Abstract: An electric machine provided with a stator structure including internal and external layers of interleaved pre-wound coils made of rectangular wire coated with enamel insulation varnish is described herein. The two layers of pre-wound coils allow the use of slightly different size of pre-wound coils, which facilitates their insertion into the stator slots.

Abstract: A method for forming the heads of coils made of rectangular wire so that it fits within the slots of the stator of an electric machine. The method includes receiving a coil having unformed first and second heads separated by first and second legs and applying controlled deformation to yield properly shaped heads. Actuators are provided for causing sequential actuated movements of one of the first and second legs to force the head-forming elements into contact with different portions of the first and second heads while allowing selective free movements of the other leg in response to the actuated movements.

Abstract: An electric machine provided with a stator structure including internal and external layers of interleaved pre-wound coils made of rectangular wire coated with enamel insulation varnish is described herein. The two layers of pre-wound coils allow the use of slightly different size of pre-wound coils, which facilitates their insertion into the stator slots.

Abstract: A method for forming the heads of coils made of rectangular wire so that it fits within the slots of the stator of an electric machine. The method includes receiving a coil having unformed first and second heads separated by first and second legs and applying controlled deformation to yield properly shaped heads. Actuators are provided for causing sequential actuated movements of one of the first and second legs to force the head-forming elements into contact with different portions of the first and second heads while allowing selective free movements of the other leg in response to the actuated movements.

Abstract: A machine that forms the heads of coils made of rectangular wire so that it fits within the slots of the stator of an electric machine. The machine receives a coil having unformed first and second heads separated by first and second legs and applies controlled deformation to yield properly shaped heads. The machine comprises first and second leg support mechanisms for gripping the first and second legs and head-forming elements mounted to the first and second leg support mechanisms for contacting portions of the heads of the coil while the first and second legs are gripped by the leg support. Actuators are provided for causing sequential actuated movements of one of the first and second legs to force the head-forming elements into contact with different portions of the first and second heads while allowing selective free movements of the other leg in response to the actuated movements.

Abstract: A machine that forms the heads of coils made of rectangular wire so that it fits within the slots of the stator of an electric machine is described herein. The machine receives a coil having unformed first and second heads separated by first and second legs and apply controlled deformation thereto to yield properly shaped heads. The machine comprises first and second leg support mechanisms for gripping the first and second legs and head-forming elements for contacting portions of the heads of the wire coil while the first and second legs are gripped by the leg support. The head-forming elements are mounted to the first and second leg support mechanisms.

Abstract: Electrically insulating material so foldable as to form an interphase insulator so configured as to be inserted in the slots of the stator or the rotor of an electric machine to prevent separate coils inserted in the same slot to be in direct contact with one another and to prevent the coil heads of different coils to be in direct contact is described herein. The interphase insulator may be so folded that the coil heads are properly insulated from one another.

Abstract: Electrically insulating material so foldable as to form an interphase insulator so configured as to be inserted in the slots of the stator or the rotor of an electric machine to prevent separate coils inserted in the same slot to be in direct contact with one another and to prevent the coil heads of different coils to be in direct contact is described herein. The interphase insulator may be so folded that the coil heads are properly insulated from one another.