A coil forming apparatus includes: a coil winding jig including a plurality of comb-shaped grooves; a coil conveying mechanism that pivotally conveys the belt-shaped coil along at least a portion of the outer periphery of the coil winding jig; and guide members guide the belt-shaped coil in an arc shape along an outer periphery of the coil winding jig while being in contact with the side ends, and allow the plurality of straight portions to be inserted into a respective one of the plurality of comb-shaped grooves in a second half portion of the belt-shaped coil upon pivot conveyance. The guide members include a reforming portion in a first half portion of the belt-shaped coil upon pivot conveyance, and the reforming portion deforms and reforms the belt-shaped coil in an arc shape in a state sandwiching the side ends of the belt-shaped coil.

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.

An insulating paper sheet has a cuff portion protruding from an axial end face of a stator core. The coil mounting apparatus includes a stator core fixing jig, a coil winding jig that is arranged inside the stator core and has thereon an annularly wound belt-shaped coil, and a cuff guide that is provided on the stator core fixing jig and has a guide groove for supporting the cuff portion. The guide groove includes a cuff portion-supporting sub-groove that supports the cuff portion from both sides in a circumferential direction of the stator core, and a coil-guiding sub-groove that is located further away from the axial end face of the stator core than the cuff portion-supporting sub-groove and that has a groove width smaller than that of the cuff portion-supporting sub-groove.

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 coil insertion guide device includes a positioning jig that positions a stator core; and a guide member that is provided in the positioning jig so as to be able to contact an end face of the stator core in an axial direction. A coil inserted into the slots along the radial direction of the stator core is guided by the guide members. The guide member includes a guide groove. The guide groove includes, on a side close to the end face of the stator core, a cuff support groove that houses and supports a cuff of one of the insulating members that protrudes from the end face of the stator core, and on a side far from the end face, a coil guide groove that protrudes toward an inside of the slot more than the cuff support groove and contacts the coil to guide movement of the coil.

A radial flux electric machine includes an inner stator and an outer rotor configured to rotate about the stator. The outer rotor may include a rotor base and a plurality of annularly arranged permanent magnets axially extending from the rotor base parallel to an axis of rotation of the rotor. A cylindrical core may extend from the rotor base encircling the plurality of permanent magnets. The core may be formed of a Soft Magnetic Composite (SMC). A sleeve may encircle the rotor. The sleeve may support the cylindrical core and the cylindrical core may support the plurality of permanent magnets. The cylindrical core may be positioned radially between the sleeve and the plurality of permanent magnets.

An electric machine includes a rotor configured to rotate about an axis of rotation, a stator having a plurality of teeth annularly arranged on a stator core about the axis of rotation, a plurality of electromagnetic coils, and a base plate. Each coil of the plurality of electromagnetic coils may be mounted on a separate tooth of the plurality of teeth, and the base plate may be located adjacent to the plurality of electromagnetic coils and the stator core. The base plate may be in thermal contact with the plurality of electromagnetic coils and the stator core such that as the plurality of electromagnetic coils and the stator core heat during operation, the base plate is configured to serve as a common heat sink for the plurality of electromagnetic coils and the stator core.

An electric machine includes a rotor configured to rotate about an axis of rotation, a stator having a stator core and a plurality of teeth annularly arranged on the stator core about the axis of rotation, a plurality of electromagnetic coils, and a base plate. Each coil of the plurality of electromagnetic coils may be mounted on a separate tooth of the plurality of teeth. The base plate may be located adjacent to the plurality of electromagnetic coils and the stator core. The base plate may have a first side and an opposing second side. The first side may be in thermal contact with the plurality of electromagnetic coils and the stator core. A liquid-coolant channel may be defined on the second side of the base plate such that as the coils and the stator core heats during operation, the base plate is configured to transfer the heat to a liquid coolant in the liquid-coolant channel to dissipate heat from the plurality of electromagnetic coils and the stator core.

Stators (2) having teeth (4) and electrical windings (5) provided on the teeth (4), wherein the electrical windings (5) comprise graphene and/or carbon nanotubes, are already known. The electrical winding (5) of the stator (2) is produced in a winding process. The electrical winding (5) in the component of an electric machine according to the invention can be produced more easily, in particular further electrical phases can be built into the electrical winding (5) in a simpler and reproducible manner. According to the invention, the electrical windings (5) are each formed as a tubular fabric which encloses the tooth (4) to which it is assigned.

A radial flux electric machine includes a rotor configured to rotate about an axis of rotation and a stator fixedly positioned proximate the rotor. At least one of the rotor or the stator may include a plurality of teeth annularly arranged about the axis of rotation. Each tooth of the plurality of teeth may extend in a radial direction such that a plurality of cross-sectional areas of each tooth in a plurality of planes perpendicular to the radial direction may vary. And perimeters of the plurality of cross-sections may be substantially the same across the plurality of perpendicular planes.