An electric machine winding assembly including a stator and windings is provided. The stator may define a central axis. The windings may extend from the stator and each may include a pair of conductor ends. Each conductor end may include a minor side and a major side. The windings are arranged with the stator such that each of the major sides are aligned along a circumferential conductor axis relative to the central axis to facilitate welding adjacent conductor ends to one another. Each of the windings may further include two portions defining a U shape. Each of the two portions may include a lower portion, a mid-portion, and an upper portion. One of the mid-portions may include a first bend defining a twist shape to orient the major sides of one of the pair of conductor ends along the circumferential conductor axis.

Various embodiments include a method for twisting a winding head of a stator. The stator has a hollow cylindrical core with a slot on the inner surface extending between the end faces. The method includes positioning two conductors in the slot, so an end section of each conductor extends over the first end face; arranging a winding core with a cam protruding outward on the stator core; and twisting the end section of the first conductor in a peripheral direction, wherein the end section of the first conductor moves over the cam, bending a part of the end section of the first conductor in the radial direction defined by the stator core enlarging a distance between the end section of the first conductor and the end section of the second conductor measured in the radial direction of the stator core.

A motor stator structure includes a core and plural hairpin wires. The core has slots, an insertion side, and an extension side. Each slot has an innermost layer, a second inner layer, a second outer layer and an outermost layer configured in a radial direction of the core. The hairpin leg protruding from the innermost layer extends for a first span distance, the hairpin leg protruding from the second inner layer extends for a second span distance, the hairpin leg protruding from the second outer layer extends for a third span distance, and the hairpin leg protruding from the outermost layer extends for a fourth span distance. The first span distance is different from the second span distance. The third span distance is different from the fourth span distance. The first and fourth span distances are substantially the same. The second and third span distances are substantially the same.

The disclosure relates to a method for producing a stator. Electrical conductor elements are arranged in slots of a laminated core of a two-layer winding. The conductor ends of the conductor elements are moved relative to one another on an end side of the sheet metal packet at one or both of the layers by a positioning process by axially plugging together a normal helix tool with the axial conductor ends of some of the conductor elements and subsequent relative rotation of the normal helix tool relative to the sheet metal packet, and by axially plugging together a selective skewing tool with the axial conductor ends of the remaining conductor elements, such that they have a provided relative end position with respect to each other for a connection of a part of the conductor ends with corresponding conductor ends of the other layer.

An assembling device (10) includes a first rotating portion (11), a second rotating portion (12), and eighteen support arms (13) for supporting coil segments (4), and a motor (29). The first rotating portion (11) includes a first rotating plate (11a) having first holding portions (1d) on an outer peripheral surface thereof. The second rotating portion (12) includes a second rotating plate (12a) having second holding portions (12c) on an outer peripheral surface thereof. The motor (29) rotates the first rotating portion (11) in a counterclockwise direction D1, and the second rotating portion in a clockwise direction D2. Thus, the base parts (21) of the first to eighteenth support arms (13) are transferred from the first holding portions (11d) to the second holding portions (12c) so that the coil segments (4) are assembled to overlap with one another.

A method of producing a rotating electric machine stator includes an insertion step, bending step, and pressing step. In the insertion step, two leg portions of each U-shaped coil wire of a stator coil are inserted into different slots, such that protruding portions as distal end portions of the leg portions protrude in parallel with an axial direction of the stator core. In the bending step, the protruding portion of a first leg portion is bent in a first circumferential direction of the stator core, at a proximal end portion of the protruding portion as a bending start point, from a condition where the protruding portion protrudes from the slot in parallel with the axial direction of the stator core. In the pressing step, a distal end of the protruding portion bent in the first circumferential direction is pressed toward its proximal end in a second circumferential direction.

An apparatus for manufacturing a stator includes a supporting member configured to support a stator core, at least one processing jig having a cylindrical part and a plurality of protruding parts, and an operating unit. The operating unit is configured to perform, in a state where each of coil protruding parts is inserted between one circumferentially-adjacent pair of the protruding parts of the processing jig and an axial end face of the stator core is located close to the protruding parts of the processing jig, a first operation and a second operation either simultaneously or alternately. The first operation is an operation of relatively rotating the stator core and the processing jig in a circumferential direction of the stator core. The second operation is an operation of relatively moving the stator core and the processing jig away from each other in an axial direction of the stator core.

A method of manufacturing a stator includes steps of: inserting a stator coil into slots of a stator core so as to have parts of the stator coil protruding from an axial end face of the stator core; and bending the protruding parts of the stator coil in a circumferential direction. Moreover, in the bending step: a bending jig with a press surface is arranged on the axial end face of the stator core to cover at least part of a corresponding tooth of the stator core; and at least one of the protruding parts is pressed against the press surface of the bending jig, thereby being bent in the circumferential direction. Furthermore, a circumferential width of the press surface is larger than a circumferential width of a facing part of the corresponding tooth; the facing part faces the at least one of the protruding parts in the circumferential direction.

An apparatus for bending and expanding hairpins of a hairpin motor includes a holder on which a stator of the hairpin motor coupled to the hairpins is mounted, and a driving unit including a jig that fixes the hairpins, a first actuator connected to the jig to rotate the jig so that the plurality of hairpins is bent, and a second actuator connected to the jig and configured to move the jig in a state in which the hairpins are fixed by the jig so that the hairpins are expanded outwardly from a center of the stator.

An electric machine includes a stator core defining slots and a first hairpin assembly installed in the stator core. The first hairpin assembly includes first and second same hairpins, each having first and second ends and separately coated to have first and second outer coating surfaces, respectively. The hairpin assembly is in first and second ones of the slots such that the first and second outer surfaces are touching. A weld material joins the first ends and another weld material joins the second ends.