Device and method for deforming a conductor protruding from one side of a stator or rotor of an electric machine

Abstract

A device (200) for deforming a conductor of at least one winding assembly (100) protruding from one side of a stator or rotor (114) of an electric machine. The at least one winding assembly (100) comprises a plurality of basic conductors (102) comprising at least one leg inserted into a cavity (115) of the stator or rotor (114), each leg having at least one corresponding free end or terminal end (108, 110). The device (200) comprises at least one torsion matrix (202, 203) adapted to rotate about an axis (X), the torsion matrix (202, 203) comprising at least one clamping element (204), the at least one clamping element (204) adapted to clamp at least one free end (108, 110) and adapted to move in a radial direction relative to the axis (X). The device comprises at least one guide (206, 207) and a radial actuator (208), wherein the at least one guide (206, 207) is suitable for guiding at least one clamping element (204) along a radial direction relative to an axis (X); the radial actuator (208) is suitable for moving at least one clamping element (204) along a radial direction relative to the axis (X).

Description

Technical Field

[0001] The present invention relates to a device and method for deforming a conductor protruding from one side of a stator or rotor of an electric machine. In particular, the present invention relates to a twisting process of a conductor end on a welding side. Background Art

[0002] It is known to provide winding sets of electrical bar conductors for a stator or rotor of an electrical machine, such as a generator or a motor.

[0003] In this type of winding, an electrical strip conductor forms an element of the winding, which is shaped in a step sequence and inserted into the stator or rotor together with others so that the ends of these elements can be welded together to form a predetermined winding pattern, also called an electrical strip winding.

[0004] Special types of electrical strip conductors are often referred to in technical terms as "hairpins" because they have the original shape of a hairpin for hair. In the following, the term "hairpin" will be used for ease of reference.

[0005] A hairpin comprising two free ends (hereinafter also indicated by the term "terminals"), which are assembled on the stator or rotor of the electric machine so as to form a circular arrangement, is generally defined by the term "winding group". Thus, depending on the desired type of operation, a bar winding may comprise one or more groups, said one or more groups being concentric with one another, wherein the hairpins are electrically connected to one another according to a predetermined pattern.

[0006] The stator or rotor core of a radial flux machine is essentially a ring with two planes and two cylindrical surfaces, with a generator perpendicular to the two planes and parallel to the axis of rotation of the rotor of the machine. Unless otherwise specified, the radial, circumferential and axial directions hereinafter refer to the axis of the latter. One of the two cylindrical surfaces is at least partially adjacent to the air gap of the machine to which the stator or rotor belongs and defines a set of slots in which the straight parts of the windings are accommodated. The two plane surfaces are divided into an insertion surface or side and a surface or side opposite to the insertion side. The part of the winding protruding from the core is called the head. The end of the free part of the conductor belongs to the head protruding from the side opposite to the insertion head, most of which is subjected to welding. If there are protrusions connected in a bridge-like manner in the winding, the protruding part belongs to the head protruding from the insertion side. The part protruding from the insertion side, whether free or connected in a bridge-like manner, is denoted below as the part protruding from the insertion side.

[0007] The area of ​​the stator or rotor core between the slots and the adjacent slots is called a tooth. The number of teeth is equal to the number of slots. The connecting part of the core teeth also defines the part of each slot and is located on the opposite side of the slot opening on the air gap of the mechanism relative to the connecting part of the core teeth itself, and the connecting part of the core teeth is called a yoke.

[0008] The slots can be divided into a matrix of positions, in each of which a leg of a rod-shaped conductor can be placed. Conductors accommodated in the same radial position of the slots define a so-called winding layer.

[0009] In other words, the term "layered" or "layer" refers to an annular array of terminals or free ends: each group comprises two layers, an inner layer and an outer layer. The method and device of the invention allow the conductors protruding from one or more welding sides to be deformed, relative to the layers defined by the rectilinear portions (legs) of these layers housed in the slots, so as to modify, preferably by using a single device, the diameter and number of layers defined by the free ends of said conductors.

[0010] As for the cross section of the hairpin, it can be rectangular, round or square. In particular, a rectangular or square cross section refers to a substantially rectangular or square cross section with rounded edges. There are also other types of cross sections (e.g. trapezoidal shapes) whose edges (like the previous rectangular cross sections) are rounded. The cross section of the hairpin itself is known to the person skilled in the art, so it will not be described again.

[0011] A known hairpin forming process basically provides three main steps: preforming, twisting on the insertion side and twisting on the welding side.

[0012] The preforming provides an initial bend of the straight strip, by means of which a "U" or "P" shape can be obtained. An example of a forming method and a corresponding apparatus is described in US patent US 7,480,987.

[0013] In this first step, the hairpin comprises two side-by-side legs connected at one end, which can be of the same length ("U" shape) or of different lengths ("P" shape). Each leg of the hairpin thus has a free end opposite the connected end. Each free end is provided with an end face resulting from the cutting of the conductor used to form the hairpin, which end face is therefore substantially a face transverse to the conductor itself.

[0014] An example of a preformed hairpin is shown in FIG. 1 , wherein a flat base conductor 102 is shown having two legs 104 , 106 and a connection 112 .

[0015] The preformed hairpin is then subjected to a so-called twisting step from the insertion side, in which the legs of the hairpin are stretched substantially relative to one another. In this respect, a twisting device from the insertion side is used, which provides concentric rollers that can rotate relative to one another. On each guide roller, a recess or cavity is provided that develops substantially parallel to the axis of rotation of the roller, into which the legs of the hairpin can be inserted. One leg of the hairpin is inserted into the cavity of the first roller, the other leg into the cavity of the second roller adjacent in radial direction.

[0016] The relative rotation between the two concentric rollers causes an expansion of the connection which will be substantially equal to the angular distance between the two stator or rotor slots housing the hairpin when the hairpin is mounted on said stator or rotor of an electric machine.

[0017] Figure 2 An example of the configuration of a hairpin after twisting from the insertion side is shown. In the figure, it can be noted that the connection 112 has a region on its top where the cross section of the conductor undergoes a 180° rotation relative to the inside surface of the hairpin (the surface passing through the inside of the hairpin and including the two legs).

[0018] Since the twisting process of the insertion side is known per se to the person skilled in the art (eg from US Pat. No. 7,805,825) and is not a specific subject matter of the present description, it will not be described further.

[0019] The torsion is applied from the insertion side to obtain the winding assembly before inserting the winding into the stator.

[0020] The hairpin can also be obtained by stamping, ie from a straight conductor pressed against a contrast of a "die" type system. The cross section of a stamped hairpin is substantially non-rotating relative to the middle surface of the hairpin.

[0021] There are other types of hairpins known in the prior art: so-called "I-pins", "W-shaped conductors" and "multi-strand hairpins".

[0022] In the context of this specification, a base conductor is a conductor that is to be inserted into a rotor or a stator.

[0023] The winding assembly may comprise, for example, a set of basic conductors having a connection on one side and mutually parallel legs, in particular free ends or terminals, on the other side so that they can be inserted, for example, into corresponding slots of a stator core.

