Abstract: A coil includes a plurality of segment coils. Ends of two corresponding segment coils are electrically connected together via a coupling member or by being fitted together. Each of the plurality of segment coils includes a conductor-exposed portion located close to a connection portion between the corresponding segment coils and to be brought into contact with a probe of a resistance measurement apparatus. When the coil is manufactured, the ends of the plurality of segment coils are electrically connected to the ends of other corresponding segment coils, and electric resistances of connection portions between the ends are measured for each layer of the ends of the segment coils.

Abstract: A method of removing an insulating coating layer of coil wiring includes: a fragmentation step in which a line-shaped region of the insulating coating layer, which separates a removal-planned portion and a remain-planned portion of the insulating coating layer, is removed; a laser irradiation step in which laser light which transmits through the insulating coating layer but which is absorbed by a coil wiring is irradiated from a side of an outer surface of the removal-planned portion toward a boundary of the coil wiring with the insulating coating layer, to carbonize a boundary portion between the insulating coating layer and the coil wiring of the removal-planned portion by generation of heat of the coil wiring; and a coating turn-over step in which air is blown onto the removal-planned portion to turn over and blow off the removal-planned portion.

Abstract: An insulation film peeling method which radiates laser light onto a front end portion of an insulation film-coated conducting wire including a conducting wire and an insulation film in a longitudinal direction, and which peels a part of the insulation film up to a peeling boundary of a predetermined regulated peeling length, includes performing a rectilinear scan of a first region, in which a radiation position of the laser light moves from one side toward the other side and then moves from the other side toward the one side upon reaching the other side, and performing a unidirectional scan of a second region, in which the radiation of the laser light is performed from one side toward the other side and then the radiation position returns to the one side in a state in which the radiation of the laser light stops upon reaching the other side.

Abstract: A coil bending machine is a machine that, in a stator core including a yoke and multiple teeth and having a slot formed between circumferentially adjacent teeth, while lead portions of a segment coil which is a U-shaped lead wire including a bent portion K and two lead portions R extending from the bent portion are inserted into two slots, push-bends end portions of the lead portions protruding from an axial end face of the stator core toward the stator core. The coil bending machine includes a coil bending member that push-bends the end portions of the lead portions protruding from the axial end face of the stator core toward the stator core, and a coil pressing mechanism that press-fixes a segment coil inside the slot toward the yoke, from the radially inner side of the stator core.

Abstract: Provided is a stator manufacturing method including: inserting a plurality of segment coils into a plurality of slots formed in a stator core; bending arms of the segment coils that protrude from the stator core, in a circumferential direction of the stator core; before or after bending the segment coils in the circumferential direction, directing parallel to each other leading end portions of the segment coils that are adjacent to each other in a radial direction of the stator core; and welding together the leading end portions of the segment coils with the leading end portions directed parallel to each other.

Abstract: A bending-forming jig used in bending and forming a protruding portion of a leg portion of a U-shaped conductor toward a circumferential direction, the protruding portion protruding from an axial end surface of a stator core, the bending-forming jig including a ring portion and a claw portion, the claw portion including a first abutting surface that rises from an axial end surface of the ring portion with the surface directed in the circumferential direction and abuts against a tip portion of the protruding portion from the circumferential direction, and a projecting portion that projects, at a tip end of the claw portion, in the circumferential direction from the abutting surface and abuts against the tip portion of the protruding portion from the axial direction toward the axial end surface of the ring portion.

Abstract: Provided is a manufacturing method for a stator coil in which end portions of one-side conductor segments inserted into slots from the side of one end in an axial direction of a stator core and end portions of other-side conductor segments are connected to each other through coupling members inside the slots. The method includes: pressing in the one-side conductor segment or the other-side conductor segment in an insertion direction in a state where the end portion of the one-side conductor segment or the end portion of the other-side conductor segment, or an end portion of the coupling member has been moved toward the inner circumferential side of the stator core; connecting the end portion of the one-side conductor segment and the end portion of the other-side conductor segment to each other; and executing the pressing in and the connecting sequentially from the outer circumferential side of the stator core.

Abstract: A method of producing a rotating electric machine stator includes an insertion step, bending step, and pressing step. In the insertion step, two leg portions of each U-shaped coil wire of a stator coil are inserted into different slots, such that protruding portions as distal end portions of the leg portions protrude in parallel with an axial direction of the stator core. In the bending step, the protruding portion of a first leg portion is bent in a first circumferential direction of the stator core, at a proximal end portion of the protruding portion as a bending start point, from a condition where the protruding portion protrudes from the slot in parallel with the axial direction of the stator core. In the pressing step, a distal end of the protruding portion bent in the first circumferential direction is pressed toward its proximal end in a second circumferential direction.

Abstract: 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.

Abstract: A coil includes a plurality of segment coils. Ends of two corresponding segment coils are electrically connected together via a coupling member or by being fitted together. Each of the plurality of segment coils includes a conductor-exposed portion located close to a connection portion between the corresponding segment coils and to be brought into contact with a probe of a resistance measurement apparatus. When the coil is manufactured, the ends of the plurality of segment coils are electrically connected to the ends of other corresponding segment coils, and electric resistances of connection portions between the ends are measured for each layer of the ends of the segment coils.

Abstract: 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.

