A method for forming a coil, including the steps of: forming a spiral coil-segment forming member that includes a plurality of coil-segment forming portions each having a shape corresponding to a coil segment including a straight slot body that is accommodated in a slot of a stator core and a non-straight coil end that projects from the stator core in a rotational axis direction of the stator core; and dividing the spiral coil-segment forming member to form a plurality of the coil segments from the plurality of coil-segment forming portions.

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.

To enhance process reliability when processing wire ends during the course of a production of a machine element of an electric machine, a positioning and clamping device configured to position and clamp one or several wire ends for further processing during the course of the production of the machine element of the electric machine, comprises a capturing device for capturing and positioning the at least one wire end, wherein the capturing device has at least one oblique guide for the relative positioning of the at least one wire end. Furthermore, a corresponding clamping and positioning method is described.

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.

A bending-forming jig used in bending and forming a protruding portion of a leg portion of a U-shaped conductor toward a circumferential direction, the protruding portion protruding from an axial end surface of a stator core, the bending-forming jig including a ring portion and a claw portion, the claw portion including a first abutting surface that rises from an axial end surface of the ring portion with the surface directed in the circumferential direction and abuts against a tip portion of the protruding portion from the circumferential direction, and a projecting portion that projects, at a tip end of the claw portion, in the circumferential direction from the abutting surface and abuts against the tip portion of the protruding portion from the axial direction toward the axial end surface of the ring portion.

A manufacturing method for a rotating electric machine, in which the distal end portions of a plurality of coil ends, which are projected from slots of a stator core of a rotating electric machine and which are arranged in the radial direction of the stator core to form a plurality of layers, are held, and the coil ends are twisted and bent while moving the distal end portions in the circumferential direction. Neutral lines for bending the coil ends are different for each layer, and the neutral lines for the bending are positioned on farther outer sides for coil ends of farther outer layers.

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.

An aim of a coil segment having an approximate U shape is placed in a slot of a stator core, and a portion protruding from the slot is bent in a circumferential direction. An arm is bent in a direction of an arrow A, and another arm positioned at an inner side in the radial direction in relation to this arm is bent in a direction of an arrow B. The arm positioned at the outer side has at least a part of a bending inner side surface of a bent portion hardened by pressurization.

A device for positioning electrically conductive segments of a winding of a stator of a rotary electrical machine, including at least one rotative ring with at least one cam arranged around a revolution axis, the rotative ring being arranged to set in a radial motion at least two series of fingers to ensure the position of the conductive segments, wherein the two series of fingers are set in motion in opposite directions one to the other, such that a finger of a first series of fingers and a finger of a second series of fingers are configured to press two conductive segments of a pair of segments against each other.

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.