An electric machine may include an stator and a rotatable rotor. At least one of the stator or the rotor may include a plurality of multi-part trapezoidal teeth with an electromagnetic coil disposed around each tooth.

There are provided first guide members inserted into the insides of the insulating members in the slots, second guide members inserted into the insides of the insulating members and onto outer sides relative to the first guide members in a radial direction in the slots, and a controller controlling movement of each of the first guide members and the second guide members. After the first guide member moves outward in the radial direction in the slot until coming into contact with or close to a second guide member, the plurality of second guide members are caused to sequentially move to an outer side of the stator core in the central axis direction in order with the second guide member closest to the first guide members first and retreat from the slot as the coil is moved outward in the radial direction by the pressers.

Certain aspects relate to a continuous winding formed from a conductor of rectangular cross-section, the winding having a compound bend in the crowns connecting successive linear segments where the compound bend does not stress the conductor insulation to its failure point. The compound bend can be formed by applying force to the conductor in a first direction, thereby shaping a first bend in the conductor to form a u-shaped conductor having a crown and two linear segments, where the crown includes a v-shaped bend and two straight segments on either side of the v-shaped bend that each connect to one of the linear segments. A second bend can be formed by applying force to the conductor in a second direction perpendicular to the first direction. The shape of the second bend can depend on the desired radius of the winding when circularly wound and positioned in a stator.

A radial flux electric machine includes a rotor configured to rotate about an axis of rotation, a plurality of electromagnetic coils, and a stator. The stator may have an annular stator ring and a plurality of core tooth-portions extending in a radial direction. The annular stator ring and the plurality of core tooth-portions may be integrally formed of a Soft Magnetic Composite (SMC). The SMC may include one or more isotropic ferromagnetic materials, a magnetic saturation induction of greater than or equal to about 1.6 Tesla, and an electrical resistivity greater than 10 micro-ohm/m.

A tooth groove is provided at a border portion between a tooth body portion and a protrusion. The angle between a tooth body portion lateral face which is a lateral face in the circumferential direction of the tooth body portion and a tooth body portion stop portion which is a face, of the tooth groove, continued from the tooth body portion lateral face is the right angle or an acute angle. The protrusion is rotated toward the outer side in the circumferential direction, to bring a protrusion stop portion into close contact with the tooth body portion stop portion, the protrusion stop portion being an outer-circumferential-side lateral face of the protrusion, thereby forming a shoe in a tooth.

A winding method of forming a coil by edgewise bending a flat rectangular conductor comprises a step of edgewise bending the rectangular conductor to form edgewise bending portions so that two predetermined two adjacent bent portions are formed so that an outward bulging portion to be generated by edgewise-bending of the flat rectangular conductor is generated in a concentrated manner in a side between the two edgewise bent portions, and the side having the bulging portion constitutes each of a pair of opposite sides of the coil.

A plurality of slots are disposed in a stator iron core. A plurality of stator coils are formed into coils having a rectangular cross sectional shape. The stator coils are inserted into each of the slots in a double-layer winding system such that a lower coil is inserted on an interior side of one slot of the plurality of slots and an upper coil is inserted on an entry side of another slot of the plurality of slots. Each of the slots is provided with a space that enables the lower coil to be rotated on the interior side of the slot when the upper coil is lifted up from another slot.

Provided is a stator of a rotary electric machine in which a bonding portion of ends of coil segments is formed at a coil end of the stator without being inflated toward the opposite side to a stator core, and the coil end can be minimized in an axial direction. The stator of the rotary electric machine includes a stator core (10) having a plurality of slots and a coil segment (30) which is disposed in the stator core to form a stator winding (3). The ends of the coil segments are overlapped in the axial direction, and bonded through the bonding portion. The bonding portion is formed in a shape such that the bonding portion is melted and flows down from the end (6a) of the coil segment on the opposite side to the stator core toward the end (5a) of the coil segment on a side near the stator core.

The invention relates to a wire assembly for electric rotary machine comprising a plurality of phase coils (P1-P6),

each phase coils (P1-P6) being aimed to be inserted in a dedicated set of slots (18) of a stator (10),

each phase coil (P1-P6) comprising a first part (61) having an input (I1-I6) and a second part (62) having an output (O1-O6), the first part (61) and second part (62) constituting a distributed wave winding,

wherein each phase coil (P1-P6) comprises a U-turn part (63) linking the first (61) and the second (62) parts so that each phase coil (P1-P6) is composed of a single wire (23).

A winding apparatus includes a pair of first latch pawls provided with a distance therebetween so as to sandwich one of magnetic poles of a multi-pole armature, a flyer that is configured to feed a wire while rotating around the pair of first latch pawls so as to loop and wind the wire around the pair of first latch pawls, and a first moving mechanism that is configured to move the pair of first latch pawls to a position of sandwiching the one of the magnetic poles, and insert the wire wound around the pair of first latch pawls into slots formed between the magnetic poles so that the wire is wound around the one of the magnetic poles.