A method of manufacturing a coil includes forming a wound body by winding a coil wire in multiple layers, and forming a coil by pressing the wound body using a die surrounding the wound body and compressively deforming the wound body. The wound body has a contour of a rectangular or substantially rectangular shape in cross section, and includes coil wire portions located in the cross section of the coil wire, the coil wire portions being aligned along each side of the rectangular or substantially rectangular shape. The coil has a contour of a fan shape or approximate fan shape in the cross section, where the coil wire portions are aligned in a direction along an arc and a radial direction of the fan shape or approximate fan shape.

A method for producing a skewed stator having a stator winding made from segmented conductors includes providing a stator core having a large number of axially layered stator core elements which form a plurality of slots extending from one end-face of the stator core to an opposite end-face, and which extend parallel in an axial direction. A large number of segmented conductors are provided which each have two leg portions extending parallel to each other and a connection portion electrically connecting the leg portions. The leg portions are introduced into the slots, and the stator core elements are rotated in a circumferential direction so they are displaced relative to each other in a circumferential direction and the slots form an inclination in a circumferential direction. The leg portions are bent by the rotation have an inclination corresponding to the slots. The stator core elements are fixed relative to each other.

A motor includes a rotor and a stator including a stator core and a winding including a first extension extending with respect to the stator core toward one side in a rotation-axis direction of the rotor, a second extension extending toward a rotation-radial direction outside of the rotor from an end of the first extension on the one side in the rotation-axis direction, and a third extension extending toward the one side in the rotation-axis direction from an end at the rotor rotation-radial direction outside of the second extension, and connected to a circuit device, and the winding forming a coil around the stator core, and such that an inner bent portion at a boundary between the first and second extensions is disposed at the one side in the rotation-axis direction with respect to an outer bent portion at a boundary between the second and third extensions.

A coil bending machine is a machine that, in a stator core including a yoke and multiple teeth and having a slot formed between circumferentially adjacent teeth, while lead portions of a segment coil which is a U-shaped lead wire including a bent portion K and two lead portions R extending from the bent portion are inserted into two slots, push-bends end portions of the lead portions protruding from an axial end face of the stator core toward the stator core. The coil bending machine includes a coil bending member that push-bends the end portions of the lead portions protruding from the axial end face of the stator core toward the stator core, and a coil pressing mechanism that press-fixes a segment coil inside the slot toward the yoke, from the radially inner side of the stator core.

A winding machine, including a receiving element for receiving a base body including teeth onto which a winding is to be wound, a nail winding head through which a wire can be guided in parallel to a surface of each tooth in order to place the wire inside a groove between two teeth of the base body, so that the tooth can be wound with the wire, and at least one retaining finger, wherein the wire can be positioned inside the groove by the retaining finger independently of the nail winding head in order to determine a target location of the wire inside the groove.

An apparatus for bending ends, arranged in annular layers, of bar conductors for an electrical machine are arranged in a stator main body having multiple coaxially arranged coupling elements with coupling recesses, by which the ends of the bar conductors can be taken layer by layer and plastically deformed. Each coupling element has a driving platform, which can be moved in the axial direction together with the coupling element. The coupling element belonging to a driving platform can be rotated on the driving platform. All of the driving platforms move axially on a common climbing linkage. Each driving platform has a dedicated first driving device for axially moving the driving platform and a dedicated second driving device for rotating the coupling element on the driving platform, wherein the two driving devices are moved axially, together with the driving platform. The apparatus is of a simple construction requiring little installation space.

A positioning device (10; 50; 60) for positioning wire ends (14) in the manufacture of an electrical machine (12) has a positioning unit (13) which has an alignment element (22a) and a counter-alignment element (22b) which are arranged one above the other in two parallel planes (16, 18) and can be displaced relative to each other along a displacement path (34), being at least partially superimposed or superimposable. Thereby, the alignment element (22a) has at least one through recess (24a) and the counter alignment element (22b) has at least one counter through recess (24b), which are arranged and designed in such a way that a clear positioning passage (99) perpendicular to the two planes (16, 18) of the alignment element (22a) and the counter-alignment element (22b), through which the at least one wire ends (14) can extend and the cross-sectional area of which can be varied by displacing the alignment and counter-alignment elements (22a, 22b) with respect to each other. In order to distort the wire ends as little as possible, the at least one through recess (24a) on the aligning element (22a) and the at least one counter through recess (24b) on the counter-aligning element (22b) each have two rectilinear edge sections (30a, 30b, 30c, 30d) which run in the respective plane (16, 18) at an oblique angle to the direction of displacement (FIG. 3).

An electrically-assisted turbocharger includes a shaft extending along an axis, a compressor wheel, a turbine wheel, a housing, and an electric machine. The electric machine includes a rotor rotatably coupled to the shaft and a stator lamination stack radially spaced from the rotor. The stator lamination stack has circumferentially spaced teeth defining gaps therebetween. The electric machine also includes a coil winding disposed in the gaps between the circumferentially spaced teeth and a guard plate disposed at one of the first and second stator ends. The guard plate extends radially away from the axis and includes a plurality of teeth guards extending radially, with each of the teeth guards aligned with one of the teeth of the stator lamination stack to electrically insulate the coil winding from the teeth of the stator lamination stack.

A method and a device by which conductor ends of hairpins sticking out from stator slots are shaped to form coil windings. The ends are shaped in the radial direction using different widening tools allowing the ends to be engaged individually or in pairs so that a first part is at a first radial position, a second part is at a second radial position and a third part is at at least one intermediate position in between. Subsequently, the ends are shaped in the circumferential direction using twisting tools, wherein a twisting tool located further out has inwardly open inner receiving pockets, and a twisting tool located further in has outwardly open outer receiving pockets. At least one of the twisting tools has both inner and outer receiving pockets, one of these located at the at least one intermediate position to shape the third part of the ends.

A coil insertion device includes coil diameter expanders, the coil diameter expanders being configured to insert a coil assembly in a wound state into slots of a stator core by expanding the coil assembly in diameter from inside of the stator core, each of the coil diameter expanders includes: a coil presser that is arranged inside the coil assembly and presses coil end portions of the coil assembly outward from inside to expand the coil end portions in diameter; and a restrictor that is arranged outside the coil assembly, restricts outward movement of the coil end portions expanded in diameter by the coil presser, and sandwiches the coil end portions of the coil assembly inserted in the slots with the coil presser.