Stator, apparatus and method for producing a preformed insulator

Abstract

The present invention relates to a stator (1) for use in a rotating electric machine, an apparatus for preparing a preformed insulator, and a method for preparing a preformed insulator. The stator (1) includes a stator core (10) having a plurality of axially extending slots (11) arranged in a circumferential direction (C) of the stator core (10) and at least two conductors (20, 21) arranged in a radial direction (R) along the same slot (11). Each conductor (20, 21) is externally wrapped by a separate insulator (30) extending around the outer periphery (22) of the conductor (20, 21), such that in the circumferential direction, the insulator (30) includes a single-layer segment (37) and an overlapping segment (31) extending along the entire axial length (29) of the insulator (30).

Description

Technical Field

[0001] The present invention relates to a stator that can be used in a rotating electric machine, an apparatus for preparing a preformed insulator, and a method for preparing a preformed insulator. Background Technology

[0002] Multiple slots are typically formed in the stator core. The slots extend in the axial direction of the stator. The stator includes stator windings made of conductors, each conductor having a slot portion disposed within the slots.

[0003] In stator assemblies, insulator sheets are used to line the walls of slots for the stator core. In stator assemblies where more than one conductor is inserted into a slot, insulator sheets can also be used to provide insulation between adjacent conductors. Although conductors are typically joined together at their ends, care must be taken to ensure that adjacent conductors do not come into contact with each other and do not short-circuit the designed winding arrangement. For this purpose, insulator sheets bent into an S-shape are known, for example, as shown in EP3427920A1.

[0004] S-shaped designs typically do not provide a complete closure, resulting in gaps between the inner surfaces of the slot liner and the stator slot, or even between two adjacent conductors. Such gaps can also exist when the insulating sheet is bent into a B-shape, as illustrated in, for example, US8,456,056B2.

[0005] US8,446,061B1 and US2015 / 0188379 disclose insulating units for stator cores. The insulator surrounds two or more adjacent conductors and provides overlapping sections.

[0006] Before the insulator sheets are inserted into the slots, they must be pre-shaped, typically from an initially flat continuous sheet. Pre-shaped insulators with one or more overlapping segments require multiple folding steps, making manufacturing complex, time-consuming, and expensive. Summary of the Invention

[0007] Therefore, the object of the present invention is to overcome the shortcomings of the prior art, and in particular to provide a stator, an apparatus, and a method that provide an arrangement with sufficient insulation and allow for improved precision in the forming operation. The apparatus and method should preferably allow for fine-tuning or adjustment of the shape.

[0008] According to the present invention, these and other objectives are achieved by the stator, apparatus and method of the present invention.

[0009] According to the present invention, the stator for a rotating electric motor includes a stator core having a plurality of axially extending slots arranged in the circumferential direction of the stator core.

[0010] In this application, the terms “axial,” “circumferential,” and “radial” refer to the geometry of the stator.

[0011] At least two conductors are arranged adjacent to each other along the radial direction of at least one slot and preferably along the radial direction of each slot.

[0012] Each of the at least two conductors is externally wrapped by a separate insulator extending around the outer periphery of the conductor, such that, in the circumferential direction, the insulator comprises single-layer segments and overlapping segments.

[0013] There may be other conductors in the same slot, which are not individually wrapped by an insulator and / or not insulated toward the stator core and / or toward another conductor.

[0014] Each insulator's single-layer and overlapping sections extend along the entire axial length of the insulator.

[0015] The axial length of each insulator is equal to or greater than the axial extension of the slot. Typically, the axial length of each insulator depends on the axial length of the corresponding conductor, such that, in particular, the conductor does not include the non-insulated portion in the slot, and that the non-insulated axial end of the conductor protrudes from the insulator to the outside of the stator core.

[0016] The perimeter of the insulator is greater than that of the conductor, thus creating overlapping sections.

[0017] Overlapping sections provide complete closure and avoid gaps.

[0018] Therefore, each conductor is insulated around its perimeter relative to the walls of the slot and relative to adjacent conductors.

[0019] In the stator implementation, the insulator overlaps on the circumferential side of the conductor.

[0020] Since each conductor includes a separate insulator, there are at least two insulating layers between two adjacent conductors.

