of conductor pieces is arranged in the stator core, the conductor pieces being arranged on a plurality of circular paths running in a circumferential direction in rows which extend in a radial direction, and wherein the reshaping takes place in a free end of the conductor piece projecting out of the stator core.

The invention relates to an apparatus and a method for shaping one or more conductor pieces arranged in a stator core, wherein the conductor piece is a hairpin with two elongate legs and a connection portion connecting these two legs, wherein a large number of conductor pieces is arranged in the stator core, which conductor pieces are arranged in rows extending in a radial direction on a plurality of circular paths extending in a circumferential direction, and wherein the shaping takes place in a free end of the conductor piece that projects from the stator core.

The invention relates to a method for welding a plurality of strands (33) of one or more electrical conductors (22), comprising at least the following steps: (a) preparing the strands (33) to be welded such that at least the free ends (22a) of adjacent strands are axially offset by a non-zero distance d. (b) melting the free ends (22a) of the strands thus arranged in order to weld them without addition of material.