A winding overhang machining method includes: cutting off corners of tip portions of conductors to form welding surfaces which are angled with respect to axes of the respective conductors; exerting a pushing force on each of the conductors, which have been inserted through an iron core so as to protrude out of the iron core, to form a bend in a base portion of the conductor so that the welding surfaces of two of the bent conductors to be connected together become contiguous and form a welding line; and connecting the two conductors together by performing laser welding on the welding surfaces. With this arrangement, a winding overhang structure can be obtained by processing the tip portions of the conductors with pushing forces but not drag forces.

A switching module includes a housing that can be attached directly to an end of a stator and over line and neutral phase hairpins of the stator, electrically conductive platforms disposed in the housing and that can contact some of the hairpins, switches disposed in the housing, connected with the platforms, and that can selectively change connections of the hairpins between wye and delta configurations, and a conduit defining a coolant channel through the housing.

An insulating film removal method according to the present disclosure includes first, second, and third removal steps. In the first removal step, an insulating film coated on a junction surface and an opposed surface opposed to the junction surface is removed, the junction surface being a surface where a rectangular conductor is joined with another rectangular conductor. In the second removal step, a corner of the rectangular conductor is removed so that a burr is formed on the junction surface and a side surface, the side surface adjoining the junction surface and the opposed surface. In the third removal step, the insulating film coated on the side surface is removed so that a burr is formed on the junction surface side.

A rectangular wire is wound on a stator core having a plurality of teeth and a plurality of slots. A plurality of rectangular wire elements is provided by cutting a rectangular wire into a predetermined length and bending into a substantial U-shape. A plurality of rectangular wire pieces configured to form a coil by connecting predetermined end portions of the rectangular wire elements is molded as a sub-assembly. Each of the plurality of the rectangular wire elements is inserted into a predetermined pair of the slots from a first end face of the stator core such that the respective end portions of the rectangular wire elements project from a second end face of the stator core. The rectangular wire pieces of the sub-assembly are fixed to the end portions of the rectangular wire elements, thereby manufacturing a stator coil having compact coil ends easily.

A stator manufacturing device includes: an abutment member configured to form a bending start point in a lead wire segment coil among a plurality of segment coils inserted into a slot of a stator core, wherein the abutment member is configured to abut on a side surface of a projecting portion protruding from the slot of the lead wire segment coil from the outside in the radial direction of the stator core to form the bending start point; and a lead wire holding portion for holding the projecting portion of the lead wire segment coil, wherein the lead wire holding portion is configured to be movable along the radial direction and the axial direction of the stator core with respect to the abutment member.

A coil end shaping apparatus shapes a plurality of edgewise bent portions that are bent in the edgewise direction in a lead wire portion extending from one end of a coil, and includes first and second shaping dies capable of approaching each other to shape the edgewise bent portions provided on the base end side with respect to the edgewise bent portion e4 that is the closest to the free end side among the plurality of edgewise bent portions, and a third shaping die capable of cooperating with the second shaping die to shape the edgewise bent portion that is the closest to the free end side.

A rectangular wire is wound on a stator core having a plurality of teeth and a plurality of slots. A plurality of rectangular wire elements is provided by cutting a rectangular wire into a predetermined length and bending into a substantial U-shape. A plurality of rectangular wire pieces configured to form a coil by connecting predetermined end portions of the rectangular wire elements is molded as a sub-assembly. Each of the plurality of the rectangular wire elements is inserted into a predetermined pair of the slots from a first end face of the stator core such that the respective end portions of the rectangular wire elements project from a second end face of the stator core. The rectangular wire pieces of the sub-assembly are fixed to the end portions of the rectangular wire elements, thereby manufacturing a stator coil having compact coil ends easily.

A manufacturing device that is used in a manufacturing method for a rotary electric machine is equipped with an insertion roller having an outer circumferential surface configured to contact a coil lead line in such a manner that the coil lead line is inserted into accommodating grooves of an insulator, a roller support section that rotatably supports the insertion roller, and a bending unit that performs a bending process to bend the coil lead line by coming into contact with the coil lead line so as to form a terminal part.

A device for positioning the ends of at least first pair of legs of hairpin conductors extending from a stator core with respect to a welder tool includes a first clamping element and a second clamping element that are independently moveable radially. The first clamping element has a first clamping surface and said second clamping element has a second clamping surface, wherein the clamping surfaces radially face each other. The clamping elements form a first radially inner receiving section between the first clamping surface and the second clamping surface, having a first radial width dimensioned to axially receive and clamp a first pair of legs during welding, and a second radially outer receiving section inside the first and second clamping elements, having a second radial width dimensioned to receive at least a further pair of legs during welding of the first pair of legs.

First-fourth slots may be provided in an inner circumferential surface of a stator core. A coil may include first-third segments conductor. Each of the conductors may include a U-shape. The first segment conductor may be inserted in the first slot and the second slot in a state where a coupling portion of the first segment conductor is located at a position facing a first end surface. The second segment conductor may be inserted in the second slot and the third slot in a state where a coupling portion of the second segment conductor may be located at a position facing a second end surface. The third segment conductor may be inserted in the third slot and the fourth slot in a state where a coupling portion of the third segment conductor may be located at a position facing the first end surface.