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.

The subject matter of the invention is the method of construction of a linear motor winding, consisting of phase paths, characterised in that a solid flat bar is cyclically bent at a selected binding radius R.sub.1, the active part and the end parts constitute a uniform plane of the phase path, which has got elongated end fragments: the beginning of the section and the end of the section or the phase path is cut of metal sheet, as shown in the figure and then, along the line, separating the end part from the active part, it is bent at the bending radius R.sub.2, where the bend angle α.sub.1 is within the range between 0° and 180°.

A system and method are provided for forming a head portion and a leg portion of a hairpin applied to a hairpin type drive motor. The system includes: an unwinder unit configured to unwind a material coil wound around a bobbin and flatten the material coil by a plurality of flattening rollers; a feeding unit configured to receive the material coil from the unwinder unit and cut the received material coil to a preset length; and a forming unit including a mold device having a plurality of forming blocks and a pair of forming roller units. The plurality of forming blocks are configured to process the material coil supplied from the feeding unit. The forming unit is configured to form the material coil by the plurality of forming blocks and the pair of forming roller units through a driving device connected to the mold device.

The present invention relates to a device, a system and a method for positioning the ends of at least first pair of legs of hairpin conductors extending from a stator core with respect to a welder tool. The device (300) comprises a first clamping element (302) and a second clamping element (303), wherein said first clamping element (302) and said second clamping element (303) are independently moveable radially. Said first clamping element (302) has a first clamping surface (304) and said second clamping element (303) has a second clamping surface (305), wherein the first and second clamping surfaces (304, 305) are radially facing each other. The clamping elements (302, 303) form a first, preferably radially inner, receiving section (306) between the first clamping surface (304) and the second clamping surface (305), having a first radial width (307) dimensioned to axially receive and clamp a first pair (5) of legs during welding, and a second, preferably radially outer, receiving section (308) inside the first and second clamping element, having a second radial width (309), dimensioned to receive at least a further pair (6) of legs during welding of the first pair of legs.

A method of manufacturing a plurality of conductor elements includes providing the plurality of conductor elements, each conductor element includes a conductor end section having an electrically insulating surface coating; securing the conductor end sections of the conductor elements with respect to each other; and simultaneously removing at least a portion of the electrically insulating surface coatings of the conductor end sections using a machining surface of a stripping tool being moved along the conductor end sections.

The unit coil is formed by: bending the coil end portions of the intermediate body such that, in a layer in which a length in an axial direction between the coil end portions is large, positions of the coil end portions projecting furthest from the accommodation portions in the axial direction move away from positions of the accommodation portions in the stacking direction, compared to the previous state; and aligning the positions, in the axial direction, of the coil end portions at an inner side of the annular shape, for each of the layers.

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).

Provided are an alignment method and an alignment device by which, immediately before aligning, the leg parts of adjacent conductors do not interfere with each other. The alignment method, in which by providing a plurality of coil elements (40) in an annular shape and moving the plurality of coil elements (40) in a direction in which the diameter of the annular shape is reduced, the plurality of coil elements (40) are aligned in a state where turn sections (42) provided at substantially apex portions are alternately overlapped, wherein the plurality of coil elements (40) are aligned by moving each of the plurality of coil elements (40) toward an annularly shaped center, and while doing so, rotating the plurality of coil elements about a rotation axis (231e) that is parallel to the central axis (C1) of the annular shape.

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).

The present invention relates to a method and an apparatus for forming a hairpin-shaped winding element from a conductor.