A stator assembly method includes a step of inserting coils into slots by pressing coil end portions of the coils from the inner peripheral side toward the radially outer side of a stator core using a pressing member while suppressing fall of the coil end portions by supporting the coil end portions from the radially outer side of the stator core using a fall suppression member.

A control device moves a split claw (11) holding a projecting portion (4d) of an eighth-layer coil segment (4) in a counterclockwise direction D1. At this time, the control device moves first to third extended blades (13a) to (13c) in an outward direction D3 so that the projecting portion (4d) of the eighth-layer coil segment (4) is bent in the outward direction D3. Then, the control device moves the first to third extended blades (13a) to (13c) in an inward direction D4. Through the above steps, the projecting portion (4d) of the eighth-layer coil segment (4) is bent in the counterclockwise direction D1 while being bent in the outward direction D3. As a result, a return force tending to return in the inward direction D4 is generated by an elastic deformation force.

A coil bending machine is a machine that, in a stator core including a yoke and multiple teeth and having a slot formed between circumferentially adjacent teeth, while lead portions of a segment coil which is a U-shaped lead wire including a bent portion K and two lead portions R extending from the bent portion are inserted into two slots, push-bends end portions of the lead portions protruding from an axial end face of the stator core toward the stator core. The coil bending machine includes a coil bending member that push-bends the end portions of the lead portions protruding from the axial end face of the stator core toward the stator core, and a coil pressing mechanism that press-fixes a segment coil inside the slot toward the yoke, from the radially inner side of the stator core.

A mother substrate that enables winding cores to be obtained in a manner in which the mother substrate is divided along x-direction division lines and y-direction division lines is prepared. Subsequently, x-direction division grooves are formed along the x-direction division lines on a first main surface of the mother substrate, y-direction division grooves are formed along the y-direction division lines on the first main surface, and shallow bottom surface exposure grooves, for exposing surfaces that are to be core portion bottom surfaces, are formed on the first main surface. The mother substrate is divided by performing a flattening process on a second main surface of the mother substrate that is opposite the first main surface until the second main surface reaches the x-direction division grooves and the y-direction division grooves to obtain the winding cores that are separated from each other.

In a coil forming device, an edge line in an escape region is formed so that a clearance between the edge line in the escape region and a recess portion in an axis direction is larger than a minimum clearance between the edge line in an inclined region and the recess portion in the axis direction. When a second die is rotated relative to a first die in the clockwise direction the flat-square conductive material end is bent in flatwise bending by the recess portion and the inclined region of a protrusion portion, and then, the flat-square conductive material end reaches the escape region.

The alignment method of the electrical conductors includes an aligning step of aligning a plurality of electrical conductors 40 in an annular shape while being overlapped in a circumferential direction of the annular shape by moving gripping devices 230 inward in a radial direction of the annular shape, in which the gripping device 230 has a pair of claws 232g1 and 232g2 capable of pinching one leg portions 41 of the substantially U-shaped electrical conductors 40 one by one, one claw 232g1 has a length capable of gripping one leg portion 41, and the other claw 232g2 has a length capable of gripping one leg portion 41 of one substantially U-shaped electrical conductor 40-1 and gripping the other leg portion 44 of the other substantially U-shaped electrical conductor 40-2.

A wire conductor alignment apparatus aligns wire conductors of coil members provided in a core of a dynamo electric motor or generator for welding the ends thereof. The apparatus has a plurality of circumferentially arranged first passages and a plurality of circumferentially arranged second passages. Each first passages is overlapped with a second passage to form a pair, each pair of passages form a combined third passage, and each third passage is configured to receive at least one end portion of at least two wire conductors of a coil member of a dynamo electric machine. The apparatus also has an actuator for moving at least one of the plurality of first passages and the plurality of second passages relative to one another in a circumferential direction to cause a respective end portion of a wire conductor for welding thereof.

A locator-equipped clamp jig capable of suppressing interference between base sections of segments when clamped by the clamp jig, a stator manufacturing device, and a method for manufacturing a stator. The locator-equipped clamp jig has a locator that is provided to part of a main clamp body on a stator core side and has a plurality of protrusions arranged on an upper surface of an electrical conductor that is adjacent, in the radial direction of the stator core, to an electrical conductor being clamped by the main clamp body, the width of the protrusions in the radial direction of the stator core being at least the width of one of the electrical conductors.

To prevent breakage of the segment of an enameled wire that extends between a pin and a winding groove on an insulating stator base, a tension servo of an automatic wire-winding machine in controlled to first wind the enameled wire tightly around the pin of the insulating stator base and then to loosely wind the enameled wire around the pin to form at least one loose winding with a gap between the enameled wire and the pin. The enameled wire is then drawn into the winding groove of the stator base and tightly wound around the stator core within the winding groove. Optionally at least one first loose winding with a gap between the enameled wire and a bottom of the winding groove may initially be formed before tightly winding additional windings within the winding groove.

Method for forming at least one U-shaped winding element (10) for an electromagnetically excitable core (11) of an electric rotation machine (12), wherein the U-shaped winding element (10) has a first rod section (13) and a second rod section (15) which are connected by an arcuate connection section (16), wherein an inner tool part (23) having at least one recess (29) in the region of its outer circumference is provided, and an outer tool part (26) having at least one recess (30) in the region of its inner circumference is provided, and at least the U-shaped winding element (10) is inserted into the inner tool part (23) and the outer tool part (26) such that one rod section (13) is inserted into a recess (29) of the inner tool part (23), the other rod section (15) is inserted into a recess (30) of the outer tool part (26), and such that the inner tool part (23) and the outer tool part (26) are rotated with respect to one another about the axis of rotation (36), wherein in that context the at least two rod sections (13, 15) are moved away from one another, wherein, prior to the at least two rod sections (13, 15) being moved away from one another, a gripping element (50) having a tooth (53) is moved toward a rod section (15), which is gripped by means of a tooth (53).