A coil insertion device includes: a pair of delivery jigs respectively formed with slits into which a pair of side portions of a coil that are parallel with each other can be inserted; and a side portion inserting mechanism configured to push out the side portions inserted into the slits from the slits to insert the side portions into slots of a stator core, the slots facing the slits, the side portion inserting mechanism has: pushing blocks inserted into the slits; and a pushing block moving mechanism configured to move the pushing blocks in a depth direction of the slits.

An apparatus for bending ends, arranged in annular layers, of bar conductors for an electrical machine are arranged in a stator main body having multiple coaxially arranged coupling elements with coupling recesses, by which the ends of the bar conductors can be taken layer by layer and plastically deformed. Each coupling element has a driving platform, which can be moved in the axial direction together with the coupling element. The coupling element belonging to a driving platform can be rotated on the driving platform. All of the driving platforms move axially on a common climbing linkage. Each driving platform has a dedicated first driving device for axially moving the driving platform and a dedicated second driving device for rotating the coupling element on the driving platform, wherein the two driving devices are moved axially, together with the driving platform. The apparatus is of a simple construction requiring little installation space.

A coil insertion device includes: a pair of delivery jigs respectively formed with slits into which a pair of side portions of a coil that are parallel with each other can be inserted; and a side portion inserting mechanism configured to push out the side portions inserted into the slits from the slits to insert the side portions into slots of a stator core, the slots facing the slits, the side portion inserting mechanism has: pushing blocks inserted into the slits; and a pushing block moving mechanism configured to move the pushing blocks in a depth direction of the slits.

An apparatus for molding a hairpin inserted into a stator core includes a clamping unit including a connection bracket mounted on a front end of a robot arm and at least one clamper mounted on the connection bracket and configured to be reciprocally driven in opposite directions in a straight line, and a mold unit detachably coupled with the at least one clamper and configured to press mold a head portion of the hairpin by a molding jig configured to be driven by the at least one clamper.

An apparatus for molding a hairpin inserted into a stator core includes a clamping unit including a connection bracket mounted on a front end of a robot arm and at least one clamper mounted on the connection bracket and configured to be reciprocally driven in opposite directions in a straight line, and a mold unit detachably coupled with the at least one clamper and configured to press mold a head portion of the hairpin by a molding jig configured to be driven by the at least one clamper.

A coil forming apparatus includes: a coil winding jig including a plurality of comb-shaped grooves; a coil conveying mechanism that pivotally conveys the belt-shaped coil along at least a portion of the outer periphery of the coil winding jig; and guide members guide the belt-shaped coil in an arc shape along an outer periphery of the coil winding jig while being in contact with the side ends, and allow the plurality of straight portions to be inserted into a respective one of the plurality of comb-shaped grooves in a second half portion of the belt-shaped coil upon pivot conveyance. The guide members include a reforming portion in a first half portion of the belt-shaped coil upon pivot conveyance, and the reforming portion deforms and reforms the belt-shaped coil in an arc shape in a state sandwiching the side ends of the belt-shaped coil.

An apparatus for bending ends, arranged in annular layers, of bar conductors for an electrical machine are arranged in a stator main body having multiple coaxially arranged coupling elements with coupling recesses, by which the ends of the bar conductors can be taken layer by layer and plastically deformed. Each coupling element has a driving platform, which can be moved in the axial direction together with the coupling element. The coupling element belonging to a driving platform can be rotated on the driving platform. All of the driving platforms move axially on a common climbing linkage. Each driving platform has a dedicated first driving device for axially moving the driving platform and a dedicated second driving device for rotating the coupling element on the driving platform, wherein the two driving devices are moved axially, together with the driving platform. The apparatus is of a simple construction requiring little installation space.

A conductor shaping apparatus includes a driving device that relatively rotates an upper die and a lower die and integrally rotates the upper and lower dies with respect to a shaping member. The driving device rotates one of the upper and lower dies in a direction from an edgewise bent portion to a distal end of a conductor so as to separate the one of the upper and lower dies from the other. One of the upper and lower dies includes a supporting surface configured to support a side surface of an end portion of the conductor as the edgewise bent portion is formed in the end portion, and a guide surface that is formed to intersect the support surface. The guide surface extends away from the end portion of the conductor in a direction opposite to a bent direction of a flatwise bent portion closest to the edgewise bent portion as it extends away from the supporting surface on an opposite side of a rotational axis.

A coil forming apparatus includes: a coil winding jig including a plurality of comb-shaped grooves; a coil conveying mechanism that pivotally conveys the belt-shaped coil along at least a portion of the outer periphery of the coil winding jig; and guide members guide the belt-shaped coil in an arc shape along an outer periphery of the coil winding jig while being in contact with the side ends, and allow the plurality of straight portions to be inserted into a respective one of the plurality of comb-shaped grooves in a second half portion of the belt-shaped coil upon pivot conveyance. The guide members include a reforming portion in a first half portion of the belt-shaped coil upon pivot conveyance, and the reforming portion deforms and reforms the belt-shaped coil in an arc shape in a state sandwiching the side ends of the belt-shaped coil.

A method can be used for inserting a hairpin in a stator core. The method includes unwinding a coil spiral-wound on an uncoiler, forming a decoated portion by decoating a predetermined portion on the coil, bending the coil in multiple stages to two-dimensionally form a leg portion and a head portion of a hairpin, cutting the coil formed with the leg portion and the head portion by a predetermined length, and moving the hairpin to be inserted into a stator core while three-dimensionally forming the head portion.