Abstract: A stator core has a plurality of slots. Insulating members are formed into a cylindrical shape and are inserted into the slots. Axial ends of the insulating members are expanded respectively and deformation marks thinner than the other portion are formed respectively. Then, the insulating members are moved toward the expanded ends to position the deformation marks in the out of the slots. After that, the conductors are inserted into the slots from the expanded side of the insulating members. Therefore, insulation failure at the portions of the deformation marks is prevented.

Abstract: A method of peeling off a coating of an elliptical cross sectional insulated conductive wire has a groove forming process of forming a groove nearly perpendicular to a longitudinal direction of the insulated conductive wire at given positions within a peeling region thereof, a first peeling process of peeling off the coating by moving a pair of first cutting edges in a longitudinal direction of the insulated conductive wire and perpendicularly to a longer diameter direction of the cross section thereof toward the groove from opposite ends of the peeling region, and a second peeling process of peeling off the coating at the peeling region by moving a pair of second cutting edges in a direction perpendicular to the longitudinal direction and in parallel with the longer diameter direction of the cross section thereof. As a result, the coating all around the outer circumference of the insulated conductive wire at the peeling region may be completely peeled off.

Abstract: In a twisting formation method having an inside jig provided in a ring shape with inside holding portions for folding one of the straight portions of a near letter U shaped wire and an outside jig provided in a shape of ring concentric with that of the inside holding portions with outside holding portions for folding the other of the straight portions, the connecting portion of the near letter U shaped wire being formed in a twisted shape by rotating relatively the inside and outside jigs, the method includes urging leading ends of the straight portions and the connecting portion in a contracting direction.

Abstract: A stator core has a plurality of slots. Insulating members are formed into a cylindrical shape and are inserted into the slots. Axial ends of the insulating members are expanded respectively and deformation marks thinner than the other portion are formed respectively. Then, the insulating members are moved toward the expanded ends to position the deformation marks in the out of the slots. After that, the conductors are inserted into the slots from the expanded side of the insulating members. Therefore, insulation failure at the portions of the deformation marks is prevented.

Abstract: A stator core has a plurality of slots. Insulating members are formed into a cylindrical shape and are inserted into the slots. Axial ends of the insulating members are expanded respectively and deformation marks thinner than the other portion are formed respectively. Then, the insulating members are moved toward the expanded ends to position the deformation marks in the out of the slots. After that, the conductors are inserted into the slots from the expanded side of the insulating members. Therefore, insulation failure at the portions of the deformation marks is prevented.

Abstract: A method of manufacturing a stator of a rotary electric machine is comprised of the following steps: providing a plurality of U-shaped basic conductor segments and a plurality of U-shaped connection conductor segments; forming the U-turn portions and straight portions into crossover portions, inserting the pair of straight portions of the basic and connection conductor segments into prescribed two slots of a stator core from one end thereof to extend from the other end, bending one of the pair of straight portions in the direction opposite to the other of the pair of extended straight portions so that the edges of straight portions extending from the prescribed slots can adjoin each other, connecting the adjoining edges to form a plurality of phase coils, and removing the U-turn portion of the connection conductor segments to form terminals of the phase coils.

Abstract: A method of manufacturing a U-shaped conductor segment which has a U-shaped head and a pair of legs includes setting a straight conductor wire of a prescribed length on the outer peripheries of a pair of parallel rollers, and pushing a bender against one side of the conductor wire opposite the rollers between the pair of rollers so that the conductor wire can be bent to allow the bender to pass between the pair of rollers.