A stator manufacturing method that includes a lead wire bending process of inserting a plurality of concentrically wound coils into slots, each of the concentrically wound coils being formed by winding a flat conductive wire for a plurality of turns, each of the slots being formed between every two adjacent teeth extending radially inward from an annular back yoke of a stator core, and bending lead wire portions of the inserted concentrically wound coils projecting in an axial direction from an end surface of the stator core, and a second bending process of bending the lead wire portions using the connection parts as fulcrums so that the lead wire portions approach the end surface of the stator core along the circumferential direction of the stator core after the first bending process.

The coil winding device includes a nozzle configured to feed a wire to wind the wire around the winding core to form a coil, a plurality of hook rods disposed in predetermined intervals around an end part of the winding core, the wire drawn out from an edge of the coil being configured to be hooked to each of the plurality of hook rods during a forming process of the coil, a winding core rotating mechanism configured to rotate the winding core together with the plurality of hook rods, a hook rod rotating mechanism configured to rotate the plurality of the hook rods, and a wire drawing-out mechanism configured to draw out the wire from the edge of the coil and hook the wire on the hook rods during the forming process of the coil.

Disclosed herein are a motor and a method of manufacturing the motor. The motor includes a rotor, a stator including a plurality of coil bobbin unit groups, and a coil prepared on coil bobbin units by winding a wire sequentially on coil bobbin units of each coil bobbin unit group, cutting the wound wire at a cutting point, connecting one end of the cut wire to a neutral point port, and connecting the other end of the cut wire to a driving point port.

Winding bodies include: a first terminal wire that extends outward at a first axial end of a stator core from a radially innermost position inside slots; and a second terminal wire that extends outward at the first axial end of the stator core from a radially outermost position inside the slots, the first terminal wires are each led radially outward over coil ends of the stator winding, the second terminal wires are each led radially outward at positions that are nearer to the stator core than end portions of the first terminal wires that are led radially outward over the coil ends of the stator winding, and end portions of intraphase connecting second terminal wires are stacked in an axial direction with, placed in contact with, and connected to end portions of intraphase connecting first terminal wires that are subject to connection therewith.

In this method for manufacturing an armature winding for an electric machine, a rectangular conductor wire is wound helically by bending and shaping linking portions between rectilinear portions and coil ends to set angles while feeding the rectangular conductor wire, by repeating steps in which the rectangular conductor wire is fed by a set amount of feeding, the rectangular conductor wire is gripped and fixed by first through fourth chucks, the rectangular conductor wire is bent by pressing a first former near a root of the rectangular conductor wire, and gripping and fixing of the rectangular conductor wire by the first through fourth chucks is released.

A coil winding system that comprises a rotational movement element of the needles and a head (4) mounted thereon, the rotational movement element of the needles comprising a movement shaft (2a), arranged so as to move the head (4) linearly and rotationally. The rotational movement element of the needles further comprises an electro-magnetic element of rotational movement of the head (4) integrated to the movement shaft (2a).

A method for producing rotating electrical machines having a motor coil produced in a cantilevered manner for motors or generators, wherein the coil already surrounds the inner part during the manufacturing process, i.e. is pre-assembled, and this is also used as an aid for coil shaping during the production of the coil, includes a first step, in which the motor coil is wound in a stepwide process between two end faces over the magnetic inner part and completely surrounds the inner part, a second step, in which the shaping of the motor coil is carried out by pressing the winding wires by moving the shaft with the surface of the inner part against the inner side of the motor coil, in particular by eccentrically rolling off of the latter and pressing it against an abutment, and a third step, in which the pressed motor coil is baked by way of applying heat. Also provided is a rotating electrical machine.

A stator for an electric motor includes: a stator core that includes a plurality of teeth on which insulating portions are provided; and a coil formed by winding a wire around each of the teeth. A lead-in opening and a lead-out opening are formed in insulating portions provided on an outside diameter side of the stator core. The lead-in opening leads in a crossover wire of the coil routed to an outer peripheral side of the insulating portions to the side of the teeth. The lead-out opening leads out the crossover wire of the coil from the side of the teeth to the outer peripheral side of the insulating portions. The length from an axial end portion of the stator core on an insulating portion side to the lead-in opening is different from the length from the axial end portion to the lead-out opening.

A rotating electric machine includes: a stator core having a plurality of slots aligned along a circumferential direction; a stator having a stator coil with an enamel coating inserted into the slots of the stator core; and a rotor rotatably arranged over the stator core through a given gap. The stator coil includes: main coils of a plurality of phases in which a plurality of segment coils each having a rectangular cross-section wire formed into a substantially U-shaped wire in advance is connected to each other; a first sub-coil having a lead wire led from the slots and attached with an AC terminal, and connected to one end of the respective main coils; and a second sub-coil having a neutral wire led from the slots, and connected to the other end of the respective main coils. The lead wire and the neutral wire are each formed of a wire with a bend structure having a plurality of straights and bends.

There are provided a coil unit, a stator member, a motor, and methods of manufacturing these, configured to achieve downsizing and simplified manufacturing steps. The coil unit includes a coil, and a bus bar including a connection end portion to which the coil is connected. One end of the coil and the connection end portion are welded by cold pressure welding with end faces of them being butted in a welded portion.