Apparatus and method for manufacturing a conductor nest or partial nest

Abstract

The invention relates to an apparatus (100) and a method for manufacturing a nest (5) or a partial nest of pin conductors (1, 1 i , 1 o ) for forming a stator. The apparatus (100) comprises a stator core template (10) having blocks (11) and radially extending ribs (12) between which there are formed slots (13) for insertion of legs (2, 2 i , 2 o ) of pin conductors (1, 1 i , 1 o ). The apparatus (100) comprises at least one ring element (25, 33, 42) arranged to provide an outer radial abutment surface for the inserted pin conductors (1, 1 i , 1 o ).

Description

TECHNICAL FIELD

[0001] The present invention relates to an apparatus and a method for manufacturing a nest or partial nest of pin conductors for forming a stator. BACKGROUND

[0002] It is known to provide a stator for an electric motor with a plurality of hairpin conductors which are arranged in slots of a stator core.

[0003] The hairpin conductors are usually provided with two legs and a bridge portion joining the two legs. Each leg is inserted into a respective slot. The bridge portion extends outside the axial direction of the stator at one axial side of the stator core, while the legs extend from the slots at the opposite axial side of the stator core. By connecting the two extending legs to each other, a continuous conductor similar to a winding can be created.

[0004] The hairpin conductors can be inserted into the slots in a raw, non-final shape, and subsequently deformed into the final shape, e.g. by a twisting operation, once inserted into the slots. Such an arrangement is known, e.g. from EP 945 952 Al. This method requires an additional twisting step and is therefore complex.

[0005] Alternatively, it is known to provide hairpin conductors which are fully pre-shaped, i.e. provided in a shape corresponding to the final shape in the stator core. Such conductors are pre-assembled into a partial or complete nest outside the stator core, and inserted into the slots of the stator as a pre-fabricated nest. In this case, no subsequent deformation, e.g. twisting of the conductors within the stator, is required.

[0006] The co-pending unpublished application EP 18201561.0, incorporated herein by reference, discloses a method and apparatus in which a stator core template is provided. The stator core template is designed similar to the stator core and in particular comprises a plurality of radially and axially extending slots corresponding to the number of slots of the stator core. The slots of the stator core template have a larger circumferential width than the circumferential width of the slots of the stator core and / or they have a larger radial length than the radial length of the slots of the stator core. This larger dimension of the slots of the stator core template allows the inserted hairpin conductors to be moved between different positions within the slots of the stator core template.

[0007] The hairpin conductors which have been inserted into the slots of the stator core template are moved within the slot(s) of the stator core template from a first position to a second position. The direction of movement is at an angle with respect to the direction of insertion and is usually perpendicular to the direction of insertion. By this subsequent movement, the problem of collisions between subsequently inserted conductors due to overlapping bridge portions can be avoided.

[0008] WO2018 / 233769 relates to a pre-pinning nest and a method for forming a ring from a plurality of U-shaped conductive hairpins so as to be able to subsequently mount the ring in a machine element of an electric machine, for example a stator. The receiving element has a plurality of slots in which the branches of the hairpins are received. The slots are sized and shaped so that in each case the first branch of a hairpin can be rotated inside the slot so as to enable the second branch of the hairpin to be positioned in another slot in an unrestrained manner. The receiving element can have an inner ring on the outside of which the side walls of the slots are formed, or an outer ring on the inside of which the side walls of the slots are formed.

[0009] However, the partial nest or nest of conductors can not only comprise hairpin conductors, but also different types of conductors, for example i-pin conductors or jumper conductors. I-pin conductors are conductors that have only one leg and are used, for example, for electrical connection with external conductors. They usually have a greater axial extension than the hairpin conductors used for the same nest. Jumper conductors are used to form a connection between two different layers of hairpin conductors and can comprise two or more legs.

[0010] Since i-pin conductors comprise only one leg, they cannot stabilize their orientation by means of a second leg in a second slot. There is therefore a risk that the i-pin conductors will tilt after insertion into the slots of the stator core template. Subsequent insertion of further conductors and / or correct connection of the extended legs can be difficult or impossible. SUMMARY

[0011] It is therefore an object of the present invention to overcome the disadvantages of the prior art and, in particular, to provide an apparatus and a method for manufacturing a partial nest or nest of conductors for forming a stator having a plurality of pin conductors, which apparatus and method provide sufficient stability for the insertion of the conductors, especially when i-pin conductors are used.

[0012] These and other objects are solved according to the present invention with the apparatus and method as described below.

[0013] The apparatus for manufacturing a nest or partial nest of pin conductors for forming a stator according to the present invention comprises a stator core template. The stator core template comprises a block provided with radially extending ribs.

[0014] The block can essentially have the form of a cylinder.

[0015] Between the ribs, slots are formed for the insertion of the legs of the pin conductors.

[0016] The ribs are preferably compact and solid elements that provide a stable distance between the slots. They preferably do not comprise and are not made of bent sheet metal.

[0017] The ribs can be machined parts which are machined to have different thicknesses in the radial direction. They can be made of steel.

[0018] Typically, the device can comprise 48 to 72 ribs to form a corresponding number of slots. The ribs can have a maximum thickness of 2 to 6 mm, a radial length of 40 to 45 mm, in particular 43 mm, an axial length of 260 to 270 mm, in particular 267 mm. The slots have an opening angle of 7.5° to 5°.

[0019] The device further comprises at least one ring element which is arranged to provide an outer radial abutment face for the inserted pin conductor.

[0020] The abutment face defines a radial limit beyond which the pin conductor cannot move radially outwardly.

[0021] Each slot has two circumferential boundaries given by the ribs and at least one radially inner boundary provided by the block. Further, a radially outer boundary can be provided by the at least one ring element. Thus, once the pin conductor leg is inserted into the respective slot, the pin conductor leg is held within the slot and cannot be tilted radially outwardly.

[0022] The ribs, the ring elements and the block can have the same axial length. However, in a preferred embodiment, the ribs, the ring elements and the block have different axial extensions.

