A method of manufacturing a reactor is provided. The reactor include: a coil including a wound flat wire, the flat wire being covered with an insulating film, and the coil having a flat surface; and a cooler facing the flat surface, in which the flat wire on an outer periphery side of the coil may be not covered with the insulating film at the flat surface, and the flat wire at the flat surface may include a plurality of wire segments lying in a pitch direction. The method may include pressing a rod against a short side of the plurality of wire segments to form at least one thickened portion in each of the plurality of wire segments, the thickened portion being a portion of the flat wire thickened in the pitch direction.

A stator is provided for a permanent magnet synchronous motor. The stator includes a multiplicity of stator teeth, each stator tooth having a tooth axis. The stator further includes a stator ring with a stator axis, wherein the multiplicity of stator teeth is arranged radially along the circumference of the stator ring, and the tooth axes cross the stator axis orthogonally within one plane. The stator further includes a multiplicity of stator coils, each stator coil having a coil axis and a coil opening and including windings made of a wire, which windings extend along the coil axis, and the coil axis of the respective stator coil is arranged parallel to the tooth axis of the respective stator tooth and the coil opening of the respective stator coil surrounds the respective stator tooth, wherein the wire of the respective coil has a rectangular cross section with a shorter side and a longer side and the shorter side of the wire of the respective coil is orientated parallel to the coil axis of the respective stator coil.

The unit coil is formed by: bending the coil end portions of the intermediate body such that, in a layer in which a length in an axial direction between the coil end portions is large, positions of the coil end portions projecting furthest from the accommodation portions in the axial direction move away from positions of the accommodation portions in the stacking direction, compared to the previous state; and aligning the positions, in the axial direction, of the coil end portions at an inner side of the annular shape, for each of the layers.

An electromagnetic machine includes a universal circuit board and a plurality of universal coils. The universal circuit board includes a first coil configuration imprint and a second coil configuration imprint. The plurality of universal coils each including a positive lead and a negative lead for electrical connection to one of the first and second coil configuration imprints.

A 3D printed metal coil for an electrical machine. The 3D printed coil has a plurality of turns and is configured to fit within a slot in an electrical machine. A cross-sectional shape of successive turns of the plurality of turns varies such that a portion of each turn forms a part of an external surface of the metal coil, the external surface forming an interface with a side of the slot.

The coil winding has an electrical conductor for an electrical machine and includes at least two layers. The electrical conductor, following its longitudinal extension, runs inwardly wound in a first of the at least two layers, and then extends to a second of the at least two layers and runs outwardly wound in the second layer. The electrical machine includes at least one such coil winding. The hybrid electric aircraft is in particular an airplane and includes such an electrical machine and/or at least one such coil winding.

The invention relates to a coil former (1) for winding conductor wire (100) into coil windings (101), in particular for subsequent insertion in a stator carrier, said coil former having a coil former front (2) and a coil former rear (3), wherein the coil former front (2) and the coil former rear (3) span, by means of a peripheral surface (4), a spiral winding path (P) around a spiral axis (W) for the conductor wire (100), and wherein support elements (10, 11) are arranged along the winding path (P) and protrude beyond the peripheral surface (4) and laterally delimit the spiral winding path (P). The invention also relates to a winding device (50) having a coil former (1) of this kind and to a method for operating the winding device (50).

A coil (1) for a rotary electric machine is annularly formed by twelve coil members (10), each coil member (10) is configured of four coil elements (10A) to (10D), the coil elements (10A) to (10D) integrally include a plurality of sets of coil element structures each set of coil element structures including a pair of base portions (11), and four arm portions (12) and two curl portions (13), and the plurality of sets of coil element structures are annularly configured.

A casting device having a casting mold and a core for producing a helical casting is described. The may have an expendable core that can be dissolved after the casting process. Advantageous effects of the device and process can be achieved by virtue of the fact that the female mold for accommodating the helical casting during the casting process is formed completely within the outer contour of the core, the female mold being delimited by the core and, at the peripheral boundary surfaces of the female mold, by the casting mold.

A method for forming a coil that is formed by winding a flat rectangular conductor wire a plurality of times, the method includes forming, in the coil end portion, an offset portion bent in a stacking direction of the flat rectangular conductor wire with an offset in the stacking direction of the flat rectangular conductor wire by an amount corresponding to a width of the single flat rectangular conductor wire by moving the outer die on the one side in the divided outer die relative to the outer die on the other side in a direction along the stacking direction.