[0024] In other configurations, there may be windings without a connection, or there may be windings with a connection and a free end on the same side.

[0025] The side of the stator or rotor core through which the legs of the base conductor are inserted is called the "insertion side" or "insertion face", while the side opposite to the insertion side through which the legs of the base conductor protrude is called the "welding side" or "connection side" or "welding face" or "exit face".

[0026] Typically, the free end of a leg of a base conductor protruding, for example, from the stator core can be subjected to a second twisting performed by a corresponding device, which is called “twist from the welding side”. Figure 3 An example of a base conductor after undergoing a twisting process from the weld side is shown.

[0027] The main purpose of twisting from the welding side is to bring together the two free ends of the legs that are initially on different circumferences but in two radial directions spaced from each other.

[0028] For example, the approach between the ends is achieved by inserting each layer of the free ends of the legs of the basic element into the seat or groove of the corresponding torsion ring. This approach of the ends is determined by rotating the mutually concentric torsion rings relative to each other.

[0029] For example, by using the distance between the parts accommodated in the grooves of the two ends to be approached as a unit, the number of grooves between the parts is taken as a distance of three grooves, and the approach can be achieved by rotating two grooves of one of the rings in one direction and rotating one groove of the other ring in the opposite direction.

[0030] Thus, the basic conductor comprises a first leg portion which is retained in a corresponding slot of, for example, a stator; a portion which is inclined relative to the main axis of the stator core in the direction of rotation of the rings; and an end portion which is substantially parallel to the main axis of the stator core but in a different radial direction relative to the first leg portion.

[0031] An example of a method and a twisting device for welding the side is described, for example, in the US patent US 8,215,000. In particular, a twisting device is described which allows obtaining different twists of the end inserted into the same ring. Different twists can be achieved, for example, by providing an annular portion comprising a slot, which can be moved along the circumference of the ring itself. The mobility means that, once the ring is rotated, the end of the base conductor inserted into the slot of the movable ring delays twisting until the movable portion is close to the rest of the ring structure.

[0032] In any case, the welding process of the ends of the elementary conductors is a very delicate step of the process by means of which a strip winding can be obtained due to the close proximity of the elementary conductors to each other.

[0033] In fact, according to the prior art, although torsion devices on the welding side are widely known, they are not without disadvantages.

[0034] First, although the proximity of the ends of the basic element is a desirable feature, this reflects the complexity of the welding process. In fact, if welding must be performed only between two ends, for example, this step must be very precise to prevent the immediately adjacent ends from being involved.

[0035] Furthermore, due to the proximity of the ends, electrical phenomena such as arcing between the terminal pairs are possible even with isolation.

[0036] Again, using a twisting device according to known techniques, if the number of conductors accommodated in each stator (or rotor) slot is high, there is a misalignment between conductors close to each other and the corresponding cavities of the twisting device, which are instead separated by radially spaced walls.

[0037] Furthermore, the radial proximity between the legs prevents the insertion of insulating rings between layers of the same group. Summary of the invention

[0038] Therefore, there is a need to address the above-mentioned shortcomings and limitations in the prior art.

[0039] Therefore, there is a need to provide an apparatus and method that allows for easier welding of the free ends of a base conductor.

[0040] Furthermore, there is a need for a device that can be integrated into the devices commonly used for twisting on the weld side of a winding assembly.

[0041] Furthermore, it would be desirable to provide a device that makes it easier to weld a given free-end assembly.

[0042] Furthermore, there is a need for an apparatus and method that allows automation of the bending of the free ends to facilitate the subsequent welding step.

[0043] Furthermore, there is a need for an apparatus and method which allows the slots of the torsion ring to be aligned with corresponding conductors protruding straight from the stator, if the number of conductors accommodated in the rotor or stator grooves is large, so that the terminals are spaced a certain distance apart to facilitate the insertion of the torsion ring into the grooves.

[0044] Furthermore, there is a need for an apparatus and method that allows for automatic insertion of insulating rings between layers of the same group, either before or after bending of the protruding conductors, or facilitates manual insertion of insulating rings.

[0045] This requirement is met by a device according to claim 1 and by a method according to claim 15 . BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Other features and advantages of the invention will become more apparent from the following description of a preferred embodiment given by way of non-limiting example, in which:

[0047] - FIG. 1 diagrammatically shows a perspective view of a preformed flat elementary conductor according to the prior art;

[0048] - Figure 2 A perspective view of a hair clip according to the prior art is diagrammatically shown;

[0049] - Figure 3 The prior art is shown in a diagrammatic manner. Figure 2 A perspective view of the hairpin in the figure after twisting on the welded side;

[0050] - Figure 4 A first embodiment of the device according to the invention is shown diagrammatically;

[0051] - Figure 5 The diagram shows the Figure 4 A cross-sectional view of the front side of the device taken along section AA;

[0052] - Figure 6 The diagram shows the Figure 4 A cross-sectional view of the front side of the device taken along section BB;

[0053] - Figure 7 The diagram shows Figure 4 A top view of components of the device;

[0054] - Figure 8 The diagram shows Figure 4 A top view of the device in FIG. 1 with some components removed;

[0055] - Fig. 9 The diagram shows Figure 4 A top view of the device in FIG. Figure 8 In comparison, the components in this device are further removed;

[0056] - Fig.10 and 11 The diagram shows a partial Figure 4 There are two steps in the operation of the device shown in;

[0057] - Fig.12 A possible embodiment of the device according to the invention is shown diagrammatically from the top;

[0058] - Fig.13 A possible alternative embodiment of the device according to the invention is diagrammatically shown in a top view;

[0059] - Fig.14is a perspective view of a device according to the present invention;

[0060] - Fig.15 A perspective view from the top diagrammatically showing part of a device according to the invention; and

[0061] - Fig.16 is a diagrammatic representation of a possible method of operation of the device according to the invention.

[0062] It is worth noting that, as those skilled in the art will easily understand from the following description and disclosure, the elements of the different embodiments described below may be combined together to provide other embodiments without limiting the technical concept of the present invention.

[0063] With regard to detailed features not described (eg minor elements which are usually used in the prior art in similar solutions), the present description also relates to the prior art for their implementation.

[0064] When introducing an element in the specification or claims, it should always be understood as "at least one" or "one or more" unless otherwise stated.

[0065] When a list of elements or features is listed in the present specification, it should be understood that the present invention “includes” or “comprises” these elements according to the present specification.

[0066] In the drawings, similar or equivalent elements are denoted by the same reference numerals.

[0067] For the purposes of this specification, a "flat" or "square" strip conductor refers to a strip conductor having four substantially flat sides, each side being connected to the adjacent sides and forming a typically rounded edge. Therefore, the words "flat" or "square" or equivalent words used to describe the cross-section of a strip conductor are used in a general sense and should not be interpreted as excluding the fact that such a strip conductor has distinctly rounded corners connected to the substantially flat sides. The expression "flat conductor" refers to a conductor having two opposing sides, the distance between the two opposing sides being greater than the distance between the other two opposing sides. For the purposes of this specification, the term "rectangular conductor" refers to a generalization of flat conductors and square conductors, the square conductor being a special case of a rectangular conductor in which the four sides have the same size.