[0023] In a preferred embodiment, the at least one ring element has a smaller axial extension than the axial extension of the ribs.

[0024] Thus, for example, more than one ring element can be provided which are arranged one above the other.

[0025] The block fills the radially inner space between the ribs at least over a part of the axial length of the ribs. Thus, the block stabilizes the arrangement of the ribs.

[0026] The pin conductor approaching the stator core template can only enter the slot between two radially adjacent ribs, as there is no other free space.

[0027] The block can be machined as a single part, but can also comprise more than one part. The block may, for example, comprise several portions which are axially aligned relative to each other.

[0028] The block can be connected or connectable to an actuator via a coupling to cause a rotational movement. Preferably, a centrally or concentrically arranged coupling is provided, so that a uniform running rotational movement of the stator core template can be achieved.

[0029] In an advantageous embodiment of the device, the upper level of the block and the upper level of the rib are substantially on the same axial level. The "upper" side is the side from which the conductor is inserted into the stator core form. During use, the stator core form usually has an upright position, so that insertion of the conductor is facilitated by gravity.

[0030] The upper edge of the rib can have a slight inclination between a radially inner end and a radially outer end, so that the pin conductor tends to slide towards the radially inner end. Preferably, the upper level of the radially inner edge of the rib merges into the upper level of the block.

[0031] At least a portion of the block and the rib can in particular be machined from a steel cylinder as a single piece. Alternatively, the rib can be fixed to at least a portion of the block, for example to at least one of the axially aligned pieces of the block.

[0032] For example, the rib can be fixed by a corresponding form-fit connection. The rib can have a male protrusion which is inserted into a corresponding female recess arranged in the block. The insertion connection can be ensured by one of the pieces of the block which prevents the male protrusion from leaving the female recess.

[0033] In a preferred embodiment of the invention, at least the upper part of the rib has a greater radial length than the radial length of the lower part of the rib.

[0034] The axial length of the upper part can be smaller than the axial length of the lower part.

[0035] The greater radial length of the upper part in particular facilitates the insertion of the pin conductor leg into the slot.

[0036] Preferably, the radial length of the upper part and more preferably the radial length of the lower part is greater than the radial length of the slot of the stator core, in order to facilitate the insertion and subsequent movement of the pin conductor.

[0037] The rib can comprise a continuous transition between the upper part and the lower part. The continuous transition can for example be formed as a step.

[0038] Advantageously, the outer diameter in the region of the lower part corresponds to the outer diameter of the stator to be manufactured.

[0039] The at least one ring element can be formed by a separate ring which is connected to the rib.

[0040] In particular, the separate ring can be non-rotatably connected to the rib. For example, when the block and the rib are rotated, the separate ring rotates together with the block and the rib.

[0041] In particular, the separate ring can be attached to a shelf element which is connected to the rib.

[0042] Since the separate ring has a fixed circumferential and axial position relative to the rib and the block, the separate ring can be considered to form part of the stator core form.

[0043] Advantageously, the upper level of the individual ring is arranged axially below the upper level of the block and / or axially below the upper level of the rib.

[0044] In particular, the rib can comprise an upper part and a lower part as described above, and the individual ring is arranged above the continuous transition.

[0045] More in particular, the inner diameter of the individual ring can correspond to the outer diameter of the upper part of the rib.

[0046] Thus, the individual ring provides a radially outer boundary of the slot in the area of the upper part of the rib and prevents the upper part of the inserted pin conductor from tilting radially outward out of the slot.

[0047] The radially outward facing side of the individual ring can comprise a contact surface for a bearing or for a drive element generating rotational movement.

[0048] In an alternative embodiment of the device, the at least one ring element is formed by a support ring which is rotatably arranged relative to the rib.

[0049] The device can comprise an individual ring and a support ring as described above.

[0050] In particular, the support ring comprises a, in particular annular, fixing flange for fastening the individual ring to the mounting frame.

[0051] The mounting frame provides a structure which is fixed in space. When the stator core form is rotated, the support ring remains in a fixed position relative to the mounting frame and the space. However, the support ring prevents the pin conductor leg from moving or tilting radially out to the outside of at least a portion of the axial length of the rib.

[0052] Preferably, the inner diameter of the support ring corresponds to the outer diameter of the lower part of the rib, such that the support ring forms a radially outer boundary of the lower part of the slot.

[0053] In particular, the device is a device with a rib comprising an upper part and a lower part as described above, and the support ring is arranged below the continuous transition. Thus, the support ring in particular provides positioning for the legs of the pin conductor when they reach their intended position in the stator core form.

[0054] Advantageously, the support ring can provide a guiding face at the upper part of its abutment face for guiding the pin conductor to the lower part of the slot. The guiding face can have a decreasing inner diameter downward.

[0055] Additionally or alternatively, the individual ring can be arranged axially above the support ring and axially above the continuous transition.

[0056] In a preferred embodiment of the device, the support ring comprises openings for inserting push rod elements from the radially outer side into the at least one slot.

[0057] The circumferential width of the openings can be at least the maximum circumferential width of the slots formed by the adjacent ribs.

[0058] The openings can extend more circumferentially than axially. The openings can extend axially downwards to the lower end of the support ring.

[0059] Preferably, the device comprises lower push rod elements arranged radially movable from the radially outer side of the support ring into the openings of the support ring, and more preferably into the slots.

[0060] The lower push rod elements can move the leg portions of the pin conductors in radial direction to change the distance to the central axis of the stator core, in particular to the leg portions of the i-shaped pin conductors.

[0061] In an alternative embodiment of the device, the at least one ring element is formed by a cover element. The cover element has a radially inner surface arranged axially above the upper level of the ribs.

[0062] The radially inner surface of the cover element has an inner diameter which is smaller than the outer diameter of the upper level of the stator core template and is adapted to contact an upper portion of at least a portion of the inserted pin conductors.

[0063] The inner diameter can correspond to the outer diameter of the nest or of the portion of the nest to be manufactured.

[0064] In particular, it is prevented that the upper portion of an i-shaped pin conductor which has only one leg portion and is generally longer than the other pin conductors is tilted radially outward out of the slot.

