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.

Provided is a rotating electric machine capable of downsizing a coil end. The rotating electric machine includes an armature core and a plurality of coils. The plurality of coils each include a plurality of turn portions. The plurality of turn portions each include an inner-layer-side turn portion and an outer-layer-side turn portion. The inner-layer-side turn portion includes a first inner-layer-side bent portion, a first inner-layer-side oblique portion, and an inner-layer-side shift portion which is twisted. The outer-layer-side turn portion includes a first outer-layer-side bent portion, a first outer-layer-side oblique portion, and an outer-layer-side shift portion. The outer-layer-side shift portion has the inner-layer-side shift portion arranged between the outer-layer-side shift portion and the armature core.

A segment coil forming apparatus is a segment coil forming apparatus for forming a segment coil from a wire rod, the segment coil including a projection portion, shoulder portions provided in both side portions of the projection portion, and end portions extending from the shoulder portions in a direction reverse to a direction where the projection portion projects. The segment coil forming apparatus includes: a first forming die including a first projection forming portion corresponding to the shape of the projection portion; and a second forming die including a second projection forming portion corresponding to the shape of the projection portion.

The method and apparatus comprise the following features: —forming coil members (21) by bending an electric conductor (20) externally coated with an outer insulation (20′); wherein the bending is made at predetermined lengths from a reference position (16′), and wherein each one of the coil members (21), when formed, comprises at least one head portion (21′) and leg portions (21″) extending from said at least one head portion (21′); —feeding the electric conductor (20) to accomplish the bending; —cutting the electric conductor (20) to detach a formed coil member (21) from said electric conductor (20); —inserting the leg portions (21″) of the coil members (21) into slots of the stator, so that parts of said leg portions (21″) extend from one end of the stator and the head portions (21′) extend from an opposite end of the stator; —arranging at least one laser beam (13′a, 13′b) to remove the insulation (20′) from predetermined areas (20a, 20b) of the electric conductor (20); —radiating the surface of the electric conductor (20) with said at least one laser beam (13′a, 13′b) situated at a predetermined position (IP, 2P) with respect to the reference position (16′) along the length of the electric conductor (20) being fed, and at a predetermined stage of the bending of a coil member (20).

To simplify a commissioning and parameter change in a 3D bending process of wires, a 3D bending device and a 3D bending method for bending a wire are provided. The wire is held by a first leg and a second leg and the legs are moved, via a first to third relative movement device, in a first to third relative movement with a first to third movement axis in order to change, in an adjustable manner independently of one another, torsion angles of the first and second legs and a distance between the central axes of the legs.

A hairpin type of stator coil forming apparatus includes a first forming machine configured to form a vertex in a material coil so that a central portion of the material coil protrudes upward, and to form inclined portions inclined to both sides of the vertex, a second forming machine configured to receive the material coil bent-formed by the first forming machine and to form a front/rear bent portion in the material coil by bending one inclined portion and a portion of the other inclined portion based on the vertex, and a third forming machine configured to receive the material coil bent-formed by the second forming machine and to roundly form the inclined portions in front and rear directions.

An electric machine includes a stator core and a hairpin winding. The stator core defines slots that are circumferentially arranged between an inner diameter and an outer diameter of the stator core. Each slot has a plurality of pin positions that is arranged in a direction that extends from the inner diameter toward the outer diameter. The hairpin winding has a plurality of paths of interconnected hairpins that correspond to a first electrical phase of the electric machine. The hairpins are arranged to occupy a portion of the pin positions according to a pattern that repeats at angular intervals along a circumference of the stator core. The pattern includes hairpins occupying each pin position within a first of the slots, harpins occupying exactly half the pin positions within a second of the slots, and harpins occupying exactly half the pin positions within a third of the slots.

The invention relates to a device for bending at least one conductor element which is U-shaped in an initial state, wherein the device includes a first pivot unit having a first limb-receiving means, a second pivot unit having a second limb-receiving means and a guide assembly comprising a first guide element having a first shaping surface and a second guide element having a second shaping surface, and a corresponding method for bending at least one conductor element which is U-shaped in an initial state.

A method and an apparatus are provided for manufacturing a stator with a plurality of hairpin conductors. For inserting the hairpin conductors (15, 15) into the slots (11) of a stator core (12) a stator core template (22) is provided. Hairpin conductors (15) are axially inserted into slots (21) of the stator core template (22) such that the hairpin conductor (15) is arranged at a first position (P1) within said slot (21). The hairpin conductor (15) is then moved within said slot (21) to a different position (P2). A complete nest (20) of hairpin conductors (15) formed within the stator core template (22) is then transferred to the stator core (12).

A stator assembly of a hairpin winding motor capable of improving the performance of the winding motor and the insulation performance of a hairpin coil, and includes a stator core through which a plurality of slots pass in a circumferential direction; and a plurality of hairpin coils respectively fastened to and interconnected with the slots to form a coil winding. The hairpin coil includes a head portion bent in a U shape and exposed to the outside of the stator core, and a pair of leg portions configured to extend in parallel from both ends of the head portion to be inserted into a specific slot and the slot spaced apart from the specific slot by one pole pitch and of which end portions are exposed to the outside of the stator core.