[0021] The insulator overlapping on the sides of the conductor also provides two sections between the conductor and the circumferential walls of the slot, thus avoiding gaps.

[0022] Preferably, all the insulators of the conductors arranged in a slot overlap on the same side. Thus, the conductors are arranged in a row, and the slot can be formed to provide sufficient space for the overlapping sections of the conductors and insulators.

[0023] Since the distance between the conductor and the first sidewall of the slot (i.e., the wall that extends radially and faces the circumferential direction) can be smaller than the distance between the conductor and the second sidewall of the slot, the arrangement can be slightly asymmetrical in a plane perpendicular to the axis of the stator core.

[0024] Advantageously, each slot opens toward the axis of the stator core.

[0025] Each slot may include a narrowing at its radially inner end, the narrowing having a radially extending centerline. Openings facing the axis may have a circumferential width smaller than the maximum circumferential width of the slot. The openings may be arranged circumferentially symmetrically or asymmetrically with respect to the maximum circumferential width of the slot.

[0026] The circumferential distance between the first sidewall of the slot and the radially extending centerline of the opening can be less than the circumferential distance between the second sidewall of the slot and the centerline. The difference in circumferential distances is preferably equal to or greater than the thickness of the insulator. Therefore, an overlapping section can be arranged between the conductor and the second sidewall.

[0027] Conductors with the same cross-sectional area can be wrapped by conductors of the same type of pre-formed insulator. Since only one or a few types of this insulator need to be provided, manufacturing is easy.

[0028] A conductor can be formed from several conductive parts, such as stranded wires or conductors. Apart from the pre-formed insulator arranged in the slot, a conductor essentially fills the slot in the circumferential direction.

[0029] The conductor may have a rectangular cross-section with a radial length of 1.5 mm to 11 mm, preferably 4 mm to 10 mm, and a circumferential width of 1.5 mm to 6 mm, preferably 3.9 mm to 4.1 mm.

[0030] The outer diameter of the stator core can be 200mm to 250mm, preferably 220mm to 225mm. The inner diameter of the stator core can be 150mm to 160mm, preferably 155mm to 156mm. The axial length of the stator core can be 50mm to 200mm, preferably 125mm to 130mm. The stator core may include 40 to 100 slots, preferably 45 to 50 slots.

[0031] According to another aspect of the invention, an apparatus is provided for preparing a preformed insulator from an insulator sheet, the preformed insulator preferably being used in a stator as described above.

[0032] The equipment includes a bending station.

[0033] The bending station has a base including a recess with a contact surface that defines a first portion of the outer periphery of the preformed insulator.

[0034] Preferably, the base includes a central bottom and two opposing walls. These walls may be arranged perpendicular to the bottom. Preferably, the width of the central bottom corresponds to the radial width of the preformed insulator to be formed, and the height of the walls corresponds to the circumferential width of the preformed insulator to be formed.

[0035] The insulator can have a rectangular cross-section, and the width of the central bottom and the height of the opposite wall can correspond to the dimensions of the preformed insulator to be formed as seen in the cross-section in a plane perpendicular to the axial direction.

[0036] Typically, the width of the center bottom of the contact surface is smaller than the radial width of the slot in the stator core because at least two conductors, and therefore at least two preformed insulators, will be inserted into a slot. The width of the center bottom of the contact surface corresponds to the radial width of the conductors.

[0037] The central bottom and the wall portion are preferably each formed by at least one rectangular flat surface.

[0038] The axial length of the abutment can correspond to the axial length of the preformed insulator to be formed, and can depend on the length of the conductor to be placed in the slot of the stator core. The axial length of the center bottom and the wall can be greater than the axial length of the slot and less than the axial length of the conductor.

[0039] Alternatively, the length of the center bottom and the wall portion can be shorter than that of the preformed insulator to be formed.

[0040] The axial length of the wall section can be shorter than the axial length of the central bottom. Several wall sections can be arranged along the length of the central bottom.

[0041] The base may include several central bottoms and / or several wall portions arranged along the axial length of the preformed insulator to be formed.