[0065] The cover element can comprise a horizontally arranged top wall comprising an abutment surface provided by the radially inner surface. The cover element can further comprise a lateral wall or side wall parallel to the longitudinal axis of the stator core template.

[0066] The abutment surface provided by the radially inner surface of the cover element can contact the upper portion of the pin conductors which protrude from the top of the slot after the pin conductors have been inserted and have been positioned in the radially outermost position. Thereby, the cover element provides an upright position of the radially outermost layer of i-shaped pin conductors of the nest or partial nest holding the pin conductors.

[0067] Preferably, the cover element is fastenable to the mounting frame and preferably rotatably arranged relative to the ribs.

[0068] Advantageously, the cover element has the shape of an annular segment with an open area allowing the entry of at least one upper push rod element to push the upper portion of at least one inserted pin conductor inward.

[0069] The opening region preferably has an opening angle between 80° and 90°, in particular 85°.

[0070] In an advantageous embodiment, at least one external positioning tool can be associated with the cover element. Each of the at least one external positioning tool has a pocket element protruding radially inwards, which provides at least one pocket for stabilizing the radially outer side of the i-pin conductor.

[0071] The at least one external positioning tool is preferably radially movable. The at least one external positioning tool remains in a radially outer position as long as and until all hairpins have been inserted into the slots. The external positioning tool does not influence the rotation of the ribs in the outer position.

[0072] Each of the outermost i-pin hairpins can be inserted into a respective pocket of the positioning tool, which is aligned with the respective slot between the ribs.

[0073] Once all i-pin hairpins have been inserted, the external positioning tool can be moved inwards to move the upper part of the i-pin conductor towards the nested inner layer.

[0074] The pocket prevents a radially outward and inward tilting or movement of the upper part of the i-pin conductor.

[0075] Since the shape and size of the pocket can be chosen so as to provide an engagement between the leg of the i-pin conductor and the pocket upon rotation of the leg, the pocket also prevents a rotation around the axis of the i-pin conductor. The leg typically has a rectangular cross-section.

[0076] The radial width of the pocket can be chosen to be slightly larger than the radial width of the leg, such that, once the i-pin conductor is rotated only slightly, the radially inner and outer surface of the leg is in contact with the radially inner and outer wall of the pocket. Rotation of the i-pin conductor is prevented. Thus, the external positioning tool stabilizes the outermost i-pin hairpins.

[0077] Preferably, the device comprises at least one such push-up rod element for pushing the upper part of the at least one inserted pin conductor inwards.

[0078] In particular the pin conductors of the inner layer have to be pushed to a second position after being axially inserted into the slots.

[0079] According to another aspect of the present invention, a device for manufacturing a nest or partial nest of pin conductors for forming a stator has a block provided with radially extending ribs, the device comprising a stator core template. Slots for insertion of legs of pin conductors are formed between the ribs.

[0080] Preferably, the device is a device as described above. The at least one rim segment is mounted to the upper surface of the block. The rim segment prevents radial inward bending or movement of at least an upper portion of the pin conductor.

[0081] Advantageously, the outer diameter of the rim segment corresponds to the inner diameter of the groove formed by the rib.

[0082] The rim segment can be fixedly mounted to the block. When the stator core template is rotated, the rim element rotates with the stator core template and continues to support the pin conductors arranged in the innermost layer.

[0083] The i-type pin conductors of the innermost layer preferably require radial inner support. Typically, only the nested or partially nested angular segments of the pin conductors are equipped with i-type pin conductors. Thus, the rim segment can extend only along a portion of the groove and thus only along an angular segment of the stator core template. Preferably, the rim segment extends over an angle of between 60° and 80°, in particular 70°.

[0084] In case more than one angular segment is required for radial inner support of the pin conductors, for example, the device can comprise more than one rim segment.

[0085] The rim segment can comprise a pocket element protruding radially outwardly, which provides a pocket for supporting the radially outer side of the i-type pin conductor.

[0086] The pocket element can be formed by a balustrade, which is mounted to the outer surface of the rim segment and extends along at least a portion of the outer surface of the rim segment in the circumferential direction.

[0087] Along the circumferential direction, at least one separating member can be further arranged, which connects the outer surface of the rim segment and the balustrade. Preferably, a plurality of pockets is formed by a corresponding number of separating members.

[0088] The balustrade, the outer surface of the rim segment, the at least one separating member and / or at least one lateral wall of the rib, i.e. the wall facing in the circumferential direction, can form a pocket for receiving an axial portion of the i-type pin conductor protruding from the block.

[0089] Preferably, the circumferential distance between adjacent separating members corresponds to the radially inner circumferential distance between the corresponding lateral walls of adjacent ribs. Each pocket can be assigned to a corresponding groove. The radial width of the separating members can preferably correspond to the radial thickness of the leg of the pin conductor. Each pocket can receive one i-type pin conductor.

[0090] The pocket element provides radial outer support for the i-type pin conductor. The pocket element prevents radial outward tilting or movement of at least an upper portion of the i-type pin conductor, in particular during removal of the nest from the device.

[0091] In a preferred embodiment, the device comprises a lifting element. The lifting element comprises a coupling for the driving element to generate axial movement, in particular to push the nest or partial nest of inserted pin conductors upwards and to facilitate the discharge of the nest or partial nest from the stator core formwork.

[0092] The coupling can be formed by an axial contact surface pointing downwards, so that the driving element can be moved below the lifting element and below the nest or partial nest.

[0093] The upper surface of the lifting element can contact the leg portions of the pin conductors.

[0094] Preferably, the lifting element comprises leg portion supports for receiving the leg portions of the pin conductors. The number of leg portion supports corresponds to the number of slots, and each leg portion support is arranged in a respective slot.

[0095] The leg portion supports can comprise seats for receiving leg portions of different lengths while each leg portion contacts a respective seat. Some seats can be lower than other seats for receiving longer leg portions that extend more in the axial downward direction than other leg portions.

