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.

Provided is a segment-core coupled body, including a plurality of segment cores each including a core back and a tooth; and a plurality of coupling portions configured to couple the core backs to one another, wherein the plurality of segment cores and the plurality of coupling portions are each a laminated body of magnetic sheets, wherein the plurality of coupling portions each include: a posture holding portion adjacent to a gap defined between adjacent core backs; a first thin portion configured to couple one corner portion of the adjacent core backs and the posture holding portion; and a second thin portion configured to couple another corner portion of the adjacent core backs and the posture holding portion, and wherein, the posture holding portion projects toward a radially outer side with respect to the adjacent core backs.

A coil insertion guide device includes a positioning jig that positions a stator core; and a guide member that is provided in the positioning jig so as to be able to contact an end face of the stator core in an axial direction. A coil inserted into the slots along the radial direction of the stator core is guided by the guide members. The guide member includes a guide groove. The guide groove includes, on a side close to the end face of the stator core, a cuff support groove that houses and supports a cuff of one of the insulating members that protrudes from the end face of the stator core, and on a side far from the end face, a coil guide groove that protrudes toward an inside of the slot more than the cuff support groove and contacts the coil to guide movement of the coil.

An apparatus (200) for deforming conductors of at least one winding assembly (100), protruding from a side of a stator or of a rotor (114) of an electric machine. The at least one winding assembly (100) comprises a plurality of basic conductors (102) comprising at least one leg inserted into cavities (115) of stator or rotor (114), each having at least one respective free or terminal end (108, 110). The apparatus (200) comprises at least one twisting matrix (202, 203) adapted to rotate about an axis (X), comprising at least one gripping element (204) adapted to grip at least one free end (108, 110) and adapted to be moved in radial direction with respect to said axis (X). The apparatus comprises at least one guide (206, 207) adapted to guide the at least one gripping element (204) along the radial direction with respect to the axis (X); and a radial actuator (208), adapted to put in motion the at least one gripping element (204) along the radial direction with respect to the axis (X).

A method for welding copper-including members includes laser-welding a first member that includes copper, and a second member that includes copper and is located adjacent to the first member. A welding surface of the first member and a welding surface of the second member are melted by moving an irradiation position of a laser to turn in a spiral shape while approaching a center of the spiral when irradiating the laser on the welding surface of the first member and the welding surface of the second member.

A miniature step motor is constructed with a permanent magnet rotor and a hybrid stator assembly. The rotor, mounted for rotation on an axial shaft, has one or more rotor sections or pieces with a pair of magnetic poles on opposed circumferential surfaces of each piece. The stator assembly, with an inner diameter to receive the rotor, is formed from a stack of bipolar phase-stators positioned in different axial planes, each phase-stator interacting with a rotor section via a two-dimensional magnetic flux path that is independent of every other phase-stator in the stack. The at least one rotor section and the phase-stators have different amounts of rotor-stator rotational offsets at specified angles 180°/N relative to each other about the axial shaft, where N is the number of motor phases. The phase-stators can be mutually offset from one another, or the rotor sections can be mutually offset.

A method for introducing an insulating layer between stator or rotor grooves and for introducing winding packets with wire webs of coil wires of a coil winding is provided. The coil winding may be inserted into the stator or rotor grooves from a transfer tool. The method has the steps of: inserting insulating layers into transfer grooves of the transfer tool, wherein at least one section of each of the insulating layers lies radially outside of the transfer groove; transferring the wire webs of the winding packets into the transfer grooves; closing the insulating layers by folding the sections in the direction of the wire webs of the winding packets and fixing the sections in the folded position of the sections; and inserting the winding packets into respective stator or rotor grooves such that the folded sections are arranged between groove bases of the stator or rotor grooves and the wire webs of the winding packets.

Provided is a coil insertion device for inserting a wound coil into slots formed in a stator core and opening to a through-hole of the stator core, by placing the coil in the through-hole, and by expanding the coil to move the coil from inside toward outside with respect to the stator core. The coil insertion device includes a coil expander having a plurality of piece members arranged in an annular shape. The plurality of piece members are movable between a first position where the plurality of piece members are reduced in diameter so as to be insertable inside the wound coil, and a second position where the plurality of piece members are expanded in diameter from the first position to press the wound coil from inside toward outside, thereby inserting the wound coil into the slots at once.

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.

An insertion apparatus includes a conductor guide member that guides a prescribed region of an electric conductor to a slot of a stator core, and a support body that supports the conductor guide member. In this configuration, the conductor guide member can float in an axial direction of the stator core.