The reliability of a rotating electrical machine is improved. A method for manufacturing a stator used in a rotating electrical machine includes: a first step of arranging a first segment coil and a second segment coil to face each other; a second step of processing the first segment coil to generate a bridge part that comes into contact with the second segment coil; and a third step of joining the bridge part and the second segment coil by laser welding.

In the formation of coil windings of an electrical machine, the invention provides a ring arrangement device for forming a ring arrangement from a plurality of concentrically arranged rings of electrical conductors to form a coil winding of a component of an electrical machine, comprising a collecting receptacle with a plurality of grooves arranged in a ring around an axis and delimited by radial webs and a ring positioning device for the relative axial positioning of one or more of the rings, wherein the ring positioning device has a support device for supporting the electrical conductors of one of the rings to be inserted in an axial insertion position and one holding device for holding the conductors in a storage position, in which the conductors of a completely inserted ring are moved further into the collecting receptacle.

A coil with a distributed winding formed from hairpins that each have two straight-line conductor portions arranged in different slots of a coil body. Contact regions shaped in circumferential direction adjoin the conductor portions at one axial end and are connected at the other axial end through a turning region. The contact regions have at the end remote of the coil body a connection portion that are aligned in radially extending rows. The contact regions of a layer are shaped in the same circumferential direction. A portion of the contact regions of an outer layer is deformed in radial direction to form an additional, and these contact regions are shaped in a circumferential direction opposite to the contact regions of the outer layer.

A widening apparatus for a hairpin-type stator coil is provided to extend a distance between welding portions of hairpin-type stator coils inserted into slots of a stator core, and the widening apparatus includes, a coil support unit installed on a base frame, a tool driving unit installed on the base frame to be vertically movable below the coil support unit, and including a first gear operation part and a second gear operation part, a plurality of lower widening tools operably connected to the first gear operation part, and reciprocally movable along a layer direction of the stator coils, and a plurality of upper widening tools operably connected to the second gear operation part, and configured to be reciprocally movable above the plurality of lower widening tools.

An apparatus for pre-assembling a winding for an electric machine stator or rotor includes a plurality of hairpins with two legs having non-circular cross-section, a ring including a plurality of slots and an outer containment ring acting in containment along the perimeter of the ring. An inner cam block and an outer cam block, surrounding and radially facing the inner cam block, are arranged opposite to the exit face of the ring. The cams are adapted to be crossed, in use, by the two legs when they cross the ring at the same time; the cams open into a free circular space between the two cam blocks. A method for pre-assembling a winding set for an electric machine stator or rotor is also provided. Hairpins are inserted in sequence in the slots of the apparatus. A finished winding set positioned in the free circular space is obtained by successive rotations of the ring.

In this stator, a first coil portion, a second coil portion, a third coil portion, and a fourth coil portion each include a one-side coil part that is disposed so as to extend over a first slot and a third slot, and an other-side coil part that is disposed so as to extend over a second slot and a fourth slot.

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).

This stator manufacturing method includes a step in which one of a skew-forming mechanism portion and a skew-forming jig presses, with the skew-forming jig, the skew-forming mechanism portion having a shape corresponding to the shape of a skew, to form a skew having a bent shape or a curved shape.

A rotating electrical machine stator and a method for manufacturing a rotating electrical machine stator with high productivity. A rotating electrical machine stator includes a stator core having a slot; and a coil having a leg part including a held-in-slot part held in the slot and a portion extending from the held-in-slot part, and a resin foam is provided between an inner surface of the slot and an outer surface of the held-in-slot part facing the inner surface of the slot. The coil is formed by joining together a plurality of segment conductors each having a joint part, and a conductive joint material is disposed between a pair of joint parts facing each other in the slot.

Coil segments of the same phase are inserted into each group of circumferentially consecutive three slots. Assuming that the grouped three slots are A, B, and C, and six groups are U1 to U6, respectively, and that slot y of group Ux are slot Uxy, a coil starting from the slot U1A is wired to pass through one turn of a stator in the order of slots U1A.fwdarw.U2B.fwdarw.U3B.fwdarw.U4C.fwdarw.U5C.fwdarw.U6A, and connected to slot U1A of the next turn. In this turn, coil segments with a wide straddle width are used for the connections of U1A.fwdarw.U2B and U3B.fwdarw.U4C, and a coil segment with a narrow straddle width is used for the connection of U5C.fwdarw.U6A.