[0096] In particular, at least one radially innermost seat and / or at least one radially outermost seat is lower than the other seats for receiving longer leg portions. Thus, i-shaped pin conductors that are typically arranged in the innermost and outermost layers and extend axially below other pin conductors can be positioned sufficiently.

[0097] Since the lifting element is adapted to move the nest or partial nest in an upward direction, each leg portion support should be moved axially within the slot. The leg portion supports are preferably connected to each other so that the leg portion supports can be moved jointly.

[0098] Preferably, the lifting element comprises an annular element that carries the radially inner side of the leg portion supports.

[0099] In particular, the annular element comprises a coupling for the driving element, such as an axial contact surface.

[0100] Preferably, the annular element has an outer diameter that corresponds to the inner diameter of the rib.

[0101] The driving element for the lifting element can be hollow. The rotating driving element extends through the driving element for the lifting element and the annular element of the lifting element and is connected to the block.

[0102] The axial length of the block can be smaller than the axial length of the rib. Thus, the annular element can be moved axially below the block.

[0103] Preferably, the annular element has an outer diameter that corresponds to the outer diameter of the block.

[0104] The invention also relates to a method for manufacturing a nest or partial nest of pin conductors for forming a stator, the method comprising the following steps.

[0105] An apparatus for manufacturing a nest or partial nest of pin conductors for forming a stator, preferably an apparatus as described above, is provided.

[0106] The apparatus comprises a stator core template having a block provided with radially extending ribs. Between the ribs grooves are formed for insertion of leg portions of pin conductors. The apparatus comprises at least one ring element arranged to provide an outer radial abutment surface for the inserted leg portions of pin conductors.

[0107] At least one pin conductor is inserted into at least one of the grooves of the stator core template such that the pin conductor is arranged in a first position within the groove. In the first position the pin conductor is arranged differently compared to the intended position in the stator core template.

[0108] The pin conductor is moved from the first position to a second position within the groove of the stator core template.

[0109] Preferably, the insertion step is repeated for at least one additional pin conductor in order to form a first layer of the nest or partial nest of pin conductors. More preferably, the stator core template is rotated before another pin conductor is inserted into the stator core template.

[0110] Finally, the nest or partial nest of pin conductors is removed from the stator core template.

[0111] Preferably, the nest or partial nest of pin conductors is removed from the stator core template by axially moving upwards a lifting element comprising leg supports for receiving the leg portions of the pin conductors.

[0112] After the stator core template has been moved upwards, the nest or partial nest can be grabbed by a gripper system.

[0113] In particular, at least one i-type pin conductor can be inserted into at least one of the grooves of the stator core template.

[0114] A lower portion of the i-type pin conductor can be supported by a ring element formed as a support ring that is rotatably arranged with respect to the ribs and is prevented from radial movement or tilting outside at least a lower portion of the ribs.

[0115] A leg portion of the i-type pin conductor can be moved radially inwards by a push rod element that is radially moved into an opening of the support ring. The opening can have a circumferential width that corresponds to a maximum circumferential width of the groove formed by the adjacent ribs.

[0116] Preferably, the rotating stator core template and inserting another pin conductor into at least another slot of the slots. More preferably, repeating the steps of inserting, supporting and moving the i-shaped pin conductor.

[0117] During the radial movement of the i-shaped pin conductor, the legs of the i-shaped pin can move radially until they reach an axial position for receiving the respective seat of the legs of the pin conductor. Preferably, the i-shaped pin conductor then falls onto the respective seat arranged on the leg support of the lifting element. BRIEF DESCRIPTION OF DRAWINGS

[0118] The application will be explained below with reference to the description of a specific embodiment and the corresponding drawings, which show:

[0119] Figure 1 is a first perspective cross-sectional view of an apparatus according to the application;

[0120] Figure 2 is a second perspective cross-sectional view of the apparatus;

[0121] Figure 3 is a first side view of the apparatus;

[0122] Figure 4 is a first perspective view of the apparatus;

[0123] Figure 5 is a cross-sectional view of the apparatus along the longitudinal axis and an enlarged detail view;

[0124] Figure 6 is a second perspective view of the apparatus;

[0125] Figure 7 is a perspective view of a rim segment;

[0126] Figure 8 is a perspective view of a part of a stator core template;

[0127] Figure 9 is a top view of a part of a stator core template;

[0128] Figure 10 is another perspective view of a part of a stator core template;

[0129] Figure 11a is a top view of an external positioning tool in a first radial position;

[0130] Figure 11b is a top view of an external positioning tool in a second radial position;

[0131] Figure 12 is a perspective view of a part of another example of a stator core template;

[0132] Figure 13 is Figure 12 another perspective view of a portion of an example of

[0133] Figure 14 is a first partial perspective view of a portion of a stator core template;

[0134] Figure 15 is a second partial perspective view of a portion of a stator core template;

[0135] Figure 16 is a third partial perspective view of a portion of a stator core template;

[0136] Figure 17 is a fourth partial perspective view of a portion of a stator core template;

[0137] Figure 18 is a top view of a portion of a stator core template;

[0138] Figure 19 is a third perspective cross-sectional view of an apparatus according to the present invention;

[0139] Figure 20 is a side view of an I-shaped pin conductor;

[0140] Figure 21 is a cross-sectional view of a portion of a nest located in a stator core template. DETAILED DESCRIPTION

[0141] Figure 1 shows a first perspective cross-sectional view of an apparatus 100 according to the present invention.

[0142] The apparatus 100 comprises a stator core template 10 comprising a block 11 provided with radially extending ribs 12.

[0143] Between the ribs 12, slots 13 are formed for inserting the leg portions 2 of pin conductors 1 (see for example Figure 3 ).

[0144] The upper portion 18 of the ribs 12 has a radial length 19 which is greater than the radial length 21 of the lower portion 22 of the ribs 12. The ribs 12 have a continuous transition 61 between the upper portion 18 and the lower portion 22, which in this case is formed as a step.

[0145] The apparatus 100 comprises at least two ring elements which are arranged to provide an outer radial abutment surface for the inserted pin conductors 1 which are not explicitly shown.

