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.

In the electric rotating machine, a crank portion that is displaced in a radial direction of an armature iron core is provided in an apex portion of a coil end portion; a first oblique side that slants with respect to an axis-direction endface of the armature iron core connects a first coil conductor portion with the crank portion; a second oblique side that slants with respect to the axis-direction endface of the armature iron core connects a second coil conductor portion with the crank portion; at least one of the first oblique side and the second oblique side has an inflection point, before being connected with the crank portion, that functions as a base point of a bending portion that is bent toward a radially outside of the armature iron core.

Provided is a device for manufacturing a stator, the device including a winding jig configured to wind a coil and to manufacture a winding coil, and an insertion jig configured to receive the winding coil from the winding jig and to insert the winding coil into a stator core, wherein the winding jig comprises a body extending along a longitudinal direction (L1), a power supply unit configured to make the body revolve around a central shaft of the body, and a protrusion formed on a surface of the body.

Provided is a coil insertion method and device that are capable of mechanically manufacturing, with good efficiency, a spirally wound stator core. This coil insertion method comprises: a winding step for winding U-phase, V-phase, and W-phase coils; a step for inserting coils into a transfer block, in which the U-phase, V-phase, and W-phase coils are inserted and held in a plurality of holding grooves of the transfer block so as to spirally overlap, the transfer block having a columnar shape overall, and the holding grooves being formed in radial fashion so as to open from an axial center part toward an outer periphery; and a step for inserting coils into a stator core, in which the transfer block is inserted into an inner periphery of the stator core, and a side part of the coils held in the holding grooves is pressed radially outward toward predetermined slots of the stator core and inserted from the inner peripheral side of the stator core into the slots.

A wire winding device includes: a rotary plate rotationally driven by a electric motor; a pair of columnar members provided on the rotary plate such that a rotation center axis of the rotary plate is positioned between the columnar members; the winding core respectively attached to the pair of columnar members; and a holding mechanism capable of changing and holding a gap distance between the pair of columnar members, the pair of columnar members are respectively provided on the rotary plate so as to be movable along a straight line, the straight line extending orthogonal to the rotation center axis of the rotary plate, and respective distances from the rotation center axis of the rotary plate to the pair of columnar members are held by the holding mechanism so as to become the same.

A method of forming a stator winding including forming a first conductor having a first end, a second end, and a first plurality of end turns therebetween, the plurality of end turns having at least a first winding pitch, forming a second conductor having a first end portion, a second end portion, and a second plurality of end turns therebetween, the plurality of end turns having at least the first winding pitch, bending a first section of the first conductor at a select one of the plurality of end turns, overlaying the second conductor onto a second section of the first conductor, and unbending the first section of the first conductor such that a first portion of the second conductor is below the first section of the first conductor and a second portion of the second conductor is atop the second section of the first conductor forming a first conductor pair.

The invention relates to a method for producing a coil (6), in which, by means of casting, a semi-finished product (5) in the form of an elongate conductor is formed in a cavity (2) of a casting tool and the coil (6) is formed following a demolding of the semi-finished product (5) by shaping this semi-finished product (5), wherein the form of the semi-finished product (5) may be derived from a shape of the finished coil (6) by stretching along a longitudinal axis of the coil (6) and/or by bending this longitudinal axis, and wherein the semi-finished product (5), during the shaping, is bent and compressed so that windings of the coil (5) already present in the semi-finished product (5) are brought closer to one another at least in some regions during the shaping and are brought into an arrangement along the longitudinal axis of the finished coil (6), wherein the conductor, whilst being shaped, is twisted or bent by no more than a right angle over the course of each individual turn. The invention also relates to a coil (6) produced in this way and to a casting tool which may be used to carry out the described method.

The invention relates to a method for producing a helical metal body (Γ), in which initially a preformed, helical metal body is produced in a mould by a casting method and is subsequently compressed along its longitudinal axis by deformation.

The present application creates a roller molding method for producing a spiral structure or a coil, in particular a spiral structure for use in electric machines, wherein material is supplied between a first roller and a second roller running opposite thereto, wherein the first roller has first teeth, and the second roller has second teeth, said first and/or second teeth having tooth flanks with cavities for receiving the supplied material, wherein the teeth are designed and aligned such that the cavity of at least one tooth is at least temporarily delimited by the surface of a tooth of the other roller when the rollers are rotating such that the supplied material is molded between the teeth into a portion of the spiral structure or the coil.

Phase coils include a first phase coil and a second phase coil, the phase coils are configured by connecting together end portions of the coil terminals of the first phase coil and the second phase coil that extend outward from identical radial positions in the slots axially outside the stator core so as to be radially outside a coil end group, and the coil terminals of the first phase coils of the phase coils of three phases include joint coil portions that extend outward from the slots within a pitch of one magnetic pole, are then bent so as to extend in an identical circumferential direction, and are placed in close proximity to the end portions of the coil terminals of the second phase coils that are intended for connection therewith.