[0068] For the purposes of this specification, the expression "non-circular conductor" or "non-circular hairpin conductor" or "non-circular hairpin" must be understood as designating a conductor having an arbitrarily polygonal cross-section, and therefore as a generalization of a "rectangular conductor". For example, conductors having regular or irregular rectangular, triangular, pentagonal, hexagonal cross-sections are included in this expression. It is also encompassed by conductors having a continuous closed curve cross-section (such as an ellipse). For example, as described in the drawings of patent application US7622843B2, the strip conductors according to this specification can also be those with less commonly used shapes. In addition, the devices and methods of this specification include conductive strips used in various alternating ways, for example, with one or more main types of some examples of different types.

[0069] For the purposes of this specification, a seat or slot in a component may be defined by both a recess or a depression completely surrounded by the component, the recess or depression being formed by a cavity in the component, wherein one or more open sides of the cavity are adapted to be effectively closed by a surface or wall of an adjacent component. In particular, a slot may also be a blind hole or a through hole in a component.

[0070] For the purposes of this specification, the expression "radial" or "circumferential" or other similar expressions defined relative to a direction or along an axis refers to a circumference lying in a plane orthogonal to that direction or axis, with the center of the circumference lying in said direction or axis. Furthermore, for the purposes of this specification, the expression "angularly spaced" (or other similar expressions) defined relative to a direction or axis must refer to the angle between two radii of a circle lying in a plane orthogonal to that direction or axis, with the center of the circle lying in said direction or axis. DETAILED DESCRIPTION

[0071] Figure 5 A possible embodiment of a device 200 according to the invention for deforming a conductor of at least one winding assembly 100 , which conductor protrudes from one side of a stator or rotor 114 of an electrical machine, is shown.

[0072] As is known, the winding assembly 100 comprises a plurality of basic conductors 102 including at least one leg 104 , 106 inserted into a cavity 115 of a stator or rotor 114 , each leg having at least one free end or terminal 108 , 110 .

[0073] The cavity 115 may have a radial opening that faces inwardly or outwardly.

[0074] The device 200 may comprise centering means for said stator or rotor 114 relative to the axis X of the device 200. The centering means allow coinciding the axis X of the device 200 with the axis of the stator or rotor 114. The centering means also allow coinciding the axis X of the device 200 with the axis Y of the winding assembly 100.

[0075] The device 200 according to the invention comprises at least one inner torsion ring 202 and an outer torsion ring 203, which are provided with at least one clamping element 204 adapted to clamp at least one free end or terminal 108, 110. The clamping element 204 may comprise an inner seat 226 and an outer seat 228 extending substantially parallel to the axis X direction.

[0076] The term "clamping" refers to the fact that the clamping element constitutes a constraint on the free end at least with respect to movement in a direction perpendicular to the insertion direction once the free end has been inserted into the inner seat 226, the outer seat 228. In this case, under given movement conditions of the clamping element with at least one free end inserted, relative sliding may occur in a direction parallel to the insertion direction.

[0077] At least one inner torsion ring 202 , outer torsion ring 203 is adapted to rotate about the axis X of the device 200 .

[0078] At least one of the clamping elements 204 of the at least one inner torsion ring 202, the outer torsion ring 203 is adapted to be actuated in a radial direction relative to the axis X. In this regard, the device comprises at least one guide 206, 207 adapted to guide the at least one clamping element 204 in a radial direction relative to the axis X. The device 200 further comprises a radial actuator 208 adapted to move the at least one clamping element 204 in a radial direction relative to the axis X.

[0079] Movement of the clamping element 204 engaging at least one free end or terminal 108, 110 is adapted to cause deformation of a leg portion of the conductor protruding from the stator or rotor cavity 115 in a manner that will be apparent from the following description.

[0080] According to a possible embodiment of the invention, all clamping elements 204 of at least one inner torsion ring 202 , outer torsion ring 203 are adapted to move in a radial direction relative to the axis X.

[0081] In an alternative embodiment, some of the clamping elements 204 belonging to the inner torsion ring 202 , the outer torsion ring 203 may be adapted to move in a radial direction relative to the axis X, for example in groups.

[0082] According to a possible embodiment of the invention, at least one movable clamping element 204 may be moved in a radial direction away from and / or towards the axis X. The legs of the conductor may then be deformed so that the final position of the leg ends is closer to the axis X or further away from the axis X than the initial position before the deformation.

[0083] According to a possible embodiment of the invention, at least one clamping element 204 is adapted to move in the axial direction along an axis parallel to the axis X approaching the stator or rotor 114. In particular, the movement may be of a corresponding type, for example providing that the insert 204 moves and the rotor or stator is fixed, or vice versa.

[0084] The clamping element 204 may be assembled on the inner insert 210 and the outer insert 212 having an "L" shape on the intersecting plane, the intersecting plane including the axis X. The inner insert 210 and the outer insert 212 may include an inner insert first portion 214, an outer insert first portion 218 and an inner insert second portion 216, an outer insert second portion 220, the inner insert first portion 214 and the outer insert first portion 218 being substantially parallel to the axis X, and the inner insert second portion 216 and the outer insert second portion 220 being substantially perpendicular to the axis X. Therefore, the clamping element 204 may be prepared at the upper ends 222, 224 of the inner insert first portion 214 and the outer insert first portion 218, the clamping element 204 facing the winding assembly 100 being used.

[0085] exist Figure 5 and Figure 6 In the embodiment shown, the device comprises an inner torsion ring 202, an outer torsion ring 203, wherein both are arranged with at least one clamping element 204 that moves in a radial direction relative to the axis X. In particular, both inner torsion rings 202, outer torsion rings 203 comprise a clamping element 204 that moves in a radial direction relative to the axis X. Inner torsion ring 202 and outer torsion ring 203 refer to the mutual position of the two inner torsion rings 202, outer torsion rings 203 in at least one of the configurations that they can adopt. More generally, for any configuration adopted by the two torsion rings, the inner torsion ring clamping element is always closer to the axis X than the at least one outer torsion ring clamping element.

[0086] In this embodiment, inner torsion ring 202 includes inner insert 210 , and outer torsion ring 203 includes outer insert 212 .

[0087] In a possible embodiment of the present invention, for example in a starting position, the inner insert 210 and the outer insert 212 may be aligned with each other in a radial direction so that:

[0088] - the first inner insert part 214 and the first outer insert part 218 are arranged parallel to each other, the first outer insert part 218 of the outer insert part 212 is at a distance from the axis X, and

[0089] The inner inserter second part 216 and the outer inserter second part 220 are parallel to each other and superimposed so that the inner inserter second part 216 is located distally relative to the winding assembly 100 in use.

[0090] Advantageously, as in Fig.15 As can be seen in the example of FIG. 2 , the inner seat 226 and the outer seat 228 arranged on the inner insert 210 and the outer insert 212 , respectively, can be aligned in the radial direction and have a development that is substantially parallel to the direction of the axis X.

