A bending unit for bending a bend of a wave winding for a coil winding of an electric machine, having a first holding element for holding a first segment of a wire to be bent, a second holding element for holding a second segment of the wire to be bent and at least one bending mold for bending a transition region of the wire between the first segment and the second segment. The first and the second holding elements are in engagement with each other via at least one mechanical control cam to control a relative pivoting and a relative displacement of the first and the second holding element. Furthermore, a bending device having a plurality of such bending units, a wave winding production apparatus having a plurality of bending units which are synchronized via control cams, and a bending method and a wave winding production method are described.

A winding mat arrangment which is provided as a stator winding for a stator, has at least two winding mats which cross one another. A method for producing a stator is also provided.

A stator includes: a stator core including teeth; pins including a working portion extending in an axial direction in a slot between the teeth; and bus bars electrically connected to the pins. In each slot, the working portions are disposed over stages in a radial direction. The pins include the two working portions disposed across the teeth, a first pin and a second pin each including a connection portion connecting the working portion in a circumferential direction, and a third pin connected to the bus bar. Each of the working portions of the second pin and the third pin is disposed in one of an outermost stage and an innermost stage of the slot. A number of teeth straddled by the second pin is smaller than a number of teeth straddled by the first pin.

A strip-shaped winding unit for a stator winding has a first winding conductor, which is led in a plurality of layers of the winding unit and includes: a. a plurality of straight groove portions which run in a transverse direction of the winding unit and are arranged mutually parallel; b. a first curved end portion, which connects a first groove portion in the first layer to a second groove portion in a second layer adjacent to the first layer and is arranged on a first longitudinal side of the winding unit; c. a second curved end portion, which connects the second groove portion in the second layer to a third groove portion in the first layer and is arranged on a second longitudinal side of the winding unit opposite the first longitudinal side; d. a third curved end portion, which connects the third groove portion in the first layer with a fourth groove portion in the second layer and is arranged on the first longitudinal side of the winding unit; and e. a fourth curved end portion, which connects the fourth groove portion in the second layer to a fifth groove portion in a third layer adjacent to the second layer and is arranged on the second longitudinal side of the winding unit.

Methods and apparatuses for forming a woven coil assembly (100), the coil assembly having adjacent superimposed linear portions (LI-L6, AL7-ALI2) extending parallel to each other in a first area (A1) of the coil assembly, and adjacent superimposed linear portions (L7-L12, AL13-AL18) extending parallel to each other in a second area (A2) of the coil assembly, wherein a plurality of head portions (T) connect the linear portions of the first area (AI) to the linear portions of the second area (A2).

A coil molding apparatus being capable of easily forming the band-shaped coil into a wound state, without the winding posture in the coil winding jig being disturbed by spring back of the band-shaped coil. The coil molding apparatus includes: a coil winding jig for winding the band-shaped coil with inserting straight portions thereof into a plurality of comb-shaped grooves in the outer periphery; a coil conveying mechanism unit for pivotally conveying the band-shaped coil along the outer periphery of the coil winding jig; and guide members for inserting the band-shaped coil into the plurality of comb-shaped grooves by guiding in an arc shape while contacting with the side end of the band shaped groove thereby gradually reducing in diameter accompanying pivoting at a second half portion of pivot conveying of the band-shaped coil, then extending with maintaining curvature of the oprtion of which the diameter has already been reduced.

A coil forming apparatus for precisely reforming a band-shaped coil having straight portions and side ends, in an arc shape includes: a coil winding jig for inserting the straight portions into comb-shaped grooves thereof and winds; a coil conveying mechanism for pivotally conveying the band-shaped coil; and guide members for guiding the side ends, and inserts each of the straight portions into a respective one of the plurality of comb-shaped grooves, in which the coil conveying mechanism unit has a conveying rail and a conveyor, the conveyor has a plurality of gripping grooves for gripping a respective one of the plurality of straight portions, the plurality of gripping grooves having a coil abutting bottom surface of a depth according to an overlapping number of the plurality of straight portions which differs according to position in the conveying direction of the band-shaped coil.

The continuous wires respectively have U-shaped parts and straight parts. The method includes: a transposition shape forming step of forming transposition shapes in each of which, among at least the two continuous wires belonging to an identical phase, the U-shaped part of one of the continuous wires is disposed inside the U-shaped part of the other one of the continuous wires; an inclined part forming step of causing the pairs of straight parts of the continuous wires respectively formed with the transposition shapes to be offset to form inclined parts on the continuous wires; and a folding step of folding the continuous wires formed with the inclined parts to form the turning parts and the slot disposition parts. The inclined part forming step and the folding step are alternately performed.

A conductor forming device includes a holder that holds a plurality of straight parts of a plurality of conductors while arranging the plurality of straight parts in parallel to each other, the plurality of straight parts forming a group of straight parts the plurality of conductors. The holder includes a fixed block on which a plurality of grooves each having a fixed side contract part capable of contacting with one end in width directions of the straight part are provided at equal intervals, a plurality of movable blocks that are disposed to be movable in the respective grooves on the fixed block and each have a movable side contact pars capable of contacting with an opposite end in the width directions of the straight part, and a driver capable of driving the movable blocks independently from each other.

A conductor forming device which folds a group of conductors in thickness directions, the group of conductors including a plurality of conductors having straight parts, includes a restrainer provided with a plurality of grooves in which fold parts of the conductors each consisting of at least two unit wires are fitted and which limit a width of each of the conductors to a predetermined distance, when the conductors each consisting of the at least two unit wires are to be folded.