[0146] The first ring element is formed by a separate ring 25 which is fixedly connected to the ribs 12 and has an axial extension 23.1 which is smaller than the axial extension 24 of the ribs 12.

[0147] A separate ring 25 is arranged above the transition 61. The inner radius 28 of the separate ring 25 corresponds to the outer radius 29 of the upper part 18 of the rib 12.

[0148] The second ring element is formed by a support ring 33 which is arranged rotatably relative to the rib 12.

[0149] The support ring 33 is arranged below the separate ring 25 and below the continuous transition 61.

[0150] The support ring 33 has an axial extension 23.2 which is smaller than the axial extension 24 of the rib 12.

[0151] The device 100 further comprises a lifting element 50.

[0152] The lifting element 50 comprises leg supports 51 for receiving the leg portions 2 of the pin conductor 1 (see Figure 5 or Figure 13 ). The number of leg supports 51 corresponds to the number of slots 13. Each leg support 51 is arranged in a respective slot 13 (see also Figure 2 ).

[0153] Each leg support 51 comprises a seat 52, 53, 57 for receiving a leg portion 2 of a different length.

[0154] The lifting element 50 has an axial contact surface 54 for axial movement by a drive element 55 (see Figure 5 ) in order to push the partial nest or nest of inserted pin conductors 1 upwards.

[0155] The lifting element 50 comprises a ring element 58 with the axial contact surface 54. The ring element 58 is connected to the radially inner side of the leg supports 51.

[0156] The lifting element 50 provides a central opening for guiding through a rotary drive element 64 which is connected to the block 11 (see Figure 5 ) to cause a rotary movement of the stator core form 10.

[0157] The axial length 56 of the block 11 is smaller than the axial extension 24 of the rib 12. The ring element 58 has an outer diameter 59 which corresponds to the outer diameter 60 of the block 11. The ring element 58 is axially movable below the block 11.

[0158] Figure 2 A second perspective sectional view showing the outside of a part of the device 100.

[0159] The upper horizontal plane 14 of the block 11 and the upper horizontal plane 15 of the rib 12 are essentially on the same axial level.

[0160] The radially outwardly facing side 30 of the individual ring 25 comprises a contact surface 31 for the bearing 32 in particular (see also Figure 5 ).

[0161] The individual ring 25 is attached to a shelf element 26 which is connected with the rib 12.

[0162] Figure 3 A first side view of the device 100 is shown.

[0163] The support ring 33 comprises an annular fixing flange 34 for fastening the individual ring 33 to a mounting frame 35.

[0164] The device 100 further comprises a third ring element formed by a cover element 42 (see also Figure 6 ).

[0165] Figure 4 A first perspective view of a part of the device 100 is shown.

[0166] The support ring 33 comprises an axially extending opening 38 for the insertion of the push-down lever element 41 (see Figure 3 and Figure 5 ). The opening 38 has a circumferential width 39 which corresponds at least to the maximum circumferential width 40 of the slot 13 formed by the adjacent rib 12 (see Figure 2 ).

[0167] Figure 5 A cross-sectional view of the device 100 is shown.

[0168] The inner diameter 36 of the support ring 33 corresponds to the outer diameter 37 of the lower part 22 of the rib 12.

[0169] The radially innermost seat 52 and the radially outermost seat 53 are lower than the other seats 57 in order to receive the longer leg 4. The longer leg 4 is pushed inwards by the push-down lever element 41 to reach the respective innermost lower seat 52.

[0170] Figure 6 A second perspective view of the top side of the device 100 is shown.

[0171] The cover element 42 has a radially inner surface 43 which is axially arranged above the upper horizontal face 15 of the rib 12. The radially inner surface 43 has an inner diameter 44 which is smaller than the outer diameter 45 of the upper horizontal face 16 of the stator core form 10 (see Figure 4 ). Thus, the radially inner surface 43 is adapted to contact at least a part of the upper portion of the inserted pin conductor 1.

[0172] The cover element 42 has the shape of an annular segment with an open area 46 which allows the entry of at least one push-up lever element 47 to push the upper portion of the inserted pin conductor 1 inwards.

[0173] The device 100 further comprises a rim segment 48 mounted to the upper surface 49 of the block 11.

[0174] The rim segment 48 prevents a radial inward tilting or movement (see Figure 5 or Figure 13 ) at the upper portion 3 of the pin conductor 1.

[0175] Figure 7 A perspective view of the rim segment 48 is shown.

[0176] The rim segment 48 comprises a main body portion 81 with a flange 82 to be mounted on the upper surface 49 of the block 11 (see Figure 8 ) and a wall 83. The wall 83 extends in axial direction A and in circumferential direction C.

[0177] On a radially outer surface 84 of the wall 83, a pocket element 85 is mounted to the rim segment 48.

[0178] The pocket element 85 comprises a rail 86 and a separation member 87. The rail 86 is connected to the wall 83 by the separation member 87. The separation member 87 forms a plurality of pockets 88 on a radially inner side of the rail 86, which are delimited by the rail 86, the wall 83 and the separation member 87.

[0179] Figure 8 A perspective view of a portion of the stator core form 10 is shown.

[0180] The rim segment 48 is mounted at a radially inward end of the rib 12.

[0181] The flange 82 comprises a mounting hole 89 for fixing the rim segment 48 to the top surface 49 of the block 11.

[0182] The pockets 88 are aligned with the slots 13 formed by the ribs 12.

[0183] Figure 9 A portion of the stator core form 10 is shown in a top view.

[0184] A circumferential distance 90 between two adjacent separation members 87 corresponds to a circumferential distance 91 between radially innermost portions of the respective lateral walls 92 of adjacent ribs 12. Thus, the pockets 88 are precisely aligned with the slots 13.

[0185] The openings 93 for inserting the i-shaped pin conductors are each delimited by the radially innermost portion of the respective lateral wall 92, by the wall 83, by the rail 86 and by the separation member 87.