[0042] The bending station also includes a stamping member that is laterally movable relative to the recess from an open position to a closed position. When the stamping member is arranged within the recess, it is in the closed position. When the stamping member is outside the recess, it is in the open position.

[0043] The stamping member includes an inner contact surface for pressing the central portion of the insulator sheet against the contact surface of the recess. When the stamping member is moved to the closed position, the inner contact surface of the stamping member and the outer contact surface of the base member form the central portion of the periphery of the preformed insulator.

[0044] Preferably, the stamping member may include an inner bottom and two opposing sides, wherein the sides may be arranged perpendicular to the inner bottom.

[0045] The contact surfaces of the base components and the inner contact surfaces of the stamping components may have corresponding shapes and dimensions.

[0046] The inner bottom and / or side may each include at least one rectangular flat surface, and may correspond to the shape and size of the bottom and / or wall of the base member, respectively.

[0047] The stamped component also includes an outer contact surface for forming a second portion of the periphery of the preformed insulator.

[0048] The outer contact surface is preferably arranged opposite to the inner bottom.

[0049] Preferably, the outer contact surface has the same width as the center bottom of the stamped member.

[0050] The width of the outer contact surface corresponds to the radial width of the preformed insulator to be formed and the radial width of the conductor to be placed in the slot of the stator core.

[0051] The external contact surface may include at least one rectangular flat surface.

[0052] The bending station also includes a first bending manipulator capable of moving relative to the base from an open position to a closed position. The first bending manipulator includes a first bending surface for bending a first tail of the insulator sheet against the outer contact surface of the stamping member when the stamping member is in the closed position.

[0053] When the first bending surface is opposite to and close to the outer contact surface of the stamping member, the first bending manipulator is preferably in the closed position.

[0054] The first curved surface may include at least one rectangular flat surface that can press against the first tail of the insulator sheet.

[0055] The bending station also includes a second bending manipulator capable of moving relative to the base from an open position to a closed position. The second bending manipulator includes a second bending surface for bending a second tail of the insulator sheet against the outer contact surface of the first tail and / or the stamping member.

[0056] When the second bending surface is opposite to and close to the outer contact surface of the stamping member, the second bending manipulator is preferably in the closed position.

[0057] The second curved surface may include at least one rectangular flat surface that can press against the second tail of the insulator sheet.

[0058] The first curved surface and / or the second curved surface may include several rectangular flat surfaces, which may be separated by grooves extending in the axial direction.

[0059] Preferably, the contact surface of the base, the inner contact surface of the stamping member, the outer contact surface of the stamping member, the first bending surface, and the second bending surface are shaped and arranged to form a preformed insulator, such that the preformed insulator has a rectangular cross-section in a plane perpendicular to the axial direction.

[0060] By moving the stamping component, the first bending manipulator, and the second manipulator, a preformed insulator formed from an insulator sheet can be provided in just a few steps.

[0061] The base, stamping component, first bending manipulator and second manipulator can be separate parts and can move independently relative to each other.

[0062] These parts can also be connected to each other.

[0063] A bending station may include a base, a stamping member, a first bending manipulator, and a second bending manipulator for forming a preformed insulator. Alternatively, the bending station may include more than one base, more than one stamping member, more than one first bending manipulator, and / or more than one second bending manipulator for forming a preformed insulator, wherein each base, each stamping member, each preformed insulator, each first bending manipulator, and each second bending manipulator may be arranged along the axial length of the preformed insulator to be formed.

[0064] The bending station may include actuating components for moving the stamping member, the first bending manipulator, and the second manipulator, such as hydraulic, pneumatic, and / or electric actuators.

[0065] According to a preferred embodiment of the present invention, the first bending manipulator and / or the second bending manipulator are rotatably mounted on the base.

[0066] To move the first bending manipulator and / or the second bending manipulator from the open position to the closed position, the first bending manipulator and / or the second bending manipulator rotate around the base station.

[0067] The stamped component can be mounted to the base via a connecting arm that can move laterally, or the stamped component can be translated along the connecting arm toward and away from the base.

[0068] The sum of the widths of the first and second curved surfaces can correspond to the width of the stamped member, particularly to the width of the outer contact surface, such that the first and second curved surfaces completely cover the width of the outer contact surface in the closed position.