[0091] Radial alignment between one twist ring insert and another twist ring insert may also be achieved at the twist ends or at other intermediate operating conditions.

[0092] According to an alternative embodiment, the device 200 may include more than two torsion rings, for example four, wherein at least two torsion rings may be of the type with an inner insert 210 and an outer insert 212 that can move radially relative to the direction of the axis X. In a possible embodiment, all torsion rings of the device may be of the type with an inner insert 210 and an outer insert 212 that can move radially relative to the direction of the axis X.

[0093] The guide 206, 207 for at least one of the inner insert 210, the outer insert 212 may include radially extending lateral abutments 230, 232 adapted to guide movement by means of a shape coupled to the inner insert 210, the outer insert 212 (e.g., to the inner insert second portion 216, the outer insert second portion 220). Figure 7 An example of a possible embodiment of a guide 206 is shown. The guide 206 is integrated with a guide plate which transmits a rotational movement to the abutments 230, 232 which are transmitted to the respective inserts by the abutments 230, 232. The guide plate can also transmit an axial movement to the inserts guided by the guide itself.

[0094] The guide 206 for the inner insert 210 and the guide 207 for the outer insert 212 may include a corresponding inner plate 234 and an outer plate 236 on which the abutments 230 and 232 are disposed. Figure 7, which shows a guide 206 for an internal insert 210, it can be noted that, according to a plane perpendicular to the axis X, each abutment 230, 232 can have a substantially triangular cross-section, so that the area over which the internal insert second part 216 of the internal insert 210 can slide is a substantially rectangular track. Figure 7 The view in shows a guide 207 for an external insert, but it can be obtained in essentially the same way.

[0095] exist Figure 7 , although two abutments guiding only one of the internal inserts 210 are denoted by reference numerals 230, 232, each internal insert 210 may be guided by corresponding lateral abutments 230, 232. In particular, internal inserts 210 adjacent to each other may be separated by abutments 230, 232, so that abutments 230, 232 are shared.

[0096] Special References Figure 5 and Figure 6 , which show two similar cross-sections of the device of the invention, it can be noted that in Figure 5 Abutment 232 can be seen in Figure 6 In the example, the plane of section BB is parallel to but away from Figure 5 In the plane of section AA in FIG. 8 , the abutment 232 cannot be seen, but the inner insert 210 , the inner insert second portion 216 , and the outer insert second portion 220 of the outer insert 212 guided by the abutments 230 , 232 can be noted.

[0097] Now refer to Figure 5-8 Detailed Description Figure 4-13 The radial actuator 208 of the device 200 is shown in FIG.

[0098] According to a possible embodiment of the present invention, the radial actuator 208 includes a cam mechanism 238. Figure 4-11 In the embodiment shown, the device is provided with a cam mechanism 238 for moving the inner insert 210 and a second cam mechanism 238 for moving the outer insert 212 .

[0099] The cam mechanism 238 may include at least one lower guide plate 240 and an upper guide plate 242 perpendicular to the axis X and provided with at least one lower formed slit 244 and an upper formed slit 245. The cam mechanism 238 may also include at least one pin 246, 248 protruding from the inner insert second portion 216 and the outer insert second portion 220 of the inner insert 210 and the outer insert 212 in a direction parallel to the axis X.

[0100] refer to Figure 8 or Fig. 9The lower forming slot 244 has a first end 250 located at a first distance relative to the axis X, and a second end 252 located at a second distance relative to the axis X, the second distance being greater than the first distance. In addition, the first end 250 and the second end 252 are located at two different radii relative to the axis X.

[0101] According to a possible embodiment, as shown in the drawings, the cam mechanism 238 may include a lower guide plate 240 and an upper guide plate 242, which are perpendicular to the axis X and arranged in parallel positions, and are provided with at least one lower forming gap 244. The cam mechanism 238 may also include at least one pin 246, 248, which protrudes from the inner insert 210, the inner insert second portion 216, and the outer insert second portion 220 of the outer insert 212 in a direction parallel to the axis X.

[0102] like Figure 8 and Fig. 9 As shown in the example of , the lower forming gaps 244 can be distributed equally in circular groups.

[0103] According to a possible embodiment of the present invention, for example, Figure 5 and Figure 6 In the illustrated embodiment, in the case of an L-shaped insert, each inner insert 210, inner insert second portion 216, outer insert second portion 220 of the outer insert 212 is at least partially accommodated between the lower guide plate 240 and the upper guide plate 242, so that the pins 246, 248 themselves are accommodated in the lower forming gap 244, upper forming gap 245.

[0104] In a possible embodiment, each inner insert 210, outer insert 212 includes a pin, so that the pin 246 protrudes in one direction, and the adjacent pin 248 protrudes in a direction opposite to the direction parallel to the axis X. In other words, each pin protrudes in a direction opposite to the adjacent pin. The lower pin 246 is accommodated in a lower formed slot 244 placed on the lower guide plate 240, while the upper pin 248 is accommodated in an upper formed slot 245 on the upper guide plate 242. With this arrangement, the movement of the inner insert 210, outer insert 212 that are very close to each other can be advantageously guided, which would be difficult to do if the lower formed slots 244 were placed on a single guide plate because the lower formed slots 244 are too close to each other.

[0105] According to a possible alternative embodiment, the insert can be provided with a plurality of pins, for example two pins, which are adapted to slide into the relevant slit. In addition, the insert can be provided with a plurality of pins, which are adapted to slide in the same slit.

[0106] In the embodiment shown in the drawings, the inner insert 210 and the outer insert 212 are provided with cam mechanisms 238 , each of which has an upper guide plate 242 and a lower guide plate 240 .

[0107] As mentioned above, alternative embodiments are possible in which two torsion rings are provided, which can be arranged with radially movable inserts and their corresponding cam mechanisms.

[0108] In another alternative embodiment, only a portion of each torsion ring is prepared with a radially movable insert. In this case, only a portion of the end portion (for example, the portion of the end portion on one layer) can be deformed in the radial direction.

[0109] According to a possible embodiment of the invention, for example, only one insert is radially movable.

[0110] In another embodiment, at least one insert can be moved in a radial direction, independent of the radial movement of the other inserts. In this case, a cam mechanism can be provided to move only one insert.

[0111] exist Fig.14 In the possible embodiment shown, the device 200 is provided for different bending of at least one leg 104, 106 of the same layer. The different bendings can be obtained by providing the device with at least one independently operable independent insert 211, which can be moved on a trajectory, since it can be operated with at least one of the following elements dedicated to it: a shaped gap, a guide disc, a guide plate with abutments; this trajectory cannot overlap with the trajectory of the inserts that bend other conductors of the same layer.

[0112] For example, the respective individual insert 211 may belong to a torsion ring comprising other inserts which may be moved differently by means of specific shaped gaps in the same guide disc. Fig.14 In the case shown, the individual inserts are actuated by guide discs with shaped slots and dedicated guide plates.

