An apparatus terminates and winds coils of a core of a dynamo electric machine. The coils are formed from at least an electric wire and the core has a longitudinal axis. The apparatus includes a wire dispenser which translates and rotates with respect to a core to wind the coils. At least a stretch of wire extends from the coil; and the stretch of wire includes a portion for a termination connection to a termination structure of the core, such as a tang terminal. The core has a groove at an end to receive at least a wire in the path of the wire to terminate the coils. The apparatus comprises a wire deflector positioned adjacent the end of the core, where the groove is located, in order to intercept and align the wire with the groove. The apparatus avoids waste cut wire.

The present technology contemplates a stator or rotor of an electric machine comprising a main cylindrical body with a circular array of slots; at least one bar winding comprising a first and second plurality of basic conductors and a second plurality of special conductors. The first and second circular array comprise a first and second arc of legs of the first and second set of said conductors which are inserted as well as legs of the conductors. The present technology also contemplates electric machines and electric or hybrid drive vehicles comprising such stators of rotors.

A blanking die apparatus includes multiple machining stations having respective cutting tools operated simultaneously to perform predetermined blanking operations on a belt-shaped workpiece fed progressively in a longitudinal direction and finally to perform a contour blanking operation on the workpiece, thereby forming core pieces used for manufacturing a laminated iron core, and an auxiliary cutting tool that forms a disposal hole by partly blanking a scrap forming area of the workpiece simultaneously with the operations of the cutting tools of the machining stations.

A laminated iron core manufacturing method in a blanking die apparatus having multiple machining stations is provided. The method includes feeding a belt-shaped workpiece progressively in a longitudinal direction in the blanking die apparatus, operating cutting tools provided in the respective machining stations simultaneously to perform predetermined blanking operations on the progressively fed workpiece and finally perform a contour blanking operation on the workpiece so as to form core pieces, and laminating the core pieces within or outside the blanking die apparatus to thereby manufacture a laminated iron core. An auxiliary cutting tool is operated to form a disposal hole by partly blanking a scrap forming area of the workpiece simultaneously with the operations of the cutting tools of the multiple machining stations, to thereby secure a load balance of the blanking die apparatus in the feeding direction.

Apparatuses and method for manufacturing coil members (230, 250) for insertion in slots of a core of an electric dynamo machine, wherein the coil members (230, 250) are formed by bending portions of an electric conductor (10). Portions of conductor of a predetermined length are fed through an aperture (80), where at least one engagement member (51) can move to engage and bend the conductor (10) so as to form the configuration of the coil member (230, 250).

Apparatus and method for winding at least one electric wire W on a coil support (10) of a core of a dynamo electric by using a wire dispensing member (19) means (21, 25) for rotating the coil support with respect to the dispensing member (19). It is foreseen to provide a relative movement of the dispensing member (19) with respect to the coil support (10) to maintain the angular orientation constant during winding. Furthermore it is foreseen to press on a portion (WP) of wire wound on the coil support (10) where the portion of wire (WP) is located immediately adjacent to a portion of wire that still has to be wound on the coil support (10). Engaging occurs also of the wire portion (WP) wound on the coils support and that extends to the dispensing member (19) when passage from one turn to another occurs for the stratification; the engagement occurring in opposition to the direction (Z) of stratification of the wire. Pressing on the wire (W) can be accomplished in a direction (K) having an angle (E) that is more than zero and not perpendicular to an axis of the coil support.

A method can be used for molding a hairpin inserted into a stator core using a clamping unit that includes a connection bracket mounted on a front end of a robot arm and at least one clamper mounted on the connection bracket. The method includes reciprocally driving the clamping unit in opposite directions in a straight line, and press molding a head portion of the hairpin using a molding jig driven by the at least one clamper.