[0069] The second curved surface preferably has a wider width than the first curved surface.

[0070] After the first bending manipulator has been brought to the closed position and the first tail has been brought into contact with the outer contact surface, there is still space to place the second tail of the insulator sheet onto the stamping member and onto the first tail to allow for overlapping sections.

[0071] Advantageously, the outer contact surface of the stamping member includes a recess for receiving a first tail portion of the insulator sheet. When the first tail portion is pressed onto the stamping member by the first bending member, the outer surface of the first tail portion and the remaining free surface of the stamping member are aligned in the same plane, and the second tail portion can be pressed onto the same plane by the second bending member. The tail portions of the insulator sheets can be pressed tightly together, and the preformed insulator has a closed shape without any gaps.

[0072] In another preferred embodiment of the invention, the stamping member includes at least one groove extending in a direction parallel to the curvature of the insulator on the side facing the base. The base includes at least one groove extending in a direction parallel to the curvature of the insulator. When the stamping member is in the closed position, the grooves open in opposite directions.

[0073] Alternatively, the stamping member may include at least one groove extending in a direction parallel to the bending line of the insulator, the groove being disposed on a side opposite to the base. The second bending surface may include at least one groove extending in a direction parallel to the bending line of the insulator. When the second bending actuator is in the closed position, the grooves open in opposite directions to each other.

[0074] When the stamping member and bending manipulator are in the closed position, the slot allows the introduction of a removal tool for removing the shaped insulator from the bending station.

[0075] The preformed insulator can be directly transferred to the slots of the stator core or transferred to a transfer station.

[0076] The removal tool can be inserted into a groove on one axial side of the bending station to push the preformed insulator out of the other axial side of the bending station.

[0077] In an advantageous embodiment, the device further includes a supply station for supplying insulating material from the continuous tape.

[0078] The supply station includes a cutter for cutting flat sheets of insulating material from a continuous supply of insulating material.

[0079] It may also include embossing units for applying longitudinal embossing to an insulating material to form a predetermined curved line.

[0080] The supply station may also include a supply unit. The supply unit may supply the cut pieces to the bending station, or it may supply a continuous belt to the bending station, where the pieces are cut before or after bending.

[0081] If the sheet is cut after at least partial bending, the second tail remains connected to the continuous strip.

[0082] Alternatively or concurrently, the apparatus may include an insertion station for inserting at least two preformed insulators into slots in the stator core. The insertion station may include a removal tool for removing fully closed insulators from a bending station and optionally for transferring the preformed insulators into slots in the stator.

[0083] Preferably, insertion can also be achieved by conveying the sheet in a fully closed shape to a transfer station for temporarily receiving at least two sheets and by conveying the at least two sheets from the transfer station to the slots in the stator.

[0084] According to another aspect of the invention, a method is provided for preparing a preformed insulator from an insulator sheet, preferably using the apparatus described above, wherein the preformed insulator is preferably used in a stator as described above.

[0085] An insulating sheet cut from a flat insulating material is provided in the bending station of the device between a base including a recess and a stamping member.

[0086] Then, a portion of the insulator sheet is pressed into the recess by moving the stamping member laterally into the recess. This forms a U-shaped insulator sheet with a first tail and a second tail.

[0087] The first bending manipulator is moved relative to the base so that the first tail portion contacts the outer contact surface of the stamping member. The second bending manipulator is moved relative to the base so that the second tail portion contacts the outer contact surface of the stamping member and / or contacts the first tail portion. The first and second bending manipulators can press the first and second tail portions onto the stamping member, pressing them onto the entire outer contact surface.

[0088] Flat insulating material is bent to form a pre-shaped insulating member with a closed shape. Preferably, the second tail rests against the first tail to form an overlapping section, thereby firmly closing the shaped section.

[0089] Advantageously, the first bending manipulator and the second bending manipulator rotate relative to the base about their respective axes of rotation.

[0090] The method may include the further steps of introducing a removal tool from the insertion station into opposing slots in the stamping member and the base, and / or into opposing slots in the stamping member and the second bending manipulator. The removal tool may contact the preformed insulator and may move within the equipment, thereby removing the preformed insulator from the bending station of the equipment.

