Disclosed is a stator assembly. By means of the process steps, such as unit body winding, multi-unit preparation, winding assembly and stator embedding, that are sequentially implemented, winding of a single unit body can be achieved by means of a single flat wire, winding of a stator winding can be completed merely by means of a bending process in a whole unit body structure.

An electric motor includes a shaft, and a stator disposed around the outer periphery of the shaft and including a plurality of slots extending toward the shaft. A plurality of coil units are arranged respectively in the plurality of slots. The coil units are each formed of a plurality of wires connected in parallel. One of the coil units that is arranged in at least one of the plurality of slots formed in the stator includes a plurality of winding groups that are connected in series and that have a different number of turns from each other. The winding groups are arranged in the slot in descending order of the number of turns in the direction toward the shaft.

A stator and a manufacturing method thereof is enabled to easily determine the quality of welding produced between conductors. The stator includes a stator core and a stator winding installed in the stator core. The stator winding is configured by including multiple flat conductor segments in which conductors 34 are coated with insulating films 35, respectively. At a leading end of each of the conductor segment, an exposed portion 33 is formed in which the conductor is exposed. At a coil end section of the stator winding, a pair of exposed portions of different conductor segments are joined together by laser welding. A collective conductor width in a joining direction in which exposed portions join with each other is smaller at a laser irradiation incidence side, which is a side of the exposed portions receiving laser irradiation than that at a side opposite to the laser irradiation incidence side.

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).

A method of manufacturing a rotary electric machine armature that includes a cylindrical armature core in which a plurality of slots that extend in an axial direction are disposed in a circumferential direction and a coil wound around the armature core, the slots having respective radial openings that open in a radial direction, and the coil being formed by joining a plurality of segment conductors to each other.

The present invention relates to a method and an apparatus for forming a hairpin-shaped winding element from a conductor.

Impregnation plant for internally hollow cylindrical components (stators) of electric motors including working stations arranged linearly and sequentially, managed and controlled by central processing unit; and a plurality of motor-driven elements to impart rotatory motion, in both directions of rotation, and tilting motion, in both directions respective to a predefined plane, to each component mounted onto a respective support device when such support device is inserted into the plant working stations. Each support device has a spring collet in turn has blocks clamping the component onto the inner diameter of its respective cylindrical body. Each spring collet entirely crosses the component cylindrical body to rest on both of its respective circumferential ends. An impregnation method for electric motor components using the impregnation plant, wherein the component is rotatable in both directions about a support device predefined axis, and tiltable respective to a predefined plane of such support device.

In a method for mounting a prefabricated form-wound coil or tooth-wound coil on a layered laminated core to form a stator segment or stator, the form-wound coil or tooth-wound coil is insulated with insulation. Laminates are punched and stacked to form partial laminated cores and/or a laminated core, with the partial laminated cores being spaced apart from one another by spacers and forming substantially axially extending open slots of the laminated core. The form-wound coil or tooth-wound coil are radially inserted into the slots such as to embrace a tooth of the laminated core, and a removable auxiliary element is placed at an axial end face of the laminated core to protect the insulation of the form-wound coil or tooth-wound coil as the form-wound coil or tooth-wound coil is radially inserted into the slots. The auxiliary element is radially removed and repositioned on a further tooth of the laminated core.

The present disclosure is directed to slotless electric motor, in particular, to a method of manufacturing a stator for a slotless electric motor. An aspect of the disclosure provides a method of manufacturing a stator for a slotless electric motor, the method comprising: disposing a conductor in the shape of an annular cylinder; bonding a plurality of bonded lengths of the conductor, wherein the plurality of bonded lengths are separated by non-bonded lengths; folding the conductor to provide a plurality of petals repeated along the conductor, wherein each petal comprises a pair of bonded lengths connected by a non-bonded length; rotating each petal about a point on the second circle to align in parallel the bonded lengths of all of the petals to thereby provide a stator comprising a cylindrically-shaped conductor wherein the bonded lengths are equidistantly disposed around and from a central longitudinal axis of the cylindrically-shaped conductor.

A method is presented for producing an arrangement of coil elements for a plug-in coil of an electric machine. The method includes providing a workpiece carrier and producing an arrangement of rod-shaped coil elements for a plug-in coil of an electric machine on the workpiece carrier, wherein the following is respectively provided for the rod-shaped coil elements: accommodating and holding the coil elements by means of a displacement device; supplying the coil element onto the workpiece carrier by means of the displacement device into an assigned proximal position on the workpiece carrier, wherein the coil elements are hereby displaced form a distal position into the assigned proximal position with respect to the workpiece carrier; and transferring the coil elements in the proximal position on the workpiece carrier from the displacement device by a gripping device, which is formed on the workpiece carrier.