[0186] Figure 10 Another perspective view of a portion of the stator core form 10 is shown during removal of the nest (not fully shown).

[0187] For the sake of clarity, Figure 10Only the innermost conductor 1 is shown.

[0188] Each of the innermost i-type pin conductors 1 i It is positioned in the corresponding recess 88.

[0189] Each of the innermost i-type pin conductors 1 i It is supported by flange segment 48.

[0190] Wall 83 prevents the I-type pin conductor from tilting radially inward. Railing 86 prevents radially outward tilting. The innermost radial portion of separating member 87 and the corresponding transverse wall 92 prevents the I-type pin conductor 1 from tilting radially outward. i Rotate about the axis in the axial direction A.

[0191] exist Figure 11a , Figure 11b , Figure 12 and Figure 13 In the embodiment shown, the stator core template 10 includes a cover element 42 having two external positioning tools 75 that are radially movable relative to the rib 12.

[0192] Figure 11a A top view of the external positioning tool 75 in its first radial position is shown. Figure 11b It is in the second radial position.

[0193] Each external positioning tool 75 includes a radially inwardly projecting recess element 76 that provides a plurality of recesses 77.

[0194] The recessed element 76 includes a railing 101 and a separating member 102. The railing 101 is connected to the radially inward-facing wall 103 of the positioning tool 75 via the separating member 102. The separating member 102 forms a plurality of recesses 77 on the radially outer side of the railing 101, the plurality of recesses being defined by the railing 101, the wall 103, and the separating member 102.

[0195] The recessed element 76 is arranged at the radially inner end of the radially movable arm 78. Figure 12 The cover element 42 includes a flange segment 79 providing a radial inner surface 43. Figure 11a The rim segment 79 has a recess 80 extending along a circumferential length 99 corresponding to the sum of the circumferential lengths of the recessed elements 76 of the positioning tool 75, such that the recessed elements 76 are arranged within the recess 80.

[0196] At radially outer position (see) Figure 11a The radial inner side of the railing 101 is axially aligned with the inner surface 43 of the wheel flange segment 79.

[0197] Therefore, the entire recessed element 76 is arranged outside the intended position of the outermost nested layer.

[0198] The outer positioning tool 75 can be pushed radially inwards to a radially inner position (see Figure 11b ).

[0199] The radially inwards movement ends when the circumferentially adjacent edges 104, 105 of the pocket elements 76 abut.

[0200] Figure 12 A perspective view showing a part of the example of the stator core form 10 with two outer positioning tools 75 is shown.

[0201] The pockets 77 are aligned with the slots 13 formed by the ribs 12. The separating members 102 have a radial length 106 corresponding to the radial width of the i-pin conductors 1 o so that each pocket 77 receives only one i-pin conductor and prevents an axial rotation of the i-pin conductors 1 o (see Figure 13 ).

[0202] Figure 13 Another perspective view showing a part of the example with two outer positioning tools 75 when the formation of the nest 5 in the stator core form 10 is almost finished Figure 12 is shown.

[0203] The outermost i-pin conductors 1 o have been introduced into the pockets 77 of the outer positioning tools 75. The outer positioning tools 75 are still in the radially outer position as shown in Figure 11a . Thus, the legs of the i-pin conductors 1 o positioned in the pockets 77 do not come into contact with the legs of the other conductors arranged radially more inwards.

[0204] Once all i-pin cards have been inserted and are correctly radially arranged, e.g. by the push-up bar elements 47, the outer positioning tools 75 can be moved inwards to move the upper parts of the i-pin conductors 1 o towards the inner layer of the nest.

[0205] The pockets prevent a radially outwards and inwards tilting or movement of the upper parts of the i-pin conductors 1 o .

[0206] The i-pin conductors 1 o are moved from a position outside the nest 5 to the outermost layer of the nest 5.

[0207] Figure 14 A second perspective view showing a part of the stator core form 10 is shown.

[0208] Each rib 12 has a male protrusion 62.

[0209] The male protrusion 62 of the rib 12 is inserted into a corresponding female recess 63 arranged within the lower part 17.1 of the block 11 to form a positive connection.

[0210] Figure 15 A first perspective view of a portion of the stator core template 10 is shown.

[0211] The block 11 comprises a lower part 17.1 and a fixing plate 17.2 arranged above the lower part 17.1.

[0212] The positive connection between the male protrusion 62 and the female recess 63 of the rib 12 (see Figure 14 ) is fixed by the fixing plate 17.2 of the block 11, which prevents the male protrusion 62 from leaving the female recess 63.

[0213] Figure 16 and Figure 17 Third and fourth partial perspective views of a portion of the stator core template 10 are shown to illustrate the fixation of the shelf element 26 to the rib 12.

[0214] The shelf element 26 comprises a fixation hole 74 for fixing the individual ring 25 (see Figure 1 ).

[0215] Some of the adjacent pairs of ribs 12 comprise an extension 70 on their outer radial surface 68. The extension 70 can be inserted into a corresponding recess 69 of the shelf element 26.

[0216] As can be seen better in Figure 17 , after the extension 70 has been inserted into the recess 69 of the shelf element 26, the connection is fixed by a bolt 71. Alternatively, screws can also be used, for example.

[0217] The bolt 71 is inserted into a corresponding bolt hole 72 in the shelf element 26 and into a bolt hole 72 in the extension 70 (see Figure 16 ).

[0218] As shown in Figure 18 , a top view of a portion of the stator core template 10 is shown, the ribs 12 can be machined parts with varying thickness along the radial extension range.

[0219] Figure 19 A third perspective cross-sectional view of the device 100 according to the invention is shown.

[0220] The device comprises a first drive motor 65 for causing a rotational movement of the rotational drive element 64.

[0221] The device comprises a second drive motor 66 for causing axial movement of the axial drive element 55 via a lifting platform 67.

[0222] Figure 20 A side view of a pin conductor 1 is shown, in this case an i-pin conductor. The i-pin conductor 1 comprises only one leg 2. The upper part 3 of the i-pin conductor 1 is usually pre-bent.