[0091] At least two preformed insulators may be arranged in a transfer station, preferably close to each other. For example, a preformed insulator may be pushed out of a bending station and enter the transfer station. The at least two preformed insulators may be inserted into slots in the stator core in one step.

[0092] To form the preformed insulator, an insulator sheet supplied by NOMEX under the name MYLAR can be used. The thickness of the sheet can be from 0.1 mm to 0.5 mm, preferably from 0.18 mm to 0.3 mm. Attached Figure Description

[0093] The invention will now be described with reference to preferred embodiments and the accompanying drawings, wherein:

[0094] Figure 1 The stator core is shown in a 3D diagram.

[0095] Figure 2 The slots with insulating plates in the stator core are shown in a top view;

[0096] Figure 3 A schematic diagram of the slots in the stator core is shown in top view;

[0097] Figures 4a to 4e A top-down view shows a schematic diagram of the curved stance in different positions;

[0098] Figure 5 A schematic diagram of the device is shown;

[0099] Figure 6a A schematic cross-sectional view along the longitudinal axis of the receiving section is shown;

[0100] Figure 6b It shows according to Figure 6a A front view of the exit of the receiving section. Detailed Implementation

[0101] Figure 1 The stator core 10 is shown in a perspective view. The stator core 10 has a plurality of slots 11 extending in the axial direction A and arranged in the circumferential direction C. Two conductors 20, 21 are arranged along the radial direction R of each slot 11. Each conductor 20, 21 is externally wrapped by a separate insulator 30.

[0102] Figure 2A schematic diagram of the slot 11 of the stator core 10 with insulating sheet 30 is shown in top view.

[0103] Each insulator 30 extends around the outer periphery 22 of the conductors 20, 21, such that the insulator 30 includes a single-layer segment 37 and an overlapping segment 31 extending along the entire axial length 29 (see Figure 4) of the insulator 30.

[0104] Two insulators 30 arranged in a slot 11 overlap on the same side 23 of conductors 20, 21.

[0105] Figure 3 A schematic diagram of slot 11 is shown in top view.

[0106] The groove 11 opens toward the axial center 12 of the stator core 10 and includes a narrowing portion 13 at the radial inner end 14 of the groove 11, the narrowing portion 13 having a radially extending centerline 15.

[0107] The circumferential distance 16 between the first sidewall 17 of the groove 11 and the centerline 15 is greater than the circumferential distance 18 between the second sidewall 19 of the groove 11 and the centerline 15. This difference corresponds to the thickness 32 of the insulator 30 (see...). Figure 2 ).

[0108] Figures 4a to 4e A top view is shown schematically of the bending station 39 during different steps of the bending process. The bending station 39 is used to form a pre-shaped insulator from the insulator sheet 33. The top view is shown in the direction perpendicular to the axial direction A (see...). Figure 1 In the plane of ).

[0109] The curved station 39 includes a base 40 with a recess 41.

[0110] The recess 41 includes a contact surface 42 for forming a first portion of the outer periphery of the preformed insulator 30.

[0111] The contact surface 42 is formed by the central bottom 47 of the base 39 and two opposing wall portions 46.

[0112] The bending station 39 includes a stamping member 50. The stamping member 50 and the base 40 are translatable relative to each other, allowing the stamping member to move relative to the recess 41 from... Figure 4a The opening position shown is moved laterally. Figures 4c to 4e The indicated closing position.

[0113] The insulator sheet 33 can be inserted between the base 40 and the stamping member 50 and can be held in place by a spring-loaded clamping element 56. For example, when the base 40 and the stamping member 50 approach each other so that the stamping member 50 enters the closed position, the clamping element 56 can be pushed into the recess of the base 40.

[0114] The stamping member 50 has an inner contact surface 51, which, when the stamping member 50 moves to such a position, allows for contact with other components. Figure 4b and Figure 4c In the closed position shown, the inner contact surface 51 presses the middle portion 34 of the insulator sheet 33 against the contact surface 42 of the recess 41.

[0115] The inner contact surface is composed of a central inner bottom 48 and two opposing inner portions 49.