Abstract: A laser welding method for a stator coil forms an abutting surface by abutting a side face of a first lead portion of a first rectangular wire to a side face of a second lead portion of a second rectangular wire. A laser beam is focused on a position more inward than a surface of an upper end of the abutting face between the first lead portion and the second lead portion, and the laser beam is moved in a helical loop on the upper end of the abutting face between the first lead portion and the second portion so as to melt the conductor wires to form a molten pool. The molten pool is then moved along the abutting face while the molten pool is continuously formed.

Abstract: Provided is a manufacturing method for a stator coil in which end portions of one-side conductor segments inserted into slots from the side of one end in an axial direction of a stator core and end portions of other-side conductor segments are connected to each other through coupling members inside the slots. The method includes: pressing in the one-side conductor segment or the other-side conductor segment in an insertion direction in a state where the end portion of the one-side conductor segment or the end portion of the other-side conductor segment, or an end portion of the coupling member has been moved toward the inner circumferential side of the stator core; connecting the end portion of the one-side conductor segment and the end portion of the other-side conductor segment to each other; and executing the pressing in and the connecting sequentially from the outer circumferential side of the stator core.

Abstract: A method of removing an insulating coating layer of coil wiring includes: a fragmentation step in which a line-shaped region of the insulating coating layer, which separates a removal-planned portion and a remain-planned portion of the insulating coating layer, is removed; a laser irradiation step in which laser light which transmits through the insulating coating layer but which is absorbed by a coil wiring is irradiated from a side of an outer surface of the removal-planned portion toward a boundary of the coil wiring with the insulating coating layer, to carbonize a boundary portion between the insulating coating layer and the coil wiring of the removal-planned portion by generation of heat of the coil wiring; and a coating turn-over step in which air is blown onto the removal-planned portion to turn over and blow off the removal-planned portion.

Abstract: Provided is a stator manufacturing method including: inserting a plurality of segment coils into a plurality of slots formed in a stator core; bending arms of the segment coils that protrude from the stator core, in a circumferential direction of the stator core; before or after bending the segment coils in the circumferential direction, directing parallel to each other leading end portions of the segment coils that are adjacent to each other in a radial direction of the stator core; and welding together the leading end portions of the segment coils with the leading end portions directed parallel to each other.

Abstract: A bending-forming jig used in bending and forming a protruding portion of a leg portion of a U-shaped conductor toward a circumferential direction, the protruding portion protruding from an axial end surface of a stator core, the bending-forming jig including a ring portion and a claw portion, the claw portion including a first abutting surface that rises from an axial end surface of the ring portion with the surface directed in the circumferential direction and abuts against a tip portion of the protruding portion from the circumferential direction, and a projecting portion that projects, at a tip end of the claw portion, in the circumferential direction from the abutting surface and abuts against the tip portion of the protruding portion from the axial direction toward the axial end surface of the ring portion.

Abstract: A laser welding method for coil wires includes welding two coil wires by irradiating a laser beam to an upper end edge of butted surfaces of side surfaces of tip end portions of the two coil wires. At this time, a molten pool is formed at the center of a welding portion on the upper end edge by scanning the laser beam in a plurality of continuous loop shapes from one or both welding end portions, and welding is performed to make the molten pool at the center portion of the welding portion greater in welding depth than other molten pools by controlling at least one among a movement pitch, a loop area, a laser scanning speed, and a laser power of loops of the laser beam.

Abstract: A method of producing a rotating electric machine stator includes an insertion step, bending step, and pressing step. In the insertion step, two leg portions of each U-shaped coil wire of a stator coil are inserted into different slots, such that protruding portions as distal end portions of the leg portions protrude in parallel with an axial direction of the stator core. In the bending step, the protruding portion of a first leg portion is bent in a first circumferential direction of the stator core, at a proximal end portion of the protruding portion as a bending start point, from a condition where the protruding portion protrudes from the slot in parallel with the axial direction of the stator core. In the pressing step, a distal end of the protruding portion bent in the first circumferential direction is pressed toward its proximal end in a second circumferential direction.

Abstract: A stator coil includes a plurality of flat wire-shaped coil pieces extending in a circumferential direction of a rotary electric machine at a position on an outer side of a stator core in an axial direction of the rotary electric machine. At the position on the outer side of the stator core in the axial direction, a distal end portion of one of the coil pieces, extending in a first direction in the circumferential direction, is joined with a distal end portion of another one of the coil pieces, extending in a second direction in the circumferential direction. The second direction in the circumferential direction is reverse to the first direction in the circumferential direction. An axially outer end face of the distal end portion of each coil piece is a circular arc face that is convex toward the outer side in the axial direction.

Abstract: An insulation film peeling method which radiates laser light onto a front end portion of an insulation film-coated conducting wire including a conducting wire and an insulation film in a longitudinal direction, and which peels a part of the insulation film up to a peeling boundary of a predetermined regulated peeling length, includes performing a rectilinear scan of a first region, in which a radiation position of the laser light moves from one side toward the other side and then moves from the other side toward the one side upon reaching the other side, and performing a unidirectional scan of a second region, in which the radiation of the laser light is performed from one side toward the other side and then the radiation position returns to the one side in a state in which the radiation of the laser light stops upon reaching the other side.