[0113] The use of an independent insert makes it possible to make the heads formed by the device of the present invention recognizable compared to those bent by the twisting devices of the prior art. Before twisting, an array of straight conductors protruding from the same side and the same position as the stator or rotor slots is bent in a known manner by the twisting devices of the prior art so that their final faces are arranged substantially along the circumference when viewed from the stator or rotor axis. The device of the present invention can bend the same conductors so that their cut faces are arranged at different distances from the twisting axis. In addition, in electrical winding diagrams, it often happens that conductors of the same layer (for example the outermost layer) must be electrically connected. This connection, which is usually established by means of a third element (electrical jumper), can be obtained as a direct connection between the two ends to be connected by means of the device of the present invention. In particular, since the independent insert can be reversely rotated and has a different radial offset compared to the insert acting on the conductor, a pair of basic conductors with parts housed in slots belonging to the same layer can be brought together, the conductors belonging to the same layer as the layer taken from the independent clamping element. This allows the ends of the pair to be directly welded and an electrical connection without intermediate elements to be established. This is possible because the individual insert deforms the end it clamps with an opposite inclination relative to the majority of the ends of the layer to which it belongs.The elimination of the third electrical connection element is a significant advantage for the productivity of an automatic winding production system.

[0114] At this point, it is convenient to expand the definition of a torsion ring. A torsion ring is a set of clamping elements and guide abutments that cannot change their mutual angular distance relative to the axis X'. For example, when accommodated, one of the clamping elements guided by the guide plate cannot change its angular distance to another clamping element of the same torsion ring or to the guide abutment, because this angular distance refers to the axis X'. Even with the use of appropriately synchronized actuators, all clamping elements and guide abutments that meet this condition constitute a torsion ring.

[0115] If in the prior art twisting apparatus there is a two-way correspondence between the conductor layers to be bent and the twisting rings, the apparatus of the present invention loses this correspondence. In fact, each annular array of twisting conductors may correspond to more than one twisting ring.

[0116] Similar to the insert described above, in this case too a radial actuator 208 is provided which may include a cam mechanism 238 and which may be rotatable relative to the guide plate with the abutment.

[0117] In particular, Fig.14 The example shows a device comprising:

[0118] an inner torsion ring 202 having a corresponding cam mechanism 238 situated between the axis X and the clamping element 204;

[0119] a first external torsion ring 203 with a corresponding cam mechanism 238 , the first external torsion ring 203 having a clamping element 204 located between the axis X and the cam mechanism 238 ;

[0120] A second external torsion ring 303 with a corresponding cam mechanism 238 , with a clamping element 204 located between the axis X and the cam mechanism 238 .

[0121] also, Fig.14 The second external torsion ring 303 in the embodiment comprises at least one independent insert 211 (three in the example), which is equipped with its own cam mechanism 238. The independent insert 211 and those of the first external torsion ring form an annular array of clamping elements in the starting position, such as Fig.14 As shown. Thus, the insert of the second outer torsion ring engages with conductors belonging to the same layer as the conductors engaged by the insert of the first outer torsion ring 203. The insert of the first outer torsion ring 203 has independent movement with the insert of the second outer torsion ring 303 for the three components of movement: radial, circumferential, axial. The insert of the first outer torsion ring 203 can:

[0122] - rotate differently, in particular in a direction opposite to the rotation of the insert of the second external torsion ring 303;

[0123] - move differently and radially, in particular in a direction opposite to the radial displacement of the insert of the second external torsion ring 303;

[0124] - Move differently and axially, in particular in a direction opposite to the axial displacement of the insert of the second external torsion ring 303 .

[0125] In the embodiment of the device just described and in alternative embodiments, a plurality of groups of independent inserts can be prepared in order to be able to bend in different ways one or more groups of conductors (for example adjacent) initially located on the same layer of conductors. In the case where the independence of the radial movement of the inserts simulating the conductors of the same layer is sufficient, it is sufficient to associate only radial drive forces specific to the independent inserts or only shaped gaps having a shape specific to the independent inserts with the independent inserts in a common radial actuator of the other inserts for bending the conductors of the same layer. The latter embodiment comprises a single torsion ring of the inserts to bend the conductors of the same layer.

[0126] Fig.13An alternative embodiment of the invention is shown in which, when viewed from the top, the outer insert 212 relative to the outer layer has an outer insert first part 218 located between the outer insert second part 220 and the axis X, and in the same view, the inner insert 210 relative to the inner layer has an inner insert second part 216 located between the inner insert first part 214 and the axis X.

[0127] In this case, the system may be provided with an inner cam mechanism 238 for moving at least one inner insert 210, and an outer cam mechanism 238 for moving at least one outer insert 212. The inner insert 210 may be prepared with the inner insert second portion 216 facing inward.

[0128] Thus, the length of the inner insert first portion 214 and the outer insert first portion 218 of both inserts may be reduced to a minimum and the space between one layer and the next may be axially accessible by the ring of insulating material.

[0129] According to an alternative embodiment, inserts placed on the same layer can be moved in radial direction but in opposite orientations.

[0130] Considering that the inner insert 210 and the outer insert 212 are in the first position and it is desired to move them outward, a relative movement is applied between the guides 206 and 207 and the lower guide plate 240 and the upper guide plate 242. For example, referring to Figure 8 , where one of the two guides 206 and the upper guide disc 242 is visible, the lower guide disc 240, the upper guide disc 242 rotates clockwise, keeping the guide 206 stationary. Thereby, the pins 246, 248 are forced to move along the corresponding lower forming slots 244, the upper forming slots 245 and in particular towards the second end 252 of the slot itself.

[0131] In a possible alternative embodiment, for example, to generate a reciprocating motion between the lower guide plate 240, the upper guide plate 242 and the guide member 206, the lower guide plate 240, the upper guide plate 242 may be held in place and the guide member 206 may be rotated counterclockwise.

[0132] exist Figure 4-11 In the illustrated embodiment, the inner torsion ring 202 and the outer torsion ring 203 respectively include an inner insert 210 and an outer insert 212. Therefore, by providing the guide 206 and the corresponding cam mechanism 238, the inner insert 210 can be moved simultaneously. In the same way, by providing the guide 207 and the corresponding cam mechanism 238, the outer insert 212 can be moved simultaneously.

[0133] In this regard, the radial actuator 208 may include a moving device 254 suitable for rotating the lower guide plate 240 and the upper guide plate 242 relative to the guide members 206 and 207.

[0134] refer to Figure 5 , Figure 6 and Fig. 9 It can be noted that each pair of lower guide discs 240, 242 can be supported by a respective guide 206, 207 so as to be free to rotate on the respective guide 206, 207 relative to the axis X. In particular, the guides 206, 207 can be anchored to a support 241, 243 which has at one end actuation means to the axial and tangential actuation supports.

[0135] According to a possible embodiment, the lower guide plate 240 and the upper guide plate 242 can be rotated manually.

[0136] Reference Figure 5 and Figure 6 The supports 241, 243 are connected to the torsion ring so that the axes of the supports 241, 243 are aligned with the axis X of the device. On said supports 241, 243 there are actuating means which impart rotational and axial movements to said torsion ring.

