The invention relates to a method for compacting coil windings (52) which are wound on a tooth core (10) of a stator segment (1), wherein an insulation layer (36) is disposed between coil windings and the tooth core, and the tooth core (10) has, between a yoke region (14) and a tooth region (12) in a tooth height direction (ZH), a tooth core neck (16) and has, between the yoke region (14) and the tooth head (12) in a tooth width direction (ZB), groove halves (30, 30) running in a tooth length direction (ZL), in which groove halves the coil windings (52) lie, and wherein according to the invention the coil windings (52) are compressed in the tooth width direction (ZB) and in the tooth length direction (ZL) by at least four pressing jaws (84, 90, 90, 100, 110, 112, 112). The invention also relates to a device, wherein according to the invention the device has, for compressing the coil windings (52), coil contour jaws (110, 110) which can be moved in a tooth width direction (ZB) and coil head jaws (90, 90) which can be moved in a tooth length direction (ZL). The invention further relates to a stator segment (1) compacted by means of the method, the stator segment having a distance space between each of a plurality of uninsulated surfaces of the tooth core (10) in the groove base gap and/or at the edge of the pole surface (20) of the tooth head (12) and a coil (50) wound around the tooth core (10).

A rotor assembly method includes an assembly step configured to install a stack of laminations on a rotor shaft of a rotor, wherein the stack of laminations includes an inner portion and an outer portion which is, compared to the inner portion, more distant to the rotor shaft. A compression step includes compressing the inner portion to provoke accordingly a fan-out of the outer portion, so as to form a compact inner portion and a fan-out outer portion. A compacting step includes compacting the fan-out outer portion to form a compact outer portion, a compact lamination package including the compact inner portion and the compact outer portion being thus formed.

The disclosure relates to a method for producing a winding of a winding carrier of an electric machine. The method includes providing a laminated core. The laminated core has an axis and a first slot for accommodating a first winding segment for producing the winding. The first slot extends in the direction of the axis. The first slot is arranged on a first circle as viewed in the direction of the axis, through the circle center point of which first circle the axis extends. The method includes: arranging the first winding segment in the first slot, where a first region of the first slot protrudes from the laminated core; and bending the first region by applying a first force acting in the direction of the axis and by applying a first force acting tangentially to the first circle onto the first region in a first direction tangentially to the first circle.

A stator manufacturing apparatus includes an insertion tool inserted into a stator core, the insertion tool having a plurality of holding grooves formed on an outer periphery, the insertion tool being configured such that a pair of side portions of a stator coil are disposed in two of the holding grooves separated by a predetermined width; and a pressing tool having a plurality of plate-like pushers narrowed toward tips arranged on a pressing body in correspondence with the positions of the plurality of holding grooves of the insertion tool. The pressing tool is configured to push the pairs of side portions of the stator coils inserted in the holding grooves radially outwardly and insert the side portions into the corresponding slots. A recessed groove enabling grippers to be inserted when the stator coil is disposed using the grippers for gripping the pair of side portions is formed on the outer periphery of the insertion tool.

A stator of a rotary electrical machine has a stator body formed by a stack of metal sheets. The stator body is delimited by inner and outer radial surfaces. Notches in the stator body extend axially. Each notch has a notch base and a notch opening, and the notch opening is on the side of the inner radial surface. A stator winding is supported by the stator body, and the winding has a plurality of winding parts. Each part is accommodated in one of the notches. Each of the notches at the notch opening has a closure element. Each winding par in a notch is retained between the notch base and the closure element. The closure elements are formed by offsetting at least one of the metal sheets of an adjacent notch in the direction of the notch.

A coil end bending jig pushes down a plurality of coil ends of coil segments held by a toric stator core, the plurality of coil ends being arranged on a same circumference. The coil end bending jig includes a plurality of bending units each having a bending tooth that makes contact with a corresponding one of the coil ends, and a guide member having a plurality of guiding slits into which the plurality of bending units is inserted, respectively. The plurality of guiding slits extends from an inner peripheral side of the stator core to an outer peripheral side of the stator core so as not to intersect with each other when viewed from an axial direction of the stator core.

A stator includes an annular stator core having a plurality of slots arranged in the circumferential direction at predetermined intervals and a stator coil formed of a plurality of electric conductor wires mounted on the stator core. Each of the electric conductor wires has a plurality of in-slot portions received in the slots of the stator core and a plurality of turn portions that connect, on the outside of the slots, adjacent pairs of the in-slot portions. The stator coil has first and second coil end parts and that respectively protrude axially outward from a pair of axial end faces of the stator core. At each of the coil end parts, the turn portions of the electric conductor wires are stacked in a radial direction of the stator core, and the axial heights h1 of the turn portions are set so as to gradually increase from the radially inside to the radially outside.

A device for bending a plurality of winding segments to form a winding of a winding carrier of an electric machine is provided. The device includes: a holding device designed for holding in place the winding carrier in which the winding segments are arranged; a main bending device, including a number of main locking elements, which point towards the holding device, are arranged along first sections of a circumferential line and are designed to lock exposed end sections of first winding segments; and a partial bending device, including a number of partial locking elements, which point towards the holding device, are arranged along second sections of the circumferential line and are designed to lock exposed end sections of second winding segments. The holding device on the one hand and the main bending device and the partial bending device on the other hand are rotatable relative to each other.

A stator including: a conductor disposed in a slot formed in a stator core; and an insulator disposed between the slot and the conductor, the stator including a coolant flow path through which a coolant flows between the slot and the conductor. The insulator includes a foam layer that foams when heated inside the slot. The foam layer includes: a foaming-function portion that fills a gap between the slot and the conductor by exhibiting a heat-induced foaming function; and a foaming-function reduction portion that is thinner than the foaming-function portion due to a reduction in the heat-induced foaming function of the foam layer, and that forms a gap between the slot and the conductor through which the coolant can flow.

A stator including: a conductor disposed in a slot formed in a stator core; and an insulator disposed between the slot and the conductor, the stator including a coolant flow path through which a coolant flows between the slot and the conductor. The insulator includes a foam layer that foams when heated inside the slot. The foam layer includes: a foaming-function portion that fills a gap between the slot and the conductor by exhibiting a heat-induced foaming function; and a foaming-function reduction portion that is thinner than the foaming-function portion due to a reduction in the heat-induced foaming function of the foam layer, and that forms a gap between the slot and the conductor through which the coolant can flow.