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.

An apparatus for pre-assembling a winding for an electric machine stator or rotor includes a plurality of hairpins with two legs having non-circular cross-section, a ring including a plurality of slots and an outer containment ring acting in containment along the perimeter of the ring. An inner cam block and an outer cam block, surrounding and radially facing the inner cam block, are arranged opposite to the exit face of the ring. The cams are adapted to be crossed, in use, by the two legs when they cross the ring at the same time; the cams open into a free circular space between the two cam blocks. A method for pre-assembling a winding set for an electric machine stator or rotor is also provided. Hairpins are inserted in sequence in the slots of the apparatus. A finished winding set positioned in the free circular space is obtained by successive rotations of the ring.

A process for making a continuous bar winding (4) for an electric machine is described, comprising: a) a step of providing a template (10) having a template axis (X) and a circular array of slots (11) extended about said template axis (X), said circular array of slots having a number of slots equal to a number of slots of the stator or of the rotor of said electric machine, each slot (11) of said circular array having a first and a second open end face (11A, 11B) which are axially spaced from one another and a third open end face (11C), said third face (11C) being a longitudinal face extended between said first and second end faces (11A, 11B) b) a step of providing a conductive bar (20); c) a step of locking a locking portion (21) of said conductive bar; d) a step of inserting the conductive bar (20) into the slots (11) of said array and shaping the conductive bar (20) so that such conductive bar (20) repeatedly passes through the slots (11) of said array from the side of the first open end faces (11A) to the side of the second open end faces (11B) and vice versa, so that said bar (20) has a plurality of bar portions (20B, 20E, 20H) received in the slots (11) of said array and a plurality of connecting portions (20C, 20D; 20F, 20G) projecting beyond said first and second open end faces (11A, 11B), each of said connecting portions joining a pair of said bar portions (20B, 20E, 20H) received in the slots (11) of said array; in which said step d) comprises: d1) an operation of inserting a first bar portion (20B) of said plurality of bar portions into a respective slot (11) of said circular array of slots (11) through said third face (11C) of such slot (11); d2) an operation of shaping a first connecting portion (20C, 20D) of said plurality of connecting portions (20C, 20D; 20F, 20G); d3) an operation of inserting a second bar portion (20E) of said plurality of bar portions (20B, 20E, 20H) into a further slot (11) of said array, different from the slot (11) into which said first bar portion (20B) has been inserted, through said third face (11C) of the further slot (11); in which said first connecting portion (20C, 20D) joins said first and second bar portions (20B, 20E) projecting beyond the second end faces (11B) of the slots (11) in which said fi

A stator for a rotating electric machine includes a laminated core, and an electrically conductive winding including a winding top layer with electrically conductive top bars, and a winding bottom layer with electrically conductive bottom bars. Each groove of a stator segment of the laminated core has arranged therein a top bar and a bottom bar in adjacent relationship. The top and bottom bars protrude out of the grooves. A connecting element connects a free end of a top bar to a free end of a bottom bar of an adjacent stator segment and includes an inclined section to connect two ends of the connecting element. The ends are angled relative to the inclined section. One end of the connecting element is connected to the free end of the bottom bar and the other end of the connecting element is connected to the free end of the top bar.

Provided is an electric generator having a stator, a rotor, a plurality of coils including conductors shaped as a tape, the stator extending axially along a longitudinal axis between a first axial end and a second axial end, the stator including a plurality of slots, the plurality of slots being circumferentially distributed around a longitudinal axis of the stator, each of the coils respectively comprising: two slot portions respectively housed in two slots of the stator, two end-windings axially protruding from stator at the first axial end and a second axial end.

A process for making a continuous bar winding (4) for an electric machine is described, comprising: a) a step of providing a template (10) having a template axis (X) and a circular array of slots (11) extended about said template axis (X), said circular array of slots having a number of slots equal to a number of slots of the stator or of the rotor of said electric machine, each slot (11) of said circular array having a first and a second open end face (11A, 11B) which are axially spaced from one another and a third open end face (11C), said third face (11C) being a longitudinal face extended between said first and second end faces (11A, 11B) b) a step of providing a conductive bar (20); c) a step of locking a locking portion (21) of said conductive bar; d) a step of inserting the conductive bar (20) into the slots (11) of said array and shaping the conductive bar (20) so that such conductive bar (20) repeatedly passes through the slots (11) of said array from the side of the first open end faces (11A) to the side of the second open end faces (11B) and vice versa, so that said bar (20) has a plurality of bar portions (20B, 20E, 20H) received in the slots (11) of said array and a plurality of connecting portions (20C, 20D; 20F, 20G) projecting beyond said first and second open end faces (11A, 11B), each of said connecting portions joining a pair of said bar portions (20B, 20E, 20H) received in the slots (11) of said array; in which said step d) comprises: d1) an operation of inserting a first bar portion (20B) of said plurality of bar portions into a respective slot (11) of said circular array of slots (11) through said third face (11C) of such slot (11); d2) an operation of shaping a first connecting portion (20C, 20D) of said plurality of connecting portions (20C, 20D; 20F, 20G); d3) an operation of inserting a second bar portion (20E) of said plurality of bar portions (20B, 20E, 20H) into a further slot (11) of said array, different from the slot (11) into which said first bar portion (20B) has been inserted, through said third face (11C) of the further slot (11); in which said first connecting portion (20C, 20D) joins said first and second bar portions (20B, 20E) projecting beyond the second end faces (11B) of the slots (11<