[0137] refer to Figure 4 The moving device 254 may include side stops 256 , 258 , which are suitable for limiting the movement of the lower guide plate 240 and the upper guide plate 242 relative to the inner plate 234 and the outer plate 236 .

[0138] According to a possible embodiment of the present invention, for example Figure 8 As shown, at least one of the lower guide plate 240 and the upper guide plate 242 of each cam mechanism 238 includes an outward protrusion 259 according to the radial direction relative to the outer surface of the lower guide plate 240 and the upper guide plate 242. The fixing devices 255 and 257 of the lower guide plate 240 and the upper guide plate 242 to the moving plate 253 are arranged on the protrusion 259. Thus, the lower guide plate 240 and the upper guide plate 242 can be moved by rotating the moving plate 253.

[0139] According to a possible embodiment of the present invention, the fixing means 255 , 257 may be a screw or a pin, which is suitable for being inserted into a seat 261 provided on the protrusion 259 .

[0140] refer to Fig.10 and Fig.11 , we will now describe a possible sequence of operations that may be performed on the winding assembly 100 (eg, on the welding side).

[0141] The inner torsion ring 202 comprises a plurality of inner inserts 210 (at each free end or terminal 108, 110 on the circumference) and the outer torsion ring 203 comprises a plurality of outer inserts 212 (at each free end or terminal 108, 110 on the circumference) placed adjacently in an initial position and in the same radial direction relative to the axis X. The initial position corresponds to the position of the conductor which, after insertion into the stator / rotor and withdrawal from the side opposite to the insertion side, must be moved by the insert itself before the conductor is subjected to any deformation of its protruding portion.

[0142] In a first step, the free end is inserted into the inner seat 226, the outer seat 228 present in the inner insert 210, the outer insert 212. To facilitate the insertion, the insert can be in a radial position equal to the radial position of the conductor. This step is as follows Fig.10 shown.

[0143] Reference Fig.11 By means of the radial actuator 208 and in particular by means of the cam mechanism 238, successively and preferably without releasing the clamping, the free ends or terminals 108, 110 of the basic conductor 102 are extended outwardly by movement in the radial direction towards the outside of the inner insert 210 and the outer insert 212.

[0144] from Fig.11 It can be seen in FIG. 1 that the clamped free ends or terminals 108 , 110 move outwardly but remain parallel to each other, in particular relative to the axis X.

[0145] Subsequently and preferably without releasing the grip on the conductor, since the inner twisting ring 202 and the outer twisting ring 203 can be rotated in a relative manner, a twisting is performed, for example, on the welding side of the winding assembly 100. During this step, the inner twisting ring 202, the outer twisting ring 203 are moved in an axial direction (parallel to the axis X) towards the stator or rotor, accompanying the upward movement of the free ends or terminals 108, 110, in a manner known per se.

[0146] In an alternative embodiment, it is possible to first twist the free ends or terminals 108, 110 and then radially deform the free ends or terminals 108, 110 without releasing the clamping.

[0147] In another alternative embodiment, the free ends or terminals 108, 110 may be twisted and radially deformed simultaneously.

[0148] According to a possible embodiment of the invention, the free ends or terminals 108 , 110 can be deformed towards the inside of the winding, in particular in a radial direction relative to the axis X, ie towards the axis X.

[0149] The method according to the invention for deforming a conductor of at least one winding assembly 100, the conductor protruding from one side of a stator or rotor 114 of an electric machine, substantially comprises:

[0150] - a step of clamping at least one free end or at least a portion of the terminal 108, 110 by at least one clamping element 204; and

[0151] - a step of releasing at least one free end or at least a portion of the terminal 108 , 110 by at least one clamping element 204 ;

[0152] Between the steps, the method comprises:

[0153] - at least one step of moving at least one clamping element 204 in a radial direction relative to the axis X, which step causes at least one free end or terminal 108, 110 to deflect in a radial direction relative to the axis X towards or away from said axis X; and

[0154] - at least one step of moving at least one clamping element 204 in the circumferential direction, thereby causing a deformation of said at least one free end or terminal 108 , 110 in the circumferential direction relative to the axis X.

[0155] The method may comprise an initial step in which the device 200 for the above-mentioned deformation step of a conductor protruding from one side of a stator or rotor of an electric machine of the above-mentioned type is provided.

[0156] Furthermore, according to possible embodiments of the method according to the invention, the movement in the radial direction can be performed before, after or simultaneously with the step of moving the welding side in the circumferential direction.

[0157] According to a possible embodiment of the present invention, the method according to the present invention comprises: simultaneously with the step of circumferential movement, the step of moving at least one clamping element 204 in the axial direction towards the winding assembly 100 .

[0158] In a possible alternative embodiment, there may be no such axial movement step. In this case, the conductor may be stretched.

[0159] The simultaneousness of two or more of the steps described means that the gripping element moves according to a trajectory resulting from the composition of the motion components associated with the individual simultaneous steps. For example, in a cylindrical coordinate system r, z, θ, centered on the axis of rotation X of the torsion ring, if a step of radial displacement of a gripping element is defined by a time law r(t)+r0, then depending on the time t, this step is simultaneous with a step of circumferential θ, displacement t(t)+θ0 of the same gripping element, the time law of which is obtained by a set of coordinates r(t)+r0, z0, θ(t)+θ0, r0, z0 and θ0 being the coordinates of the initial position.

[0160] The gripping elements placed on the insert belonging to the same device and in particular guided by the same guide plate and actuated by a cam gap of the same shape and size have substantially overlapping trajectories. In fact, in this case, the trajectory of the i-th gripping element is r(t)+r0i, z(t)+z0i, θ(t)+θ0i, where r0i, z0i, θ0i denote the coordinates of the initial position. These trajectories can be superimposed when each trajectory points to the initial position of the corresponding element, i.e. by eliminating the terms r0i, z0i, θ0i, all of which are defined by the triple of coordinates r(t), z(t), θ(t).

[0161] The method may further comprise the step of centering the winding assembly 100 and the stator or rotor 114 relative to the axis X of the device 200 .

[0162] Therefore, it is apparent that the winding assembly 100 may be deformed due to the continuous or simultaneous movement of the free ends or terminals 108, 110, including:

[0163] - according to a movement in a circumferential direction relative to the axis X;

[0164] - according to a movement in a radial direction relative to the axis X;

[0165] - move in an axial direction relative to the axis X; and

[0166] - Rotation of the cross section of the free end or terminal 108 , 110 relative to an end axis Z parallel to the axis X.

[0167] The rotation of the cross-section of the free end or terminal 108, 110 is due to the shape coupling between the clamping element 204 and the outer surface of the free end or terminal 108, 110. Fig.16 As shown in the example in , during deformation due to circumferential movement, the cross-section of the free end or terminal 108, 110 follows the movement of the clamping element 204, thereby changing the position of the cross-section of the free end or terminal 108, 110 on a plane perpendicular to the axis X, but maintaining the orientation relative to the radial direction.

[0168] In particular, the inner side of the cross section may advantageously be kept tangential to the circumferential direction so that free ends on different layers can be welded via a surface adjacent to and parallel to the surface of the first layer.

