A method is for manufacturing a stator of a rotary electric machine. The method includes; forming a stator core; forming each of cassette coils by concentrically winding rectangular wire for the specified number of turns, each of the cassette coils being formed by applying a shift amount with respect to an axis in a winding direction to a wire shape of at least one of the turns before being attached to the teeth; attaching each of the cassette coils to each of teeth while canceling the shift amount; and forming a wire coil of the rotary electric machine by connecting a winding terminal of one of the cassette coils to a winding terminal of another of the cassette coils.

A method for manufacturing a coil that is formed by winding a conductor in a loop shape and stacking loops of the conductor and that includes a slot placement portion to be placed in a slot of a stator core, and a coil end placement portion to be placed outside the slot. The method preferably involves a winding step, a protrusion forming step, a crank forming step, an opening step, and an arc forming step. The winding step forms a winding having slot placement and coil end placement portions. The protrusion forming step forms a protruding shape that protrudes in a radially outward direction of the winding. In the crank forming step a stepped portion. The opening step of forming the winding so that an interval between the pair of expected slot placement portions gradually increases. The arc forming step forms an arc-shaped portion curved in the stacking direction.

The invention essentially relates to a method for the production of a winding of a rotary electric machine stator, comprising the following steps: forming a winding web (52) comprising a plurality of conductors (37); placing the winding web (52) in a comb (83); winding the winding web (52) around a spindle (105) such as to obtain a winding; and transferring the winding from the spindle (105) to the stator, wherein the winding web (52) is wound around the stator (105) over at least two turns.

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.

An electrical machine, particularly a permanent magnet motor, having a number of poles and teeth or tooth groups that is divisible by a whole number A around which coil-forming loops of winding wire are arranged such that B coils are arranged in series, the coils having a number of windings equivalent to C/B where C is a whole number divisor of B and indicates the wire diameter as a quotient of a traditional standard winding, as well as a method to provide a corresponding winding structure.

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 of forming a diamond coil wound stator winding including introducing a plurality of diamond coils into a plurality of slots of a linear magazine forming a diamond coil wound stator winding, transferring the diamond coil wound stator winding into a circular cassette, and shifting the diamond coil wound stator winding from the circular cassette into a plurality of slots arranged in an inner annular surface of a stator core in a single operation.

A coil attachable to a tooth includes a first winding body including a first wound flat wire, a second winding body including a second wound flat wire that is located on a radial side of the first winding body and that is connected to the first winding body, a pair of first axially extending portions extending in an axial direction of a central axis on two circumferential sides of the tooth to which the first winding body is attached, and a pair of second axially extending portions extending in the axial direction of the central axis on two circumferential sides of the tooth to which the second winding body is attached. The pair of second axially extending portions is respectively arranged adjacent to radially outer sides of the pair of first axially extending portions.

The unit coil is formed by: bending the coil end portions of the intermediate body such that, in a layer in which a length in an axial direction between the coil end portions is large, positions of the coil end portions projecting furthest from the accommodation portions in the axial direction move away from positions of the accommodation portions in the stacking direction, compared to the previous state; and aligning the positions, in the axial direction, of the coil end portions at an inner side of the annular shape, for each of the layers.