Rotary electric machine and method of manufacturing the same

A rotary electric machine including:

• a stator core having a plurality of slots, a multi-phase stator winding composed of a plurality of wave-wound phase-windings having coil ends respectively disposed in a plurality of adjacent cylindrical areas at opposite ends of said stator core, and
• a rotor having a plurality of magnetic poles, wherein
• each of said plurality of wave-wound phase-windings comprises a pair of semi-phase windings made of a flat conductor segment disposed one pole pitch different from each other,
• each of said semi-phase windings comprises a starting end portion, a plurality of series-connected wave-coil units, and a connecting end connected to the same of the other of said pair of semi-phase windings,
• each of said plurality of series-connected wave-coil units comprises a pair of parallel in-slot portions and a pair of inclined crossing portions each of which has a U-shaped flat folded portion,
• said pair of semi-phase windings is mounted in said stator core to pile up in the radial direction so that one of said in-slot portions is on top of another in one of said slots and one of said crossing portions extending from one slot is in the same one of said plurality of cylindrical area as another of the next slot,
• each of said in-slot portions has a rectangular cross-section that has thinner radial sides than circumferential sides, whereby each of said plurality of cylindrical areas is approximately twice as thick as said conductor segment;
• and
• said coil ends pile up flat in the radial direction.

A rotary electric machine including:

• a stator having a plurality of slots,
• a multi-phase stator winding composed of a plurality of wave-wound phase-windings having coil ends respectively disposed in a plurality of adjacent cylindrical areas at opposite ends of said stator core and a rotor having a plurality of magnetic poles, each of said wave-wound phase-windings comprising:
• a pair of semi-phase windings made of flat conductor segment disposed in said slots one pole pitch different from each other, wherein
• each of said semi-phase windings comprises a starting end portion, a plurality of series-connected wave-coil units, and a connecting end connected to a connecting end of the other of said pair of semi-phase windings, and is mounted in said stator core to pile up in the radial direction,
• each of said plurality of series-connected wave-coil units comprises a pair of parallel in-slot portions and a pair of inclined crossing portions each of which has a U-shaped flat folded portion,
• said conductor segment has a rectangular cross-section that has thinner radial sides than circumferential sides, so that one of said in-slot portions is on top of another in one of said slots and one of said crossing portions extending from one slot is in the same one of said plurality of cylindrical areas as another of the next slot, whereby each of said plurality of cylindrical areas is approximately twice as thick as said conductor segment;
• and
• said coil ends pile up flat in the radial direction.