[0169] According to a possible embodiment, at the end of the deformation process, the resulting free end is placed at a predetermined axial distance from the stator or rotor, the resulting free end being substantially identical to the free ends of most ends protruding from a side of the stator or rotor to which it belongs.

[0170] The end protruding from one side of the winding may be deformed simultaneously with the other end or at different time intervals so that a predetermined distance value may be allocated between the fixed portion constrained by the slot and the deformed end of the conductor.

[0171] Once the ends of the windings protruding from one side of the stator are divided into groups defined by the layers of windings, i.e. groups of ends protruding from the same radial position of the slots, the method described herein can be applied to:

[0172] a) bending said ends between different conductors of at least one of said layers along equal trajectories, i.e. with the same radial, circumferential and axial components (uniform twist);

[0173] b) Bending the ends of the subassemblies of the same layer according to equal trajectories between the different ends of the subassemblies, ie with the same radial, circumferential and axial components between the ends of the subassemblies of the layer.

[0174] In case the conductors are in the same slot position, they may all have the same distance between the cross section remaining fixed and the extreme end of the conductor being deformed. Advantageously, at least one of the conductors may be deformed differently, ie according to a different trajectory.

[0175] The advantages that can be achieved by the apparatus and method according to the present invention are apparent from the detailed description that has just been outlined.

[0176] In particular, an apparatus and method are provided that allow the free ends to be separated from each other so that they can be easily welded together.

[0177] In particular, with the device and method according to the invention, the free end can be radially deformed to facilitate the welding process.

[0178] Furthermore, by extending the winding and being able to determine the distance between the terminals, the space in the radial direction can be increased, thereby facilitating the welding process and improving insulation.

[0179] Likewise, if a plurality of conductors are provided in the same stator or rotor slot, it is possible to achieve an initial separation between the conductors in the radial direction by radial displacement of the inserts, before the actual twisting of the winding is carried out. Such an extension allows each insert to be aligned with the corresponding conductor, which makes it easier to insert the conductor into the insert recess. This advantage is particularly felt in the case of windings with a number of conductors stacked radially in the slots. In fact, in these cases, and in the absence of the device of the invention, a step of radial positioning of the conductors must be carried out before the twisting is carried out with the aid of the prior art device, the conductors being aligned with the recesses of the conventional twisting machine and operated by a third device.

[0180] Furthermore, the radial distance between the free ends allows the insertion of insulating rings between the layers of the same group even before the circumferential bending of the conductor ends, thus facilitating the integrity of the winding insulation.

[0181] Furthermore, this method allows to locate the free end of each protruding conductor at a radial position different from the radial position defined in the slot. For example, this allows to directly connect two adjacent groups by directly connecting two conductors placed on non-adjacent layers of the two groups themselves.

[0182] Furthermore, a device is provided which can be easily used to prevent arcing between close ends.

[0183] In the above-described embodiments, those skilled in the art will be able to change and / or replace the described elements with equivalent elements without departing from the scope of the appended claims in order to meet specific requirements.

[0184] For example, the same concepts as described above can also be applied to the winding insertion side, such as where the I-pins and conductors are welded on both sides.

[0185] List of reference symbols in the drawings

[0186] 100 Winding Components

[0187] 102 Basic Conductors

[0188] 104 legs

[0189] 106 legs

[0190] 108 free end or terminal

[0191] 110 free end or terminal

[0192] 112 connection

[0193] 114 stator or rotor

[0194] 115 chambers

[0195] 200 devices

[0196] 202 internal torsion ring

[0197] 203 External torsion ring

[0198] 204 clamping element

[0199] 206 Lower internal guide

[0200] 207 upper external guide

[0201] 208 Radial Actuator

[0202] 210 Internal Inserts

[0203] 211 independent insert

[0204] 212 External Inserts

[0205] 214 Internal Insert Part 1

[0206] 216 Internal Insert Part 2

[0207] 218 External Inserts Part 1

[0208] 220 External Insert Part 2

[0209] 222 Upper internal end

[0210] 224 upper external end

[0211] 226 internal seat

[0212] 228 External Seat

[0213] 230 side reference

[0214] 232 Side Reference

[0215] 234 inner plate

[0216] 236 outer panel

[0217] 238 Cam mechanism

[0218] 240 lower guide plate

[0219] 241 Support

[0220] 242 upper guide plate

[0221] 243 Support

[0222] 244 lower forming gap

[0223] 245 Upper forming gap

[0224] 246 Down Pin

[0225] 248 Upward Sales

[0226] 250 Internal First End

[0227] 252 External second terminal

[0228] 253 mobile board

[0229] 254 mobile devices

[0230] 255 Fixtures

[0231] 256 side block

[0232] 257 Fixtures

[0233] 258 side guard

[0234] 259 Protrusion

[0235] 261 Fixing device seat

Claims

1. A device (200) for deforming a conductor of at least one winding assembly (100), the conductor protruding from one side of a stator or rotor (114) of an electric machine, the at least one winding assembly (100) comprising a plurality of basic conductors (102), the basic conductors (102) comprising at least one leg inserted into a cavity (115) of the stator or rotor (114), each leg having at least one respective free end or terminal (108, 110); The device (200) comprises at least one of an inner torsion ring (202) and an outer torsion ring (203) adapted to rotate about an axis (X), wherein at least one of the inner torsion ring (202) and the outer torsion ring (203) comprises at least one clamping element (204), wherein the at least one clamping element (204) is adapted to clamp at least one free end or terminal (108, 110) and is adapted to move in a radial direction relative to the axis (X); The device comprises at least one guide (206, 207) and a radial actuator (208), wherein the at least one guide (206, 207) is suitable for guiding the at least one clamping element (204) along the radial direction relative to the axis (X); the radial actuator (208) is suitable for moving the at least one clamping element (204) along the radial direction relative to the axis (X).

2. The device according to claim 1, characterized in that The clamping element (204) comprises an inner seat (226) and an outer seat (228) extending in a direction substantially parallel to the axis (X).

3. The device according to any one of the preceding claims, characterized in that The at least one clamping element (204) is suitable for translating according to an axial direction parallel to the axis (X).

4. The device according to claim 1, characterized in that Said at least one guide (206, 207) is anchored to a support (241, 243) suitable for being connected to an actuation device suitable for transmitting a rotational movement relative to said axis (X) and a translational movement in said direction of said axis (X).

5. The device according to claim 1, characterized in that All clamping elements of at least one of the inner torsion ring (202) and the outer torsion ring (203) are adapted to move in a radial direction relative to the axis (X).

6. The device according to claim 1, characterized in that The at least one clamping element (204) is adapted to be movable towards and / or away from the axis (X) in a radial direction relative to the axis (X).

7. The device according to claim 1, characterized in that The device comprises an inner torsion ring (202) and an outer torsion ring (203), both of which are provided with at least one clamping element (204) movable in a radial direction relative to the axis (X); the device comprises a component dedicated to each of the inner torsion ring (202) and the outer torsion ring (203), comprising a radial actuator (208) and at least one guide (206, 207).

