A wire forming apparatus comprises a first rack moveable relative to a second rack in a first direction, a plurality of first forming structures provided on the first rack, and a plurality of second forming structures provided on the second rack. Each of the plurality of first forming structures is configured to move in the first direction, is separated from an adjacent first forming structure, and is configured to move in a second direction closer to the adjacent first forming structure when the first rack moves relative to the second rack. Each of the plurality of second forming structures is configured to move in the first direction, is separated from an adjacent second forming structure, and is configured to move in the second direction closer to the adjacent second forming structure when the first rack moves relative to the second rack. The second direction is different from the first direction.

In an armature coil according to the present invention and, more particularly, in an armature coil including a plurality of coil conductors wound around a plurality of slots which are formed in a stator core and opened on the radially inner side, the circumferential width of the plurality of the coil conductors is formed in a substantially trapezoidal shape which gets narrower toward the radially inner side and the cross-sectional areas of the plurality of the coil conductors in the slot are each substantially the same and the circumferential width thereof is formed narrower as the coil conductor is arranged toward the radially inner side; and one coil conductor is formed in a convex shape and another coil conductor is formed in a concave shape along the convex shape.

A coil segment forming apparatus includes a second bending section for bending a first bent body consisting of a pair of slot insertion portions that are substantially parallel to each other and a linking portion for connecting the pair of slot insertion portions formed in the same plane. The bending of the first bent body is carried out in a plane perpendicular to the aforementioned same plane. The second bending section has a plurality of pairs of press jigs arranged to oppose to each other in directions intersecting with the aforementioned same plane for pinching and pressing the linking portion, and a plurality of drive mechanisms for moving respectively the plurality of pairs of press jigs in directions intersecting with the aforementioned same plane based on moving amounts respectively set depending on forming conditions of the coil segment to be formed.

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, including 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.

An object of the invention is to provide a method for manufacturing a stator of a rotating electric machine that can reduce the size of a coil end. According to the invention, a method for manufacturing a stator, which includes a stator core and a stator coil to which ends of a plurality of substantially U-shaped segment coils inserted into slots of the stator core are connected, includes twisting the end of the segment coil using a twisting jig 600. In the twisting, in a state in which the end of the segment coil is inserted into a groove portion 610 of the twisting jig, an edge portion 620 forming a part of the groove portion 610 is used as a twisting fulcrum, and a load is applied to the segment coil to forma press trace of the edge portion on the segment coil.

Provided is a stator manufacturing method including: inserting a plurality of segment coils into a plurality of slots formed in a stator core; bending arms of the segment coils that protrude from the stator core, in a circumferential direction of the stator core; before or after bending the segment coils in the circumferential direction, directing parallel to each other leading end portions of the segment coils that are adjacent to each other in a radial direction of the stator core; and welding together the leading end portions of the segment coils with the leading end portions directed parallel to each other.

A stator for a rotating electrical machine includes a stator coil and a stator iron core having slots into which the stator coil is mounted, wherein a coil end of the stator coil is elliptical in shape around a center axis of the stator iron core.

An electric machine includes a stator having a winding, and at least one temperature sensor for detecting the temperature in the region of the winding. The temperature sensor is arranged on an elongate support that is elastic at least in the region of the temperature sensor. The support is placed in an elongate recess which is open to at least one of the sides of the windings and the temperature sensor is pressed into thermal contact with the winding by the support.

A method of manufacturing a coil includes a preparation step of preparing a copper wire, a winding step of winding a plurality of aluminum wires around the copper wire, and a pressing step of pressing the copper wire and the plurality of aluminum wires so as to form an aluminum coat around the copper wire and form an anodized aluminum film on the surface of the aluminum coat.

A system for manufacturing a stator assembly having a stator core that includes slots and coils inserted into the slots includes a core loader, an insulation sheet inserter at a rear of the core loader to insert an insulation sheet into the slots, a coil former at a rear of the insulation sheet inserter to form the coils by bending, a preliminary aligner along the coil former to align the coils into a dummy core, a coil inserter at a rear of the insulation sheet inserter and connected to the preliminary aligner to insert the coils into the slots of the stator core, a coil winder at a rear of the coil inserter to twist end portions of the coils inserted into the stator core, and a varnish impregnator at a rear of the coil winder to impregnate varnish into the slots.