[0223] Since the i-pin conductor 1 comprises only one leg 2, the pin conductor has no self-stability, unlike for example a hairpin conductor, which has two legs arranged in different slots (not explicitly shown in the figures).

[0224] The i-pin conductor therefore requires a specific handling when being inserted into the stator core template 10.

[0225] When the i-pin conductor 1 is inserted into the slot 13 of the stator core template 10, the lower part of the i-pin conductor is prevented from moving radially outside of at least the lower part 22 of the rib 12 by the support ring 33, for example as shown in Figure 5 .

[0226] The upper part of the slot 13 is radially defined by a separate ring 25.

[0227] The leg 2 of the nested inner i-pin conductor 1 is moved radially inwards by the push-down lever element 41 moving it into the opening 38 of the support ring 33.

[0228] The i-pin conductor 1 is then radially aligned with the respective seat 52 and can drop onto the leg support 51 of the lifting element 50 into the respective seat 52.

[0229] The upper part 3 of the inner i-pin conductor 1 is stabilized by the rim segment 48.

[0230] Similarly, the nested outer i-pin conductor is radially held in the respective seat 53 and is prevented from moving out of the stator core template by the push-down lever element 41 through the opening 38.

[0231] The i-pin conductor 1 therefore does not need to be precisely placed in a specific radial position for insertion. The i-pin conductor 1 can be inserted anywhere into the slot 13, in particular in the radially outer region, in which the slot 13 has a greater circumferential width 40 (see Figure 2 ). After having been inserted into the slot 13, the i-pin conductor 1 can be pushed to the intended radial position. Since the leg 2 of the i-pin conductor 1 cannot be detached from the respective seat 52, 53, the radial position of the i-pin conductor 1 remains fixed.

[0232] After insertion of the i-shaped pin conductors 1, the stator core template 10 is rotated by means of the drive motor 65 and the rotary drive element 64 (see Figure 18 ).

[0233] Then another pin conductor 1 is inserted into at least one of the slots, and the steps of radially moving the pin conductor and positioning the pin conductor by means of the upper push rod element 47 and / or the lower push rod element 41 are repeated.

[0234] Once all the pin conductors required for the partial nest or nest 5 have been positioned appropriately, the nest can be pushed upwards by axially moving the lifting element 50 via the drive element 55.

[0235] Then, the partial nest or nest 5 can be removed from the stator core template 10.

[0236] The final position of the nest 5 in the stator core template 10 can be seen in Figure 21 , which shows a schematic representation of a cross-sectional view of a portion of the nest in the stator core template.

[0237] The i-shaped pin conductors 1 in the innermost layer of the nest 5 i and the i-shaped pin conductors 1 in the outermost layer of the nest 5 o are longer than the remaining i-shaped pins of the nest 5. The respective leg portions 2 i and 2 o are therefore positioned in the seat 52, 53 which is axially lower than the other seats 57.

Claims

1. A method for manufacturing pin conductors (1, 1) for forming a stator i 1 o A nested device (100), the device comprising a stator core template (10), characterized in that, The stator core template (10) includes a block (11) provided with radially extending ribs (12), and the ribs (12) form a space between them for the pin conductors (1, 1). i 1 o ) legs (2, 2) i 2 o The slot (13) is inserted, and The device (100) includes at least one ring element, the at least one ring element being arranged as an inserted pin conductor (1, 1) i 1 o Provides an external radial contact surface. The rib (12) has at least an upper portion (18) having a radial length (19) greater than the radial length (21) of the lower portion (22) of the rib (12), and the rib (12) includes a continuous transition portion (61) between the upper portion (18) and the lower portion (22).

2. The device according to claim 1, wherein, The upper horizontal plane (14) of the block (11) and the upper horizontal plane (15) of the rib (12) are on the same axial horizontal plane.

3. The device according to claim 1, wherein, At least a portion (17.1) of the block (11) and the rib (12) are machined into a single part.

4. The device according to claim 1, wherein, At least a portion (17.1) of the block (11) and the rib (12) are machined from steel columns into individual parts.

5. The device according to any one of claims 1 to 4, wherein, The at least one ring element has an axial extension range (23.1, 23.2) smaller than that of the axial extension range (24) of the rib (12).

6. The device according to any one of claims 1 to 4, wherein, The at least one ring element is formed by a separate ring (25) connected to the rib (12).

7. The device according to claim 6, wherein, The upper horizontal plane of the individual ring (25) is arranged axially below the upper horizontal plane (14) of the block (11).

8. The device according to claim 6, wherein, The radially outward side (30) of the individual ring (25) includes a contact surface (31) for generating rotational motion of the bearing (32) or drive element.

9. The device according to any one of claims 1 to 4, wherein, The at least one ring element is formed by a support ring (33) arranged in a rotatable manner relative to the rib (12).

10. The device according to claim 9, wherein, The inner diameter (36) of the support ring (33) corresponds to the outer diameter (37) of the lower part (22) of the rib (12), and the support ring (33) is arranged below the continuous transition portion.

11. The device according to claim 9, wherein, The support ring (33) includes an axially extending opening (38) for insertion of a lower push rod element (41), the circumferential width (39) of which is at least the maximum circumferential width (40) of the groove (13) formed by adjacent ribs (12).

12. The device according to claim 11, wherein, The device (100) includes the lower push rod element (41) which is arranged to be radially movable from the radially outer side of the support ring (33) into the opening (38) of the support ring (33).

13. The device according to any one of claims 1 to 4, wherein, The at least one ring element is formed by a cover element (42) having a radially inner surface (43) axially arranged above the upper horizontal plane (15) of the rib (12) and having a radially inner diameter (44) smaller than the radial diameter (45) of the upper horizontal plane (16) of the stator core template (10). The cover element is adapted to contact the inserted pin conductor (1, 1). i 1 o At least part of the upper part of ).

14. The device according to claim 13, wherein, The cover element (42) has the shape of an annular segment with an opening region (46) that allows at least one upper push rod element (47) to enter and push inward the upper part of at least one inserted pin conductor.

