Abstract: A method of manufacturing a stator coil includes the steps of: (1) forming substantially planar electric wires each including in-slot portions to be received in slots of a stator core and turn portions to be located outside of the slots to connect the in-slot portions; (2) rolling each of the planar electric wires into a spiral shape by plastically deforming the turn portions; and (3) assembling the rolled electric wires through relative axial movements therebetween, each of the relative axial movements being made by axially moving first and second components relative to each other with both the first and second components radially elastically deformed and with each of the first and second components circumferentially positioned by at least one positioning member, each of the first and second components being one of the rolled electric wires or an electric wire sub-assembly comprised of a plurality of the rolled electric wires.

Abstract: A method of manufacturing a stator coil includes the steps of: (1) forming substantially planar electric wires each including in-slot portions to be received in slots of a stator core and turn portions to be located outside of the slots to connect the in-slot portions; (2) rolling each of the planar electric wires into a spiral shape by plastically deforming the turn portions; and (3) assembling the rolled electric wires through relative axial movements therebetween, each of the relative axial movements being made by axially moving first and second components relative to each other with both the first and second components radially elastically deformed and with each of the first and second components circumferentially positioned by at least one positioning member, each of the first and second components being one of the rolled electric wires or an electric wire sub-assembly comprised of a plurality of the rolled electric wires.

Abstract: A method of manufacturing a stator coil to be wound in and around a stator by bending an insulating-coating conducting wire so as to alternately have slot-held conductor sections to be held in slots of the stator and a coil-end conductor sections each mutually connecting two of the slot-held conductor sections outside the slots. The method includes arranging three or more pairs of molds at predetermined intervals along the insulating-coating conducting wire, each pair of molds having paired molds facing each other with the wire located therebetween. First, the coil-end conductor sections are formed by moving the mold pairs such that the paired molds come closer to each other. Then the slot-held conductor sections are formed by moving the molds, in parallel, in both the longitudinal direction along which the insulating-coating conducting wire extends and in a direction perpendicular to the longitudinal direction.

Abstract: A first tool set holds a wire covered with an insulation film at a bending point of the wire to protrude the wire from the first tool set. A second tool set holds the protruded portion of the wire. The second tool set is rotated about the first tool set to bend the wire along a wall of the first tool set and to form a boundary corner in the wire at the same radius of curvature as the wall. The wire is released from the second tool set and is moved to place the first tool set at another bending point while protruding from the first tool set. The second tool set is placed at the protruded portion of the wire. When the wire is bent at a predetermined number of bending points and is rounded, a stator coil formed in a corrugated shape is manufactured.

Abstract: A first tool set holds a wire covered with an insulation film at a bending point of the wire to protrude the wire from the first tool set. A second tool set holds the protruded portion of the wire. The second tool set is rotated about the first tool set to bend the wire along a wall of the first tool set and to form a boundary corner in the wire at the same radius of curvature as the wall. The wire is released from the second tool set and is moved to place the first tool set at another bending point while protruding from the first tool set. The second tool set is placed at the protruded portion of the wire. When the wire is bent at a predetermined number of bending points and is rounded, a stator coil formed in a corrugated shape is manufactured.

Abstract: A stator coil to be wound in and around a stator is manufactured. An insulating-coating conducting wire is bent to alternately provide the wire with slot-held conductor sections held in slots of the stator and a coil-end conductor section mutually connecting the slot-held conductor sections outside the slots. The coil-end conductor section is deployed outside the stator in the circumferential direction thereof. In manufacturing the stator coil, three or more pairs of molds are located along a portion of the wire in its longitudinal direction at predetermined intervals. The coil-end conductor section is formed by moving the molds along a direction allowing paired molds of each mold to come closer to each other, and the slot-held conductor sections is formed by moving the molds, in parallel, in both a direction perpendicular to the longitudinal direction and the longitudinal direction thereof.