A laser welding method according to this disclosure is a laser welding method for welding first and second coils (members) to each other by applying a laser beam to the first and second coils in a state where the first and second coils are brought into contact with each other. The laser welding method includes: a first step of forming a weld pool by applying a laser beam to the first coil; and a second step of continuing the application of the laser beam to the first coil until the width of a bridge formed between the first and second coils becomes wider than the width of the laser beam, the bridge being formed such that the weld pool is attached to the second coil by growing.

A stator (1) for an electric motor, including; a plurality of pins (11, 12, 13, 14, 21, 22, 23, 24, 31, 32, 33, 34) which are arranged on at least two concentric circles; and an interface (10, 20, 30) with at least one contact face (19, 29, 39), which is connected to two electrically conductive legs (10a, 10b, 20a, 20b, 30a, 30b) and is supported by the legs, wherein the legs are connected to at least one pin on different concentric circles.

The invention relates to a method for producing a coil winding (70) for insertion into radially open slots (82) in a rotor or stator (80) of an electrical machine, wherein the coil winding (70) has a wire pack (60) consisting of a number of wires (32), wherein the wires (32) of the wire pack (60) run parallel to one another and are connected to one another in pairs at one end of the wire pack (60), and wherein the coil winding (70) is formed by a flat winding former which can be rotated about an axis of rotation (26). According to the method, the wire pack (60) is fixed on a winding former (26) and winding heads (42) are produced by displacing fixations of the wire pack (60). The winding shaft (26) can be rotated so that, after carrying out the method, a coil winding (70) is present in the form of a wave winding having wires (32) of the wire pack (60) preconnected in pairs at one end. Such a method allows a particularly space-saving coil winding (70) to be produced, which has a particularly high mechanical stability and requires the least amount of installation space in a rotor or stator (80).

Coil segments of the same phase are inserted into each group of circumferentially consecutive three slots. Assuming that the grouped three slots are A, B, and C, and six groups are U1 to U6, respectively, and that slot y of group Ux are slot Uxy, a coil starting from the slot U1A is wired to pass through one turn of a stator in the order of slots U1A.fwdarw.U2B.fwdarw.U3B.fwdarw.U4C.fwdarw.U5C.fwdarw.U6A, and connected to slot U1A of the next turn. In this turn, coil segments with a wide straddle width are used for the connections of U1A.fwdarw.U2B and U3B.fwdarw.U4C, and a coil segment with a narrow straddle width is used for the connection of U5C.fwdarw.U6A.

A method for manufacturing a stator for a rotary electric machine including: a process of abutting, on each other, tip end parts of one coil piece and an other one coil piece for forming a stator coil of a rotary electric machine; and a welding process of irradiating a welding target location regarding the tip end part having been abutted with a laser beam having a wavelength of 0.6 μm or less, in which in the welding process, the laser beam is generated for every pulse oscillation in a laser oscillator in a mode of having a laser output of 3.0 kW or more, and in at least a part of a period during one pulse oscillation, the laser beam is moved so that an irradiation position changes linearly parallel to an abutment surface of the tip end part.

According to one embodiment, in a method, while supporting as end of an extension part of a coil segment by a flange of a forming jig from the radially outside and pressing an inclined, surface toward the other end surface in an axial direction of the stator core by a pressing part of the forming jig, rotating the stator core in a circumferential direction relative to the forming jig, in order to bend the extension part in the circumferential direction of the stator core such that the inclined surface is positioned to be substantially parallel to the other end surface. Thereafter, joining the inclined surfaces adjacent to each other is the radial direction of the stator core.

A method for manufacturing a stator for a rotary electric machine including: a first disposing process of disposing one workpiece for stator in a first station (ST1); a first welding process of completing welding of a first part of stator coil in the one workpiece in ST1; a second disposing process of disposing an other one workpiece for stator in a second station (ST2); and a second welding process of completing welding of a second part of stator coil in other one workpiece in ST2, wherein first welding process includes first irradiation process of irradiating first part with a laser beam for welding, second welding process includes second irradiation process of irradiating second part with a laser beam for welding, first and second irradiation processes have a time difference, and laser beam used in each of the first and second irradiation processes are generated based on the same oscillator.

There is disclosed a method for manufacturing a stator for a rotary electric machine including: a process of abutting, on each other, tip end parts (40 of one coil piece (52) and an other one coil piece (52) for forming a stator coil (24) of a rotary electric machine (1); and a welding process of irradiating a welding target location regarding the tip end part having been abutted with a laser beam (110) having a wavelength of 0.6 .Math.m or less, in which an output distribution at a focal point of the laser beam has a flat center part.

A stator for a rotating electric machine according to one implementation of the present disclosure includes a stator core having a plurality of slots, and a stator coil formed by electrically connecting a plurality of hairpins inserted into the slots in a preset pattern, wherein the stator coil includes voltage distribution hairpins disposed in a voltage distribution section preset from an end to which power is to be input, wherein the voltage distribution hairpins include a plurality of first and protruding parts protruding from the plurality of slots and extending away from the stator core, wherein one of the plurality of first protruding parts and one of the plurality of second protruding parts are electrically coupled to form a coil pair, and wherein an insulating member is disposed between the first protruding parts and the second protruding parts to insulate between the first and second protruding parts.

In a stator, coils of multiple phases are wound around a stator core via an insulator. A guide member is provided on one side of the stator core in the axial direction and guides the terminal line of the coil in the circumferential direction at a position overlapping the coil in the axial direction. The coils have coils of different systems connected to circuits of different systems. The guide member has a collecting portion that collects the terminal lines of the different systems at one place in the circumferential direction.