A stator has a stator core composed of teeth and slots. Segment coils are inserted into the corresponding slots. The segment coil projecting from the slot has an exposed conductor part and a covered conductor part covered with an electrical insulation film. The exposed conductor part is arranged at the distal end side from the covered conductor part of the segment coil. The segment coils are connected together through the exposed conductor parts thereof projecting from the slots. The exposed conductor part has a thickness T2 thinner than a thickness T1 of the covered conductor part. A step part is formed at a position of the stator core side, adjacent to the exposed conductor part of the segment coil. The step part and the covered conductor part are covered with the electrical insulation film continuously from the stator core side of the covered conductor part.

In an embodiment a method includes cutting a material coil by a predetermined length, forming a vertex and inclined portions on the material coil, loading the vertex and the inclined portion so as to be interposed between an upper mold and a lower mold, forming the vertex into a front/rear bent portion so that the inclined portions are positioned on different lines based on the vertex by combining the upper and lower molds, loading ends of the inclined portions so as to be interposed between clamping pins and rotating a clamping part so that the inclined portions are rounded in front and rear directions.

A stator includes a stator core and a coil wound around the stator core. The coil includes a basic coil segment including a pair of first legs and a first transition portion disposed on a first end surface side of the stator core, and a transition coil segment including a pair of second legs and a second transition portion. The second transition portion includes a pair of shoulders and a pair of second rising portions. An inclination angle of the second rising portion is larger than an angle of the shoulder with respect to a first end surface, so that the second transition portion is in contact with the first transition portion.

A manufacturing method of a rectangular wire bundle product includes a bending step of bending an assembled wire composed of a plurality of strand wires having an insulating film into a predetermined shape, a rectangular shape formation step of forming the assembled wire bent into the predetermined shape in the bending step into a rectangular shape so that a cross section becomes a rectangular shape, and an integration step of integrating at least a part of the assembled wire formed into the rectangular shape in the rectangular shape formation step by thermal bonding.

A method for manufacturing a coil with an insulating film 130 is provided that includes: a preparation step of preparing a formed workpiece W to which the insulating film has not yet been applied; and an electrodeposition coating step of generating, with the workpiece W immersed in an electrodeposition bath, a potential difference between a first electrode connected to the workpiece W and a second electrode in the electrodeposition bath. In the electrodeposition coating step, the insulating film is simultaneously applied to a portion of the workpiece W and another portion of the workpiece W in such a manner that a film thickness on the portion is thicker than a film thickness on the other portion.

This method for manufacturing a stator includes, after a cross section forming step for forming a sectional shape of a coil portion by compressing the coil portion and a coating step for applying an insulation coating to the coil portion, a common heat treatment step for performing, by the same heat treatment, annealing of the coil portion whose sectional shape has been formed in the cross section forming step and baking of the insulation coating applied to the coil portion in the coating step.

Presented are segmented hairpin bar conductors for electric machines, methods for making/using such segmented bar conductors, electromagnetic motors using such segmented bar conductors, and vehicles equipped with an induction motor generator unit using segmented hairpin bar conductors. An electric machine includes a stator that defines multiple circumferentially spaced, radially elongated stator slots. A rotor is located adjacent and movable with respect to the stator. One or more permanent magnets are mounted to the rotor, and one or more U-shaped hairpin windings are mounted to the stator in juxtaposed spaced relation to the magnet(s). Each hairpin winding is formed from an array of collimated, electrically conductive wires that are bundled together into a unitary bar conductor. The segmented hairpin winding has a pair of hairpin legs, each of which adjoins and projects from a respective end of a hairpin crown. Each hairpin leg inserts into a respective one the stator slots.

An electric machine is disclosed that includes a stator with a winding having a plurality of conductors associated with one or more phases and interconnected with one another. The ends of at least part of the conductors protrudes from the winding, wherein one part of said ends is connected to an interconnecting ring placed axially on the winding and a further part of said ends is connected to a current connection arranged radially outside the winding via connecting conductors. The connecting conductors are fixed to at least one holding element provided on the interconnecting ring.

A device for bending a plurality of winding segments to form a winding of a winding carrier of an electric machine is provided. The device includes: a holding device designed for holding in place the winding carrier in which the winding segments are arranged; a main bending device, including a number of main locking elements, which point towards the holding device, are arranged along first sections of a circumferential line and are designed to lock exposed end sections of first winding segments; and a partial bending device, including a number of partial locking elements, which point towards the holding device, are arranged along second sections of the circumferential line and are designed to lock exposed end sections of second winding segments. The holding device on the one hand and the main bending device and the partial bending device on the other hand are rotatable relative to each other.

A method of manufacturing an armature includes: a step of placing a bonding agent on bonding surfaces of the distal ends of a plurality of segment conductors; a step of placing the plurality of segment conductors on an armature core; a step of bonding the distal ends to each other; and a step of increasing a viscosity of the bonding agent placed on the distal ends, after the step of placing the bonding agent on the distal ends, and before the step of bonding the distal ends to each other.