8. The device according to claim 1, characterized in that The device comprises an inner torsion ring (202), an outer torsion ring (203), and a second outer torsion ring (303), each of which is formed by at least one clamping element (204) movable in a radial direction relative to the axis (X); the device comprises an assembly of at least one guide (206, 207) and a radial actuator dedicated to each of the inner torsion ring (202), the outer torsion ring (203), and the second outer torsion ring (303).

9. The device according to claim 1, characterized in that The radial actuator (208) includes a cam mechanism (238), the cam mechanism (238) is used to move at least one of the internal insert (210) and the external insert (212), and the at least one clamping element (204) is arranged on at least one of the internal insert (210) and the external insert (212); the cam mechanism (238) includes at least one of a lower guide plate (240) and an upper guide plate (242), the lower guide plate (240) and the upper guide plate (242) have a horizontal plane perpendicular to the axis (X), and are provided with at least one of a lower forming gap (244) and an upper forming gap (245), at least one of the lower forming gap (244) and the upper forming gap (245) has a first end (250) and a second end (252), and the first The first end (250) is arranged at a first distance relative to the axis (X), the second end (252) is arranged at a second distance relative to the axis (X), the second distance is greater than the first distance, and the first end (250) and the second end (252) are located on two different radii relative to the axis (X); the cam mechanism (238) further includes at least one pin (246, 248), the pin (246, 248) protrudes from a part of the inner insert (210) and the outer insert (212) in a direction parallel to the axis (X), and the inner insert (210) and the outer insert (212) are suitable for sliding in at least one of the lower forming gap (244) and the upper forming gap (245) according to a direction belonging to a plane perpendicular to the axis (X).

10. The device according to claim 9, characterized in that The clamping element (204) is arranged on an internal insert (210) and an external insert (212), wherein the internal insert (210) and the external insert (212) have an "L" shape in a transverse plane including the axis (X), and the internal insert (210) and the external insert (212) include: - an inner insert first portion (214), an outer insert first portion (218) substantially parallel to said axis (X), and - an inner insert second portion (216), an outer insert second portion (220) substantially perpendicular to said axis (X); The inner insert first part (214) and the outer insert first part (218) are provided with the clamping element (204) at the upper end (222, 224), and the inner insert second part (216) and the outer insert second part (220) are provided with the at least one pin (246, 248).

11. The device according to claim 10, characterized in that The cam mechanism (238) comprises a lower guide plate (240) and an upper guide plate (242), wherein the lower guide plate (240) and the upper guide plate (242) each have a horizontal plane perpendicular to the axis (X) and spaced apart from each other; the second part (216) of the internal insert and the second part (220) of the external insert of each of the internal insert (210) and the external insert (212) are at least partially accommodated between the lower guide plate (240) and the upper guide plate (242), so that the corresponding pins (246, 248) are accommodated in the lower forming gap (244) and the upper forming gap (245).

12. The device according to any one of claims 9 to 11, characterized in that The device comprises an inner torsion ring (202) provided with an inner insert (210) and an outer torsion ring (203) provided with an outer insert (212), wherein both the inner insert (210) and the outer insert (212) are provided with a dedicated cam mechanism (238).

13. The device according to any one of claims 9 to 11, characterized in that The cam mechanism (238) is located between the at least one clamping element (204) and the axis (X), or is located outside the clamping element (204) so ​​that the clamping element (204) is located between the axis (X) and the cam mechanism (238).

14. The device according to claim 1, characterized in that Each of the inner torsion ring (202) and the outer torsion ring (203) is provided with at least one independent insert (211) and a dedicated radial actuator (208).

15. A method for deforming a conductor of at least one winding assembly (100) protruding from one side of a stator or rotor (114) of an electric machine, the at least one winding assembly (100) comprising a plurality of basic conductors (102), the basic conductors (102) comprising at least one leg inserted into a cavity (115) of the stator or rotor (114), each leg having a respective free end or terminal (108, 110), the method comprising: - a step of clamping at least one free end or at least a portion of the terminal (108, 110) by at least one clamping element (204); as well as - a step of releasing said at least one portion of at least one free end or terminal (108, 110) by means of said at least one clamping element (204); in said step, said method comprises: - at least one step of moving said at least one clamping element (204) in a radial direction relative to the axis (X), towards or away from said axis (X); and - at least one step of moving the at least one clamping element (204) in a circumferential direction about the axis (X).

16. The method according to the preceding claim, characterized in that The clamping element (204) comprises an inner seat (226) and an outer seat (228) extending in a direction substantially parallel to the axis (X).

17. The method according to claim 15, characterized in that The method comprises, between the steps of clamping and releasing, at least one step of relatively moving the at least one clamping element (204) and the stator or rotor (114) in an axial direction along an axis parallel to the axis (X).

18. The method according to claim 15, characterized in that At least two of the steps of moving the clamping element (204) in radial and circumferential directions occur at least partially simultaneously.

19. The method according to claim 17, characterized in that At least two of the steps of moving the clamping element (204) in radial, circumferential and axial directions occur at least partially simultaneously.

20. The method according to any one of claims 15 to 19, characterized in that The at least one clamping element (204) maintains an orientation relative to a radial direction at all positions occupied in space.

21. The method according to any one of claims 15 to 19, characterized in that The step of moving the clamping element (204) occurs without any loosening of the clamping of at least one free end or at least a portion of the terminal (108, 110).

22. The method according to claim 15, characterized in that The deformation of at least one free end or terminal (108, 110) of the winding assembly (100) is performed by means of a device according to any one of claims 1 to 14.

23. The method according to any one of claims 15 to 19, characterized in that The deformation of the free ends or terminals (108, 110) of the conductors belonging to the winding assembly (100) is performed by means of an assembly of clamping elements (204) formed by at least one clamping element (204) moving along a movement trajectory, the free ends or terminals (108, 110) occupying the same radial portion of the cavity (115), the movement trajectory not overlapping with the movement trajectories of other clamping elements (204) of the same assembly.

24. The method according to any one of claims 15 to 19, characterized in that The free end or terminal (108, 110) of the at least one winding assembly (100) is deformed from a straight shape to a corresponding end shape of end deformation, clamped by a corresponding clamping element (204), and retained after clamping is released.

25. The method according to any one of claims 15 to 19, characterized in that Most of the free ends or terminals (108, 110) have end sections that are substantially aligned at the same axial position, ie, the end sections are substantially located on the same plane perpendicular to the axis (X).

26. The method according to any one of claims 15 to 19, characterized in that The at least one free end or terminal (108, 110) on one side of the stator or rotor (114) is deformed at different or overlapping time intervals relative to the duration of the deformation action of part or all of the remaining free ends or terminals (108, 110) protruding from one side of the stator or rotor (114).

27. The method according to any one of claims 15 to 19, characterized in that At least one free end or terminal (108, 110) of an assembly of free ends of conductors occupying the same radial position within the cavity, projecting from one side of the stator or rotor (114), is deformed at different or overlapping time intervals relative to the duration of the deformation action of part or all of the remaining part projecting from the assembly.

Images