15. The device according to any one of claims 1 to 4, wherein, The device includes at least one external positioning tool (75) having a radially inwardly projecting recessed element (76) that provides for positioning the i-type pin conductor (1, 1) i 1 o At least one recess (77) is radially stable on the outer side.

16. The device according to any one of claims 1 to 4, wherein, The device includes at least one upper push rod element (47) for pushing the upper part of at least one inserted pin conductor inward.

17. The device according to claim 1, wherein, The pin conductor (1, 1) i 1 o Nesting includes local nesting.

18. The device according to claim 9, wherein, The at least one ring element is formed by a separate ring (25) connected to the rib (12), and the support ring (33) includes a retaining flange (34) for fastening the separate ring (25) to the mounting frame (35).

19. The device according to claim 13, wherein, The cover element (42) can be fixed to the mounting frame (35) and arranged in a rotatable manner relative to the rib (12).

20. The device according to claim 15, wherein, The at least one external positioning tool (75) is capable of radial movement.

21. A method for manufacturing pin conductors (1, 1) for forming a stator i 1 o The nested device includes a stator core template (10) having a block (11) provided with radially extending ribs (12), wherein the ribs (12) form spaces for the pin conductors (1, 1) i 1 o ) legs (2, 2) i 2 o The slot (13) to be inserted, wherein, The rim segment (48) is mounted to the upper surface (49) of the block (11), and the rim segment prevents the pin conductor (1, 1) from being inserted. i 1 o At least one of the upper parts (3) of the ) is radially bent or moved inward, and, The rib (12) has at least an upper portion (18) having a radial length (19) greater than the radial length (21) of the lower portion (22) of the rib (12), and the rib (12) includes a continuous transition portion (61) between the upper portion (18) and the lower portion (22).

22. The device according to claim 21, wherein, The device includes a lifting element (50) having an axial contact surface (54) for a drive element (55) to generate axial movement, thereby pushing the inserted pin conductor (1, 1) upward. i 1 o Nested ).

23. The device according to claim 22, wherein, The lifting element (50) includes a component for receiving the pin conductors (1, 1) i 1 o ) legs (2, 2) i 2 o The number of leg supports (51) corresponds to the number of slots (13), and each leg support (51) is arranged in a corresponding slot (13).

24. The device according to claim 23, wherein, Each leg support (51) includes legs (2, 2) of different lengths for receiving legs. i 2 o The seat of ).

25. The device according to claim 23 or 24, wherein, The lifting element (50) includes an annular element (58) including the axial contact surface (54), and the annular element is connected to the radially inner side of the leg support (51).

26. The device according to claim 25, wherein, The axial length (56) of the block (11) is less than the axial extension range (24) of the rib (12), and the annular element (58) is axially movable below the block (11).

27. The device according to claim 21, wherein, The rim segment (48) includes radially outwardly projecting recessed elements (85) that provide support for the I-type pin conductors (1, 1). i 1 o At least one recess (88) on the radially outer side of the ) 28. The device according to claim 21 or 22, wherein, The pin conductor (1, 1) i 1 o Nesting includes local nesting.

29. A method for manufacturing pin conductors (1, 1) for forming a stator i 1 o The nested method (5) includes the following steps: a. Providing a pin conductor (1, 1) for manufacturing a stator according to any one of claims 1 to 28 i 1 o The nesting device (100) includes a stator core template (10) having a block (11) provided with radially extending ribs (12) and forming a space between the ribs for the pin conductors (1, 1). i 1 o ) legs (2, 2) i 2 o The slot (13) is inserted, and The device (100) includes at least one ring element, the at least one ring element being arranged as an inserted pin conductor (1, 1) i 1 o The legs (2, 2) i 2 o Provides an external radial contact surface; b. Place at least one pin conductor (1, 1) i 1 o The pin conductor (1, 1) is inserted into at least one slot in the slot (13) of the stator core template (10), such that the ... i 1 o The pin conductor (1, 1) is arranged in a first position within the groove (13), wherein, in the first position, the pin conductor (1, 1) is positioned... i 1 o The arrangement is different from the expected position in the stator core template (10); c. Place the pin conductors (1, 1) in the groove (13) of the stator core template (10). i 1 o Move from the first position to the second position; d. Repeat steps a and b for at least one additional pin conductor, such that pin conductors (1, 1) are formed. i 1 o The first level of nesting; e. Remove the pin conductors (1, 1) from the stator core template (10). i 1 o The nesting of ).

30. The method according to claim 29, The pin conductors (1, 1) are removed from the stator core template (10) by the axially moving lifting element (50). i 1 o The nesting of the pin conductor, wherein the lifting element includes legs (2, 2) for receiving the pin conductor. i 2 o ) leg support (51).

31. The method according to claim 29 or 30, f. Among them, At least one type I pin conductor (1, 1) i 1 o The core template (10) is inserted into at least one of the slots (13) of the stator core template (10); and g. Wherein, by means of the ring element formed as a support ring (33) arranged in a rotatable manner relative to the rib (12), the lower portion of the i-type pin conductor is prevented from radially extending to the outside of at least the lower portion (22) of the rib (12); and h. Wherein, the i-type pin conductor (1, 1) i 1 o The legs (2, 2) i 2 o The lower push rod element (41) moves radially inward by moving radially into the opening (38) of the support ring (33), the opening (38) having a circumferential width (39) corresponding to the maximum circumferential width (40) of the groove (13) formed by the adjacent ribs (12).

32. The method according to claim 31, in, During step h, the i-type pin conductors (1, 1) are... i 1 o The leg moves radially until it reaches the leg (2, 2) arranged on the leg support (51) for receiving the pin conductor. i 2 o The radial position of the corresponding seat part is reached.

33. The method according to claim 29 or 30, wherein, The pin conductor (1, 1) i 1 o Nesting includes local nesting.

34. The method according to claim 29, wherein, i. Rotate the stator core template; j. and insert another pin conductor into at least one of the slots in the groove.

35. The method according to claim 34, wherein, The method includes repeating steps f through i.

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