An apparatus for molding a hairpin inserted into a stator core includes a clamping unit including a connection bracket mounted on a front end of a robot arm and at least one clamper mounted on the connection bracket and configured to be reciprocally driven in opposite directions in a straight line, and a mold unit detachably coupled with the at least one clamper and configured to press mold a head portion of the hairpin by a molding jig configured to be driven by the at least one clamper.

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.

A step of inserting an insulating paper into a slot of a stator core (second step) is performed, a step of placing a jig at a position that is on a side opposite to a side from which a segment coil is inserted into the slot of the stator core and that overlaps with a protrusion when viewed in an inserting direction of the segment coil (third step) is performed, and then a step of inserting the segment coil into the slot (fourth step) is performed. Therefore, even when the insulating paper is dragged by the segment coil in the process of inserting the segment coil into the slot, the insulating paper abuts the jig and the movement of the insulating paper is restricted, thereby suppressing displacement of the insulating paper from the slot.

An electric machine is disclosed that includes a rotor, a stator and a plurality of pins. The stator is received inside the rotor and defines a plurality of slots for receiving the pins. The pins are conductors that are each joined with a circumferentially adjacent pins to form a conductive path for each power phase. The pins each have a first axial leg and a second axial leg that are each disposed in one of the plurality of slots. The first and second axial legs are joined by an asymmetric crown portion of the pin conductors. The crown portion includes a long arm and a short arm that are joined at an apex that is radially and circumferentially offset to be closer to the second leg than the first leg.

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.

An apparatus for molding a hairpin inserted into a stator core includes a clamping unit including a connection bracket mounted on a front end of a robot arm and at least one clamper mounted on the connection bracket and configured to be reciprocally driven in opposite directions in a straight line, and a mold unit detachably coupled with the at least one clamper and configured to press mold a head portion of the hairpin by a molding jig configured to be driven by the at least one clamper.

A method for introducing an insulating layer between stator or rotor grooves and for introducing winding packets with wire webs of coil wires of a coil winding is provided. The coil winding may be inserted into the stator or rotor grooves from a transfer tool. The method has the steps of: inserting insulating layers into transfer grooves of the transfer tool, wherein at least one section of each of the insulating layers lies radially outside of the transfer groove; transferring the wire webs of the winding packets into the transfer grooves; closing the insulating layers by folding the sections in the direction of the wire webs of the winding packets and fixing the sections in the folded position of the sections; and inserting the winding packets into respective stator or rotor grooves such that the folded sections are arranged between groove bases of the stator or rotor grooves and the wire webs of the winding packets.

A manufacturing system for manufacturing a stator for an electric machine, in particular an electric motor, wherein the stator has a main part and a plurality of bent and/or straight bar conductors. The manufacturing system has the following: a bending machine for bending free ends of the bar conductors, a spreading machine for spreading the free ends of the bar conductors in the radial direction, a welding machine for welding the free ends of at least two bar conductors, and a holding device for the stator. The holding device has at least one first set of fingers for engaging between the bar conductors at a first end face of the main part. The holding device can be secured to the bending machine, the spreading machine, and the welding machine. The manufacturing system facilitates an accelerated and inexpensive manufacture of stators with bar conductors.

A flat wire stator which includes an iron core and a flat wire winding; the flat wire winding includes a first phase winding, the first phase winding includes a plurality of coils, the plurality of coils are distributed in rotational symmetry around an axis of the iron core, the coils are wound in a portion of iron core slots in the plurality of iron core slots, and first ends and second ends of the coils are located at the same end of the iron core; and the plurality of coils are connected in series in sequence, the first end of each coil is connected to the first end of one coil of two coils adjacent to the coil, and the second end of the each coil is connected to the second end of the other coil of the two coils adjacent to the one coil.