A stator for an electric machine comprises a cylindrical stator core, windings positioned on the stator core, and an end disc positioned an end of the stator core. The stator core defines an inner diameter and an outer diameter. A plurality of slots are formed in the core and extend radially from the inner diameter toward the outer diameter. The windings include in-slot portions, end turns, and at least one jumper. The end disc defines a plurality of slots aligned with the slots of the stator core and at least one dog hole removed from the slots of the end disc. The at least one jumper is bent circumferentially around the dog hole and connects two of the in-slot portions of the windings.

A method for insulating connection ends of a stator winding includes a resin placing step of placing a resin member formed of a thermosetting resin which is to be melted by heating on connection ends in a coil end portion of a stator winding of a rotary electric machine, a melting step of melting the resin member by heating to cover the connection ends with a melted resin, and a curing step of curing the melted resin after the melting step. Recesses and projections for positioning that correspond to the arrangement locations of the connection ends can be provided on a surface of the resin member.

Provided are a rotary-electric-machine stator coil, a rotary-electric-machine stator having the same, and a rotary electric machine having the same, capable of improving a bonding strength and insulation reliability of a conductor bonding portion. A rotary-electric-machine stator coil includes: a conductor 110 having a bonding portion 104 bonded to other conductors; and a bonding member 401 having a melting point lower than a melting point of the conductor, wherein a tip of the bonding portion has an alloy layer 402 formed of an alloy of the conductor and the bonding member, and a root of the bonding portion is electrically connected by the bonding member.

A processing apparatus for a stator bar of a generator according to an embodiment of the present disclosure may allow a worker to safely and easily perform welding on both ends of a plurality of stator bars to be installed in the generator, thereby improving workability.

A stator of an electric machine having stator slots and conductor elements running through the stator slots in order to form an electric winding is already known, wherein the conductor elements protrude with their conductor ends out from the stator slots and form a winding head at each of the two end faces of the stator, the conductor ends of the conductor elements each having a cabinet portion running in the circumferential direction and a joining portion for contacting another of the conductor elements, each of the joining portions arranged adjacently to one another of two conductor elements being joined, for example welded, by means of a joint and in each case forming a conductor pair, the conductor pairs being arranged in the winding head in a specific radial winding head position in relation to a stator axis. The strength of the joints in the stator according to the invention is dependent on the mechanical connection of each conductor pair to the corresponding winding head. In accordance with the invention, conductor pairs (11) are provided in the winding head (6), the joint (10) of which conductor pairs has a greater strength, in particular a greater weld depth (14), greater seam width or a greater seam cross section (15), than the joint (10) of the other conductor pairs (11).

A winding head arrangement for an electric rotating machine includes a base body including an electrically conductive material having an electrically insulating coating, and a plurality of conductors made from a first metal material and connected to the base body via the electrically insulating coating by a first additive production method.

An electric machine includes a stator core and interconnected hairpins attached to the stator core and defining a path. A pair of the interconnected hairpins have first and second ends, respectively, and are circumferentially spaced apart from each other. A jumper is interconnected between the first and second ends. The jumper has a body defining first and second holes that receive the first and second ends, respectively. The first hole is defined by a perimeter having opposing first and second walls and opposing third and fourth walls.

The present invention relates to a device (100) and a method for widening ends of legs of hairpin conductors arranged in slots of a stator core, and to a device (200) and a method for twisting ends of legs of hairpin conductors arranged in slots of a stator core. The device (100) for widening comprises at least one finger (111), preferably a plurality of fingers (111), for radially moving the ends of legs of hairpin conductors-said at least one finger (111) is arranged moveably in a radial inward and in a radial outward direction. Said at least one finger (111) is arranged moveably in an axial upward and in an axial downward direction. Said at least one finger (111) comprises at least one radially extending arm (101) and a separation member (102) being arranged adjacent to an, preferably radially inner, end of the arm (101). Said separation member (102) is designed for being positioned between two ends (5a, 5b) of radially neighbouring legs of pairs (6, 6′) of hairpin conductors. Said finger (111) has a first, preferably radially inner, section (104) adjacent to the separation member (102). Said first section (104) has a first radial width (114) dimensioned to receive at least one pair (6) of ends of legs and is adapted for moving said pair (6) of end of legs when the finger (111) is radially moved. Said finger (111) has a second, preferably radially outer, section (105), which does not overlap with the first section (104). Said second section (105) has a second radial width (116). Said first radial width (114) is smaller than the second radial width (116), and wherein said second section (105) is dimensioned to receive at least one pair (6) of legs without moving, when the finger (111) is radially moved.

A method for welding a plurality of wire segment pairs is disclosed. Each wire segment pair has two adjacent wire segments, and each adjacent wire segment has a contact region where the wire segment is to be welded to the respective other wire segment. The wire segment pairs are successively guided between two elements of a pressing unit, and at a weld moment in which at least one of the wire segment pairs is located between the two elements. The pressing unit exerts a pressing force onto the wire segment pair such that the contact regions of the wire segments are pressed against each other. At each weld moment, laser radiation is irradiated onto the wire segment pair to which the pressing unit is exerting the pressing force, and the laser radiation is irradiated onto a region in which the contact regions are pressed against each other.

A stator winding structure includes a stator core formed from a stack of a plurality of steel sheets, the stator core comprising a plurality of slots that are circularly arranged in multiple rows around an axis of rotation; a plurality of conductor bars positioned in the plurality of slots; a plurality of first barrier ribs electrically shielding between the plurality of conductor bars contiguous to each other in a radial direction; and a plurality of second barrier ribs electrically shielding between the plurality of conductor bars contiguous to each other in a circumferential direction; and a pair of end-turn members disposed at axial ends of the stator core and coupled to the conductor bars; wherein the plurality of conductor bars are arranged within the stator core by a casting process including die casting.