The method includes producing a stack of coil loops from a continuous electrical conductor, the coil loops having two parallel straight side portions and two opposite curved end portions connecting the ends of the side portions. A length of each coil loop in the stack of coil loops decreases, whereby a staggered end portion is formed at each end of the stack of coil elements. The end portion of the stack of coil loops is bent into a predetermined bending angle, whereby the staggering has been determined so that an outer end of the end portion of the stack of coil loops is substantially straight when the stack of coil loops is bent into the predetermined bending angle.

The invention relates to a method for producing stranded wires, including the steps of applying an insulation layer to lines, separating the insulated lines, individually removing the insulation layer from the separated lines along a partial length of the lines, and bringing the lines together to form a stranded wire, wherein the partial lengths are arranged at the same level at least in sections for the purpose of forming a non-insulated contact region.

A conductor shaping apparatus includes a driving device that relatively rotates an upper die and a lower die and integrally rotates the upper and lower dies with respect to a shaping member. The driving device rotates one of the upper and lower dies in a direction from an edgewise bent portion to a distal end of a conductor so as to separate the one of the upper and lower dies from the other. One of the upper and lower dies includes a supporting surface configured to support a side surface of an end portion of the conductor as the edgewise bent portion is formed in the end portion, and a guide surface that is formed to intersect the support surface. The guide surface extends away from the end portion of the conductor in a direction opposite to a bent direction of a flatwise bent portion closest to the edgewise bent portion as it extends away from the supporting surface on an opposite side of a rotational axis.

A coil is a coil of a conductive wire that has a quadrangular cross section, that is spirally wound and laminated to have a series of turns including first to n-th turns (n is an integer of 3 or more), and that is provided, on at least some of the first to n-th turns in the coil, with deformed portions representing recesses each having a shape different from a shape of another portion of the conductive wire. In each of the first and n-th turns respectively lying at both ends of the series of turns, an outer surface lying on a side opposite to a center of the series of turns extends flush along with a plane intersecting the series of turns.

Systems, computer readable media storing instructions, and computing device-implemented methods include receiving one or more signals that represent an angular speed of a permanent magnet electric motor of a hybrid electric vehicle, receiving a signal representing a voltage from the electric motor, determining if the angular speed is within a predetermined threshold, calculating an error angle representing a correction factor for an alignment of the electric motor based on a ratio of the voltage and the angular speed, determining if the error angle indicates that the motor is installed in a correct or an incorrect orientation, and adding an orientation correction factor to the error angle.

A coil mounting device includes a stator coil, a coil winding jig that has an outer diameter smaller than an inner diameter of the stator core and winds therearound a belt-shaped coil in an annular shape, a stator core fixing jig that fixes the stator core at a predetermined position and in a predetermined posture, and a coil expansion mechanism that expands the belt-shaped coil. The coil expansion mechanism includes a holder that holds the coil winding jig inside the stator core in a state where the inter-comb-teeth grooves are matched in phase with the slots, and a coil expander that expands the belt-shaped coil by pressing a portion nearer to a side end than the straight portions of the belt-shaped coil wound around the coil winding jig held by the holder so as to expand the portion, thereby inserting the straight portions into the slots.

A method for forming the heads of coils made of rectangular wire so that it fits within the slots of the stator of an electric machine. The method includes receiving a coil having unformed first and second heads separated by first and second legs and applying controlled deformation to yield properly shaped heads. Actuators are provided for causing sequential actuated movements of one of the first and second legs to force the head-forming elements into contact with different portions of the first and second heads while allowing selective free movements of the other leg in response to the actuated movements.

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.

Systems, computer readable media storing instructions, and computing device-implemented methods include receiving one or more signals that represent an angular speed of a permanent magnet electric motor of a hybrid electric vehicle, receiving a signal representing a voltage from the electric motor, determining if the angular speed is within a predetermined threshold, calculating an error angle representing a correction factor for an alignment of the electric motor based on a ratio of the voltage and the angular speed, determining if the error angle indicates that the motor is installed in a correct or an incorrect orientation, and adding an orientation correction factor to the error angle.

An electric machine comprising a stator with a plurality of open slots accommodating double-layer distributed winding with conductors transposed in the end-winding area. The conductors are litz wire conductors and the end-winding portions of the conductor are not twisted or turned around the axis of the conductor.