A stator includes a stator core having a through hole and a plurality of slots, and a continuous wire coil that, is mounted in the stator core, wherein the continuous wire coil includes a conductor wire and has a plurality of straight portions inserted in the slots, and a coil end portion that connects ends of the straight portions adjacent to each other on an outer side in an axial direction of the stator core, the coil end portion has a top portion formed by folding the conductor wire in a radial direction, the top portion has a width W in a circumferential direction, and the width w satisfies the following condition:

W≤2πR/N

where,
R is an innermost diameter of continuous wire coil wound so that an outer diameter is smaller than an inner diameter of a through hole,
N is the number of slots.

A method for producing a stator for an electrical machine, the stator having a substantially hollow-cylindrical stator core, which has a plurality of grooves spaced apart in a circumferential direction, the method including: providing at least one strip-shaped winding unit having a first winding conductor with a plurality of groove portions running straight in a transverse direction that are mutually parallel; fastening a first end of the winding unit to a lateral surface of a mandrel; winding the winding unit onto the mandrel such that it is bent around the lateral surface of the mandrel spirally; inserting the mandrel, together with the winding unit, into a cavity in the stator core; and unwinding the winding unit from the mandrel with the groove portions of the winding unit being inserted into the grooves of the stator core.

A stator assembling method where each of the plurality of the concentrically wound coils has vertexes oriented outward in a axial direction in the planned coil end portions, and a distance in the axial direction between the vertexes of the planned coil end portions on both sides in the axial direction of each of the plurality of concentrically wound coils is gradually reduced toward the conductive wire mounted on the inner diameter side of the stator core from the conductive wire mounted on the outer diameter side of the stator core.

The rotary machine of the present disclosure is provided with an annular stator that has: an annular yoke section; multiple salient poles that protrude radially inward and are arranged circumferentially; and coils disposed on the salient poles. Circumferential surfaces of the salient poles are formed into tapered surfaces that taper toward the tip of the salient poles, and the coils include a first coil and a second coil.

A stator manufacturing method in which a coil including a plurality of coil units formed by winding a rectangular wire is fitted in a cylindrical core having a plurality of slots extending in a radial direction and opening in a core inner peripheral surface so that the slots are distributed in a circumferential direction, the rectangular wire being a linear conductor having a rectangular section.

A coil insertion device includes: a pair of delivery jigs respectively formed with slits into which a pair of side portions of a coil that are parallel with each other can be inserted; and a side portion inserting mechanism configured to push out the side portions inserted into the slits from the slits to insert the side portions into slots of a stator core, the slots facing the slits, the side portion inserting mechanism has: pushing blocks inserted into the slits; and a pushing block moving mechanism configured to move the pushing blocks in a depth direction of the slits.

Provided is a coil insertion method and device that are capable of mechanically manufacturing, with good efficiency, a spirally wound stator core. This coil insertion method comprises: a winding step for winding U-phase, V-phase, and W-phase coils; a step for inserting coils into a transfer block, in which the U-phase, V-phase, and W-phase coils are inserted and held in a plurality of holding grooves of the transfer block so as to spirally overlap, the transfer block having a columnar shape overall, and the holding grooves being formed in radial fashion so as to open from an axial center part toward an outer periphery; and a step for inserting coils into a stator core, in which the transfer block is inserted into an inner periphery of the stator core, and a side part of the coils held in the holding grooves is pressed radially outward toward predetermined slots of the stator core and inserted from the inner peripheral side of the stator core into the slots.

An axial flux motor for an appliance includes a stator yoke. A plurality of stator teeth extend from the stator yoke in an axial direction and are positioned about a central rotational axis. Each stator tooth includes a plurality of laminations that extend in the axial direction and form a “T” shaped member. The plurality of stator teeth are overmolded with a polymeric material to define a plurality of axial stator poles. At least one winding extends around the plurality of axial stator poles. A ring-shaped rotor rotates about the central rotational axis of the stator yoke. The rotor is positioned proximate an axial end of the plurality of axial stator poles.

A method for introducing an insulating layer between stator or rotor grooves and for introducing winding packets with wire webs of coil wires of a coil winding is provided. The coil winding may be inserted into the stator or rotor grooves from a transfer tool. The method has the steps of: inserting insulating layers into transfer grooves of the transfer tool, wherein at least one section of each of the insulating layers lies radially outside of the transfer groove; transferring the wire webs of the winding packets into the transfer grooves; closing the insulating layers by folding the sections in the direction of the wire webs of the winding packets and fixing the sections in the folded position of the sections; and inserting the winding packets into respective stator or rotor grooves such that the folded sections are arranged between groove bases of the stator or rotor grooves and the wire webs of the winding packets.

Provided is a coil insertion device for inserting a wound coil into slots formed in a stator core and opening to a through-hole of the stator core, by placing the coil in the through-hole, and by expanding the coil to move the coil from inside toward outside with respect to the stator core. The coil insertion device includes a coil expander having a plurality of piece members arranged in an annular shape. The plurality of piece members are movable between a first position where the plurality of piece members are reduced in diameter so as to be insertable inside the wound coil, and a second position where the plurality of piece members are expanded in diameter from the first position to press the wound coil from inside toward outside, thereby inserting the wound coil into the slots at once.