[0116] The contact surface 42 of the base member 40 and the inner contact surface 51 of the stamping member 50 form a first portion of the preformed insulator 30, which is formed by the middle portion 34 of the insulator sheet 33.

[0117] The stamping member 50 also includes an outer contact surface 52 opposite to the inner bottom 48.

[0118] The bending station 39 includes a first bending manipulator 60, which is capable of bending relative to the base 40 from... Figures 4a to 4c Move the indicated opening position to... Figure 4d and Figure 4e The indicated closing position.

[0119] The first bending manipulator 60 includes a first bending surface 61 for bending the first tail 35 of the insulator sheet 33 against the outer contact surface 52 of the stamping member 50, such as... Figure 4d As shown.

[0120] The bending station 39 includes a second bending manipulator 70, which is capable of bending relative to the base 40 from... Figures 4a to 4d Move the indicated opening position to... Figure 4e In the closed position shown, the second bending manipulator 70 includes a second bending surface 71. The second bending manipulator 70 presses the second tail 36 of the insulator sheet 33 against the first tail 35 and the outer contact surface 52 of the stamping member 50, as shown. Figure 4e As shown. This forms an overlapping section 31.

[0121] The first bending manipulator 60 and the second bending manipulator 70 can rotate about their respective axes of rotation 63 and 74.

[0122] The rotational motion can be driven by a lever system connected to the gas storage tank (not shown in the figure).

[0123] The width 62 of the first curved surface 61 (see...) Figure 4c and Figure 4e ) and the width 72 of the second curved surface 71 (see Figure 4c and Figure 4eThe sum of the two surfaces corresponds to the width 44 of the stamping member 50, such that the first curved surface 61 and the second curved surface 71 together with the outer contact surface 52 of the stamping member 50 form the second part of the outer periphery of the preformed insulator 30.

[0124] like Figure 4d and Figure 4e As shown, the stamping member 50 includes two grooves 54 extending in a direction parallel to the curvature of the insulator 33, and the base 40 includes two grooves 45 extending in a direction parallel to the curvature of the insulator. When the stamping member 50 is in the closed position (see...), Figure 4d The grooves 45 and 54 open in opposite directions to each other.

[0125] Another groove 73 is arranged in the second curved surface 71, extending in a direction parallel to the curvature of the insulator. Furthermore, the stamping member 50 includes another groove 55 on the side opposite to the base 40, extending in a direction parallel to the curvature of the insulator 30. When the second bending actuator 70 is in the closed position (see...), Figure 4e The grooves 55 and 73 open in opposite directions to each other.

[0126] When the bending station 39 is in the closed position, the paired grooves 55, 74 and 45, 54 facing each other allow the insertion of the removal tool 91 (see...). Figure 5 The removal tool 91 is used to push the shaped insulator 30 out of the bending station 39. The removal tool includes blades (not explicitly shown) for each pair of grooves 55 and 74, 55 and 74, and 45 and 54.

[0127] The axial length of the bending station 39 can correspond to the axial length of the preformed insulator 30 to be formed.

[0128] Alternatively, multiple bending stations 39 may be arranged along the axial length to form a preformed insulator 30.

[0129] The axial lengths of the stamping member 50, the first bending manipulator 60, and the second bending manipulator 70 may correspond to the axial length of the base 40. Alternatively, a plurality of stamping members 50, a plurality of first bending manipulators 60, and / or a plurality of second bending manipulators 70 may be arranged along the axial length of the base 40.

[0130] Figure 5 A schematic diagram of device 100 is shown. Device 100 includes, as follows: Figures 4a to 4e The curved station 39 is shown.

[0131] Equipment 100 also includes a supply station 80.

[0132] The supply station 80 includes an embossing unit 81 for applying longitudinal embossing to a continuous supply sheet of insulating material 38.

[0133] The supply station 80 includes a supply unit 82 for supplying the embossed insulating material 38 to the bending station 39.

[0134] The supply station 80 includes a flat sheet 33 for cutting insulating material from a continuous supply sheet of insulating material 38 (see [link]). Figure 4a ) cutter 83.

[0135] The supply station 80 includes a supply unit 83 for supplying the cut pieces 33 to the bending station 39.

