A production method of rotary electric machines is provided that can laser weld the leading end parts of a plurality of electrical conductors projecting from respective slots with high joint strength. A production method of rotary electric machines that produces a rotary electric machine by joining, by way of laser welding, leading end parts of a plurality of electrical conductors inserted in respective slots provided in a stator core and projecting from the respective slots, includes the steps of matching and arranging the leading end parts of two adjacent electrical conductors; and joining the leading end parts of the two adjacent electrical conductors by irradiating a laser onto the two adjacent electrical conductors from a direction sloped at an angle relative to a joining face of the leading end parts of the two adjacent electrical conductors.

A rotating electric machine includes: a stator core having a plurality of slots aligned along a circumferential direction; a stator having a stator coil with an enamel coating inserted into the slots of the stator core; and a rotor rotatably arranged over the stator core through a given gap. The stator coil includes: main coils of a plurality of phases in which a plurality of segment coils each having a rectangular cross-section wire formed into a substantially U-shaped wire in advance is connected to each other; a first sub-coil having a lead wire led from the slots and attached with an AC terminal, and connected to one end of the respective main coils; and a second sub-coil having a neutral wire led from the slots, and connected to the other end of the respective main coils. The lead wire and the neutral wire are each formed of a wire with a bend structure having a plurality of straights and bends.

A joining method for coil ends includes: pressing a pair of tapered portions such that a pair of first pressing jigs provided with a pair of detent portions is brought closer to the coil ends along an axial direction of the stator core, the pair of detent portions being fitted to the tapered portions; fixing axial positions of the pair of tapered portions such that the pair of detent portions is fitted to the pair of tapered portions so that the pair of tapered portions is sandwiched in a circumferential direction; fixing radial positions of the pair of tapered portions such that the pair of tapered portions is sandwiched by a pair of second pressing jigs so that the tapered portions of the pair of tapered portions make contact with each other; and welding a contacting portion where the tapered portions make contact with each other.

A stator coil forming method includes a bending step of bending portions of a linear lead wire so as to form bent portions; a cutting step of cutting curve parts of the bent portions thus formed, along a perpendicular plane that is approximately perpendicular to an extending direction of the lead wire so as to form coil segments; a U-shape forming step of bending the coil segments in a U-shape; an assembling step of assembling the coil segments to respective slots of a stator core; a tilting step of tilting both distal ends of the coil segments in a circumferential direction of the stator core so that cut surfaces of the distal ends are oriented toward a central-axis direction of the stator core; and a joining step of joining the distal ends of the coil segments adjacent to each other in a radial direction of the stator core.

A stator of an electric motor is provided. The stator includes a plurality of segments, each of the segments including a tooth having a magnetically-permeable material, an electric coil surrounding the tooth, and at least one insulator. The stator also includes a plurality of connectors, each connector including first and second terminals, the first terminal adapted to be inserted into the at least one insulator and to couple to the electric coil of each of the plurality of segments and a circuit board coupled to input power lines and including apertures adapted to receive the second terminals of the plurality of connectors. The circuit board is coupled to the electric coils of each of the plurality of segments via when the second terminals are received in the apertures.

A conductive wire welded structure of which a stator is composed can be obtained using a conductive wire welding method in which a plurality of conductive wires are welded together using a high-frequency induction heating device. This conductive wire welding method involves performing a disposition step in which a plurality of conductive wires are made to intersect and the end of at least one of the conductive wires is disposed at a location that is extended from an intersection portion, and a welding step in which the end of the at least one conductive wire that is at a location extended from the intersection portion is welded outside an induction heating coil by induction heating, and the welded material thereof is solidified at the intersection portion.

A rotating electric machine includes: a stator core having a plurality of slots aligned along a circumferential direction; a stator having a stator coil with an enamel coating inserted into the slots of the stator core; and a rotor rotatably arranged over the stator core through a given gap. The stator coil includes: main coils of a plurality of phases in which a plurality of segment coils each having a rectangular cross-section wire formed into a substantially U-shaped wire in advance is connected to each other; a first sub-coil having a lead wire led from the slots and attached with an AC terminal, and connected to one end of the respective main coils; and a second sub-coil having a neutral wire led from the slots, and connected to the other end of the respective main coils. The lead wire and the neutral wire are each formed of a wire with a bend structure having a plurality of straights and bends.

The present invention relates to a stator of an electric machine with a stator body having a stator axis, which stator body comprises stator grooves in which there runs an electric plug-in winding which is formed from multiple conductor elements (4), conductor elements (4) being provided which each run with conductor branches through one or two of the stator grooves and protrude from the stator grooves on at least one end face of the stator by means of conductor ends (4b) and form a winding head, the conductor ends (4b) of the conductor elements (4) being arranged in the corresponding winding head in a plurality of groups (7) distributed in the circumferential direction in relation to the stator axis, each group (7) comprising a plurality of conductor ends (4b) arranged in a radial direction in relation to the stator axis, in particular aligned in the radial direction, characterized in that at least one, in particular a plurality, of the conductor ends (4b) of each group (7), as viewed in the radial direction, has raised structures (8) arranged on both sides, in such a way that the raised structures (8) on a first side (14) of the conductor end (4b), when the entire group (7) of conductor ends (4b) is clamped between two clamping jaws, permit the conductor end (4b) adjacent to the first side (14) and the conductor end (4b) having structures (8) to be approached towards one another elastically or plastically by the clamping jaws in order for the relevant conductor ends (4b) to be welded, and, on an opposite, second side (15) maintain a distance between the conductor end (4b) adjacent to the second side (15) and the conductor end (4b) having structures (8) in order to prevent a welding of the relevant conductor ends (4b).

There are provided a coil unit, a stator member, a motor, and methods of manufacturing these, configured to achieve downsizing and simplified manufacturing steps. The coil unit includes a coil, and a bus bar including a connection end portion to which the coil is connected. One end of the coil and the connection end portion are welded by cold pressure welding with end faces of them being butted in a welded portion.

A manufacturing system for manufacturing a stator for an electric machine, in particular an electric motor, wherein the stator has a main part and a plurality of bent and/or straight bar conductors. The manufacturing system has the following: a bending machine for bending free ends of the bar conductors, a spreading machine for spreading the free ends of the bar conductors in the radial direction, a welding machine for welding the free ends of at least two bar conductors, and a holding device for the stator. The holding device has at least one first set of fingers for engaging between the bar conductors at a first end face of the main part. The holding device can be secured to the bending machine, the spreading machine, and the welding machine. The manufacturing system facilitates an accelerated and inexpensive manufacture of stators with bar conductors.