Embodiments of the currently claimed disclosure are directed to methods for inserting an undulated coil assembly in the slots of a hollow core of a dynamoelectric machine. In some embodiments, the method can include positioning at least a first coil portion of the coil assembly around a support member, aligning a guide device with respect to end faces and the slots of the core, feeding the first coil portion from the drum support member along the guide device to insert adjacent superimposed linear portions (LI) of the coil assembly in the slots, engaging the superimposed linear portions (LI) along at least one guide surface during the feeding, and relatively moving the core with respect to the guide assembly device to position the slots for receiving the superimposed linear portions (LI).

The invention is directed to an apparatus (100) and a method for manufacturing a partial nest or a nest (5) of pin conductors (1, 1.sub.i, 1.sub.o) for forming a stator. The apparatus (100) comprises a stator core template (10) with a block body (11) and radially extending ribs (12) forming slots (13) there between for insertion of legs (2, 2.sub.i, 2.sub.o) of the pin conductors (1, 1.sub.i, 1.sub.o). The apparatus (100) comprises at least one ring element (25, 33, 42) being arranged to provide an outer radial abutment face for inserted pin conductors (1, 1.sub.i, 1.sub.o).

A hairpin twisting device of a hairpin winding motor includes a fixing jig on which a stator core is seated, the stator core including a plurality of slots positioned through the stator core in a circumferential direction and including a plurality of layers positioned in the slot in a radial direction, and a twisting module positioned under the fixing jig and rotated in a predetermined direction to twist hairpins while clamping respective end portions of the plurality of hairpins inserted into the plurality of slots.

The invention relates to a device for bending at least one conductor element which is U-shaped in an initial state, wherein the device includes a first pivot unit having a first limb-receiving means, a second pivot unit having a second limb-receiving means and a guide assembly comprising a first guide element having a first shaping surface and a second guide element having a second shaping surface, and a corresponding method for bending at least one conductor element which is U-shaped in an initial state.

Disclosed are stators including a stator core having a plurality of slots formed in a circumferential direction, a plurality of coil bundles respectively inserted into the plurality of slots, connection coils each having one side joined to one of the plurality of coil bundles, and the other side joined to another of the plurality of coil bundles, and a plurality of layers being respectively formed in the plurality of slots in a radial direction of the stator core, wherein the plurality of coil bundles each comprises a plurality of hairpins each including a crown portion protruding toward one side in an axial direction of the stator core, and a leg portion protruding toward the other side in the axial direction.

Provided is a twisting device of a hair pin-type stator coil. The twisting device of a hair pin-type stator coil, which is to twist-form a plurality of hair pin-type stator coils inserted as a plurality of layers in a stator core, includes i) a base frame, ii) a coil fixing unit installed on the base frame through a plurality of support rods, iii) a twisting tool unit allowing a plurality of stator coils of two adjacent layers, among the plurality of layers, to be inserted thereinto, the two layers being rotated in different directions, and installed to be movable up and down in the base frame on a lower side of the coil fixing unit, iv) a tool driving unit installed on the base frame and operatively connected to the twisting tool unit.

In one embodiment, a stator coil that includes a first turn with two or more strands is provided. The first turn includes first and second opposite sides, a coil termination at a first end of the first turn and an inversion region disposed at a second end, opposite the coil termination. The stator coil also includes at least one additional turn with two or more strands. The at least one additional turn includes first and second opposite sides, and an inversion region located adjacent to the inversion region of the first turn. The first and second sides of the first turn are inverted relative to the first and second sides of the at least one additional turn outside their respective inversion regions.

A method and apparatus for inserting an undulated coil assembly (90) in the hollow core (101) of a dynamoelectric machine, the coil having a planar configuration with adjacent superimposed linear portions (LI) extending parallel to each other and a plurality of turn portions (T) connecting the linear portions (LI), comprising positioning at least a first coil portion (90′) of the coil assembly around a support member (200); aligning a guide assembly (302,303,304) with respect to the end faces and the slots (102) of the core (101); engaging the superimposed linear portions (LI) along guide surfaces that form a passage (301) during the feeding along the guide assembly (302,303,304); feeding the first coil portion (90) from the support member (200) along the guide assembly (302,303,304) to change orientation of adjacent superimposed linear portions (LI) being fed and to insert the adjacent superimposed linear portions being fed in the slots (102); relatively moving the core (101) with respect to the guide assembly (302,303,304) to position the slots (102) for receiving the superimposed linear portions (LI). A hollow core of a dynamoelectric machine wound with an undulated coil assembly comprising superimposed linear portions positioned at different pitch distances (PT1,PT2) in two adjacent slots (102).

An electrical machine with a winding support is provided, which comprises a cylindrical base body and support teeth projecting radially from the base body and has grooves bounded by the base body and in each case two of the support teeth, and at least one winding supported by the winding support, which winding is formed by conductively connected conductor sections, which are each guided through at least one of the grooves of the winding support and project beyond the winding support at the axial end faces of the winding support, wherein a respective clamping ring is arranged at each axial end face of the winding support, wherein each clamping ring forms support sections that each extend radially along a respective axial end face of a respective one of the support teeth and mechanically contact at least parts of the conductor sections guided through the grooves adjacent to the respective support tooth, wherein the respective support section contacts the axial end face of the respective support tooth in a contact region, which is spaced apart from the adjacent grooves.

The invention relates to a method for provided shaped rods, which are intended for the use in electric windings of electric machines. The invention comprises providing conductor wire (11); positioning the conductor wire (11) and a bending axis (26) for the conductor wire relative to one another, such that the longitudinal axis (18) of the conductor wire (11) and the bending axis (26) run at an oblique angle relative to one another; holding, gripping, or supporting the conductor wire (11) in a first and second section (20, 21) of the conductor wire (11); and carrying out a swivel bending or folding movement (30) between the first and second section (20, 21) of the conductor wire (11) about the bending axis (26). Thereby, a simultaneous forming of a combined torsional and also curved section (17, 19) in the conductor wire (11) and also a lateral offset (16) between the first and second section (20, 21) of the conductor wire (11) is made possible. Moreover, a correspondingly shaped shaped rod is indicated.