[0136] The device 100 includes a removal tool 91 for pushing the preformed insulator 30 out of the bending station 39 into the transfer station 90.

[0137] Conveyor station 90 collects at least two preformed insulators 30, which are introduced into a slot 11 of stator core 10 (see...). Figure 6a )middle.

[0138] Figure 6a A schematic cross-sectional view of the bending station 39, the transfer station 90, and a portion of the stator 10 is shown. The transfer station 90 has three channels 98a, 98b, and 98c, each with its own receiving opening 99a, 99b, and 99c. The transfer station 90 is laterally movable relative to the bending station 39 (see...). Figure 5 and Figure 6a (The arrow in the image). Thus, the receiving openings 99a, 99b, 99c can be connected with the preformed insulator 30 arranged around the stamping member 50 of the bending station 39 (see the image). Figure 4e )alignment.

[0139] Figure 6b A side view of a transfer station 90 with receiving openings 99a, 99b, and 99c is shown. When using removal tool 91 (see...) Figure 5 As the preformed insulator is translated along the bending station 39, it will leave the bending station 39 and be conveyed into the aligned receiving opening 99c. Once the preformed insulator has been conveyed into the receiving opening 99c and into the channel 98c, the transfer station 90 will be laterally translated so that another receiving opening (e.g., receiving opening 99b) is aligned with the bending station 39 so that another preformed insulator can be received by the transfer station 90.

[0140] Receiving channels 98a, 98b, and 98c are separated from each other by wall 101. Wall 101 exists only for approximately two-thirds of the length of transmission station 90, causing channels 98a, 98b, and 98c to merge together to form a combined channel 102 within transmission station 90. Figure 6a(As shown on the right). Wall 101 tapers slightly so that... Figure 6a The preformed insulators converge slightly in the axial direction (from left to right). By axially pushing the three preformed insulators through channels 98a, 98b, and 98c, the preformed insulators will be pushed toward each other in the combined channel 102. The three preformed insulators can then be jointly conveyed from the outlet 97 of the transfer station 90 to a slot 11 of the stator 10. Of course, fewer or more than three channels can be used where fewer or more preformed insulators should be inserted into a slot.

Claims

1. An apparatus (100) for preparing a preformed insulator (30) from an insulator sheet (33), the apparatus (100) comprising a bending station (39) having: - A base (40) including a recess (41) having a contact surface (42) that defines a first portion of the outer periphery of the preformed insulator (30); - A stamping member (50) capable of laterally moving relative to the recess (41) from an open position to a closed position, the stamping member (50) including an inner contact surface (51) for pressing the middle portion (34) of the insulator sheet (33) against the contact surface (42) of the recess (41) and defining a first portion of the inner periphery of the preformed insulator (30), the stamping member (50) including an outer contact surface (52) defining a second portion of the inner periphery of the preformed insulator (30); - A first bending manipulator (60) is movable relative to the base (40) from an open position to a closed position. The first bending manipulator (60) includes a first bending surface (61) for bending a first tail (35) of the insulator sheet (33) against the outer contact surface (52) of the stamping member (50). - A second bending manipulator (70) is capable of moving from an open position to a closed position relative to the base (40). The second bending manipulator (70) includes a second bending surface (71) for bending the second tail (36) of the insulator sheet (33) against the first tail (35) and / or the outer contact surface (52) of the stamping member (50). - wherein the first bending manipulator (60) and / or the second bending manipulator (70) are rotatably mounted on the base (40).

2. The device according to claim 1, wherein, The sum of the width (62) of the first curved surface (61) and the width (72) of the second curved surface (71) corresponds to the width (44) of the outer contact surface (52) of the stamping member (50).

3. The device according to claim 2, wherein, The second curved surface (71) has a wider width (72) than the first curved surface (61).

4. The device according to claim 1, wherein, The outer contact surface (52) of the stamping member (50) includes a recess (53) for receiving the first tail (35) of the insulator sheet (33).

5. The device according to claim 1, wherein, The stamping member (50) includes at least one groove (54) extending in a direction parallel to the bending line of the preformed insulator, and the base (40) includes at least one groove (45) extending in a direction parallel to the bending line of the preformed insulator. When the stamping member (50) is in the closed position, the grooves (45, 54) open in opposite directions to each other and allow the introduction of a removal tool for removing the preformed insulator from the bending station (39) of the device (100).

