Method and processing line for manufacturing a stator for electric motors

A method for manufacturing a stator for electric motors, the stator comprising a stator body which comprises a plurality of side-by-side teeth arranged radially about a common central axis and defining, between them, a plurality of sectors in which one or more coils of conducting wire are at least partially inserted,

• the method comprising:
• a coil making step, wherein one or more conducting wires are wound on a winding tool such as to form at least one coil comprising at least one linear portion in turn comprising a plurality of individual linear portions of wire and which is adapted to be inserted into one of said sectors;
• a coil housing step, wherein the linear portion of the coil is inserted into a stator component comprising a subset of said plurality of side-by-side teeth, said linear portion of the coil being inserted between said two side-by-side teeth;
• a shaping step, wherein said stator component is deformed such as to move the at least two side-by-side teeth close to each other, such as to achieve a finished stator portion comprising the two side-by-side teeth which define, between them, the sector in which the linear portion of the coil is comprised;
• an assembling step, wherein a plurality of finished stator portions, achieved by means of respective housing and shaping steps, are assembled to one another such as to form said stator body,
• characterized by the step of:
• after the shaping step, rototranslating of a first finished stator portion with respect to a second finished stator portion, wherein the first finished stator portion and the second finished stator portion engage the same coil, until reaching the relative position which said first finished stator portion will have with respect to said second finished stator portion in the stator body, and consequently deforming the coil,
• or as an alternative
• before the shaping step, rototranslating a first stator component with respect to a second stator component, until reaching the relative position which said first stator component will have with respect to said second stator component in the stator body, deforming the coil correspondingly to the arrangement of the first rototranslated stator component and of the second rototranslated stator component and proceeding to the coil housing step,
• and further characterized by a pressing and/or carburizing step, wherein said linear portion of the at least one coil is subjected to a pressing step or to a thermal carburizing treatment, or to both the pressing step and the thermal carburizing treatment, in the desired order or contemporaneously, such as to compact said individual linear wire portions.