Patent ID: 7530157
Filing Date: 2009-05-12
Classification: H02K,Y10T

Abstract:
1. A method of manufacturing coils of a rotary electric machine to be mounted in a stator thereof having a predetermined number of stator slots comprising the steps of: forming a predetermined number of pairs of U-shaped conductor segments to be disposed radially inside and outside in the stator slots, each of the U-shaped conductor segments having a pair of parallelly extending radially inside and outside straight portions and a turn portion connecting the inside and outside straight portions; twist-forming the U-shaped conductor segments by using an inside twisting formation jig composed of a first inside ring and a first outside ring and an outside twisting formation jig composed of a second inside ring and a second outside ring; and radially compressing the U-shaped conductor segments that are twist-formed in radially inward directions, wherein the twist-forming comprises: holding one of each pair of straight portions by one of holding slots that are circumferentially formed in each of the first and second inside rings and first and second outside rings; and coaxially rotating the first and second inside rings and the first and second outside rings to shift relative circumferential position between the inside rings and the outside rings by a predetermined angle; and wherein the compressing comprises: setting a diameter of an inscribed circle of the conductor segments by a metal core having a cylindrical outer periphery; forming guide spaces by a plurality of guiding arrow members respectively disposed in radial directions at equal intervals between the guiding arrow members; and compressing the conductor members in radially inner directions when straight portions of the conductor segments are disposed in the guide spaces by a plurality of thrusting arrow members respectively disposed in the guide spaces.