A method for producing a spiral-shaped body, in particular an electric coil, made of an electrically conductive material. First, the material is wound about a mandrel in a casting mold in order to form a coil with a plurality of windings, and pressure is then exerted onto the coil in the axial direction of the coil. The pressure leads to a deformation and compression of the cross-section of the individual windings in the axial direction of the coil. By compressing the coil, an optimal use of space is achieved with an electric coil, for example for an electric machine.

A conductor forming apparatus that forms a wave winding coil group by folding a conductor, in which the conductor forming apparatus includes: a folding jig that is arranged on an inside of a folding direction of the conductor, the folding jig including a support plate with a tip serving as a starting point for folding the conductor, and a plurality of guide protrusions arranged on a side of the tip of the support plate so as to hold the conductor before folding from both sides in a width direction, the plurality of guide protrusions each including a guide surface that can guide a folding operation of the conductor from the start of folding.

A joining method for joining a coil mat to the stator of an external rotor motor by: providing a coil mat having straight wire sections connected by winding heads, providing a stator with stator slots opening radially outwards, winding up the coil mat on a winding carrier which has radially outwardly opening winding carrier receiving slots, transferring the coil mat from the winding carrier to a transfer tool which has radially inwardly opening transfer tool receiving slots, and transferring the coil mat from the transfer tool to the stator. In addition, a joining device, a control unit and a computer program for carrying out the joining method.

A rotating electrical machine includes a supporting member, a stator core, a winding set, a shaft, a rotor, a magnetic generator, and a magnetic detector. The stator core has a ring-shaped yoke held inside the supporting member and tooth portions projecting from the yoke in a radial inward direction of the yoke. The winding set is wound on the tooth portions. The shaft extends through the stator core and is rotatably supported by the supporting member. The rotor is located in the stator core and rotates with the shaft. The magnetic generator is located at an end of the shaft. The magnetic detector outputs a signal indicative of a change in magnetic flux density created by the magnetic generator. The number of the tooth portions for every magnetic pole pair in the rotor is even.

Method for producing a stator winding (18) of an electric machine (10), in particular an AC generator, wherein the stator winding (18) has at least n phase windings (120, 121, 122, 123, 124), and one phase winding (120, 121, 122, 123, 124) has a plurality of successive wound coils (82) with coil sides (88) and coil side connectors (91), wherein the coils (82) are divided into first coils (82.1) and second coils (82.2), with a forming tool (100), in which slots (105, 106) are provided which are suitable for accommodating the coils (82), wherein a first coil (82.1) is arranged in a slot (105), and a second coil (82.2) is arranged in the same slot (105).

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.

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.

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).

A manufacturing method of a coil includes: a step of winding a round wire conductor to form a round wire coil; and a step of pressing the round wire coil with a molding metal mold to form a flat square wire coil having one turn in a substantially rectangular shape.

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.