6. The device according to claim 1, wherein, The stamping member (50) includes at least one groove (55) extending in a direction parallel to the bending line of the preformed insulator, and the second bending surface (71) includes at least one groove (73) extending in a direction parallel to the bending line of the preformed insulator. When the second bending manipulator (70) is in the closed position, the grooves (55, 73) open in opposite directions to each other and allow the introduction of a removal tool for removing the preformed insulator from the bending station (39) of the device (100).

7. The device according to claim 1, wherein, The device also includes a transfer station (90) for inserting at least two preformed insulators (30) into slots (11) of the stator core (10).

8. The device according to claim 1, wherein, The device further includes a supply station (80), which includes at least one of the following: - A cutter (83) for cutting flat sheets of insulating material from a continuous supply of insulating material (38); - Embossing unit (81), which is used to apply longitudinal embossing to the flat sheet or to the continuously supplied sheet of insulating material (38); as well as - Supply unit (82) for supplying the cut flat sheet to the bending station (39) or for supplying the continuous supply sheet of insulating material (38) to the bending station (39) before cutting.

9. The device according to claim 1, wherein, The equipment is used to prepare a preformed insulator (30) for a stator (1) of a rotating electric motor. The stator includes: - Stator core (10) having a plurality of axially extending slots (11) arranged in the circumferential direction (C) of the stator core (10); - At least two conductors (20, 21) are arranged along the radial direction (R) of at least one / each slot (11). Each conductor (20, 21) is wrapped around its outer periphery by a separate preformed insulator (30) extending around the outer periphery (22) of the conductor (20, 21), such that in the circumferential direction, the preformed insulator (30) includes a single-layer segment (37) and an overlapping segment (31) extending along the entire axial length (29) of the preformed insulator (30).

10. The device according to claim 9, wherein, The preformed insulator (30) overlaps on the sides (23, 24) of the conductor (20, 21).

11. The device according to claim 9, wherein, Each slot (11) opens toward the axial center (12) of the stator core (10) and includes a narrowing portion (13) at the radially inner end (14) of the slot (11), the narrowing portion having a radially extending centerline (15). The circumferential distance (16) between the first sidewall (17) of the groove (11) and the center line (15) is less than the circumferential distance (18) between the second sidewall (19) of the groove (11) and the center line (15).

12. The device according to claim 9, wherein, The conductors (20, 21) are formed by a plurality of conductor elements.

13. A method for preparing a preformed insulator using the apparatus (100) according to claim 1, the method comprising the steps of: - An insulating sheet (33) cut from a flat insulating material is provided in the bending station (39) of the device (100), located between the base (40) including the recess (41) and the stamping member (50); - By moving the stamping member (50) laterally into the recess (41), a portion of the insulating sheet (33) is pressed into the recess (41), thereby forming a U-shaped insulating sheet having a first tail (35) and a second tail (36); - By moving the first bending manipulator (60) relative to the base (40), the first tail (35) comes into contact with the outer contact surface (52) of the stamping member (50); and - By moving the second bending manipulator (70) relative to the base (40), the second tail (36) comes into contact with the outer contact surface (52) of the stamping member (50) and / or with the first tail (35). The first bending manipulator (60) and the second bending manipulator (70) rotate about their respective rotation axes (63, 74).

14. The method according to claim 13, wherein, The second tail (36) presses against the first tail (35) to form an overlapping section (31).

15. The method according to claim 13, wherein: - The removal tool is introduced into the opposing grooves (45, 54, 55, 73) of the stamping member (50) and the base (40) and / or the second bending manipulator (70); - The removal tool contacts the preformed insulator (30); - The removal tool moves within the device (100) to remove the preformed insulator (30) from the bending station (39) of the device (100).

16. The method according to claim 13, wherein, At least two preformed insulators (30) are arranged in the transfer station (90).

17. The method according to claim 16, wherein, The at least two preformed insulators (30) are inserted into the slots (11) of the stator core (10) in one step.

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