Removable apparatus for inserting and processing segmented conductors in mold to form winding

Abstract

The present invention relates to a removable apparatus (500) for loading and operating base conductors (255, 255-R, 255-IP, 255-IVP) configured to load, operate and insert base conductors in a circumferential receptacle arrangement (300, 600), each base conductor comprising a head end and one or more legs having respective free insertion ends, a removable loading and operating apparatus (500) configured to assemble a stator or rotor winding (100) consisting of one or more sectors (100-CI) extending circumferentially about a winding axis (50), each sector comprising one or more layers, each layer consisting of a circumferential arrangement of basic conductors, the apparatus comprising: a first reverse mold (521) and a second reverse mold (522), a plurality of first and second counter-molds (52011, 52012, 521, 522) configured to define a receptacle volume (52011, 52012, 521, 522) of the basic conductor, the first and second counter-molds each having an extension along an axial direction, which in use is parallel to the winding axis (50); and loading means (530, 540) for loading the base conductor into the receptacle volume; wherein the receptacle volume comprises an end volume (500F) of the base conductor against said first and second reverses, the end volume (500F) being configured such that the base conductor slides along the axial direction (z) until being inserted into the circumferential receptacle means (300, 600) within the sector of the one or more sectors (100-CI) that is being assembled (100-CIN).

Description

[0001] Applicant: Techmarch Ltd.

[0002] Inventors: Giovanni Ruggeri, Maurilio Micucci, Giuseppe Ranali Technical Field

[0003] The invention relates to a dismantling device for loading and handling elementary conductors for the assembly of stator or rotor windings. Background Art

[0004] It is known to provide a stator or rotor of an electric motor such as a generator or an electric motor, for example for applications on hybrid electric vehicles (HEV), wherein the stator or rotor winding consists of a plurality of strip conductors that are bent and connected to each other in various ways to obtain an electrical winding also called a "strip winding". The bent strip conductors are also called "hairpin conductors" or simply "hairpins". The strip winding may consist of one or more groups of concentric windings, sometimes called "crowns", each group of windings being already a winding in itself ("winding group").

[0005] In particular, windings with hairpins having a circular cross section (also called "round wire conductors") or a rectangular cross section, or even conductors having a variable cross-sectional geometry along the length (e.g. a round conductor made rectangular in the portion received in the stator or rotor slots) are known in the prior art. In this regard, a "rectangular" or "square" conductor refers in this specification to a wire having four generally flat sides, each side being connected to the adjacent side, usually by a rounded edge. Strip conductors having a trapezoidal cross section are known.

[0006] The above-mentioned bar conductors are usually preformed by bending into a "U" or "P" shape starting from a straight bar conductor. Patent US7480987 describes an example of a method for preforming a bar conductor to form a hairpin. The "U" or "P" shaped preformed conductor, also commonly referred to as a "preformed basic conductor" in the technical field, usually has two adjacent legs of equal or different lengths, each leg having a free end portion and an opposite end portion, which is connected to the other of the two legs by a bridge-like connecting portion. Since these two end portions protrude when inserted into the rotor or stator, they will be referred to as "free protruding portions" and "oppositely connected protruding portions". The protruding portion may also be referred to as a "head" or "bridge-like connecting portion". The assembly of the "heads" of the legs of the same hairpin forms a so-called "bridge-like connection".

[0007] Referring to FIG. 1( a ), the hairpin 255 is preformed from a linear hairpin (not shown) by bending it to form a first leg 255a with a corresponding free protruding end 255aE and a second leg 255b with a corresponding free protruding end 255bE. The bending simultaneously forms a bridge-like connection 255c between the two legs 255a, 255b. In this example, the preformed hairpin is a flat “U” shape. For example, in order to form a stator for an electric motor, it is known to perform two different types of twisting on a “U” or “P” shaped preformed hairpin.

[0008] The stator or rotor core of a radial flux motor is generally a ring with two planes and two cylindrical surfaces, the generatrix of which is perpendicular to the two planes parallel to the axis of rotation of the motor rotor. Unless otherwise specified, the radial, circumferential and axial directions in the following text refer to the last mentioned axis. One of the two cylindrical surfaces is at least partially adjacent to the air gap of the motor and defines a set of slots in which the straight parts of the windings are accommodated. The two planes are divided into an insertion face or insertion side and a face or side opposite to the insertion side. The part of the winding protruding from the core is called the header. The ends of the free parts of the conductors are located in the header protruding from the side opposite to the insertion side, and most of the ends of the free parts of the conductors are subjected to welding. If there are protruding parts in the winding that are connected in a bridge-like manner to the legs inserted into the stator slots, they are located in the header protruding from the insertion side. The part protruding from the insertion side, whether free or connected in a bridge-like manner, is hereinafter indicated as the part protruding from the insertion side.

[0009] The area of ​​the stator or rotor core between one slot and the adjacent slot is called a tooth. The number of teeth is equal to the number of slots. The connecting portion of the core teeth is called a yoke, which also defines a portion of each slot and is located on the opposite side of the slot opening (if present) on the air gap of the motor relative to that portion.

[0010] The slot may be divided into an array of positions, in each of which one leg of the elementary conductor may be placed. The conductors housed in the same radial position as the slot define a so-called winding layer.

[0011] In the first type of twisting, also called "twisting on the insertion side", preformed elementary conductors are suitably inserted into corresponding radially aligned cavities or "slots" which are radially aligned in a twisting apparatus adapted to deform the conductors after insertion. The twisting apparatus is generally used to spread out the legs of a "U" or "P" shape so that after the conductors are removed from the apparatus, the two legs of each conductor can be inserted into a corresponding pair of slots of the stator core, the pair of slots being angularly offset from each other by a predetermined distance which is substantially equal to the angular distance between the slots into which the legs are inserted, and the two legs being radially spaced apart by the radial distance between the slot positions respectively occupied by the two legs.

[0012] For example, but not exclusively, as shown in FIG. 1( a ), starting from a preformed hairpin, a hairpin of suitable shape is formed by widening the legs 255a, 255b and forming the bridge-like connection 255c for inserting the hairpin into the stator (or rotor), for example to obtain the shape in FIG. 1( b ). Reference numeral 255p indicates the spacing of the hairpin, i.e. the linear or angular distance between the two legs, or the distance expressed as the slot spacing. It is worth noting again that in this case, the central top 255c2 of the hairpin formed is the area where the cross section of the conductor is rotated 180° relative to the middle surface of the hairpin (the surface passing through the interior of the hairpin and including the two legs). The rotation is useful in some layered hairpins, which will be defined below, to transpose multiple layers (exchange the slot positions), so that when they are welded together, the eddy currents circulating through the ends of these layers are reduced compared to the case where multiple identical layers extend in parallel without exchanging the slot positions in the transition from one leg to another.

[0013] The patent application published under US 2009 / 0178270 describes an example of a twisting method on the insertion side for twisting preformed pins at uniform pitches after inserting them into a chamber of a twisting device, wherein the hairpins have a rectangular cross section.

[0014] According to the prior art and with reference to Figure 2, hairpins can also be obtained by molding, in which a straight conductor is pressed against a contrast with a punch and die type system. Figure 2 (a) shows such a molded conductor; it has no cross section rotated relative to the middle surface of the hairpin.

[0015] As shown in (b) of Figure 2, such a molded hairpin or preformed and unfolded hairpin obtained as described above can undergo so-called "welding side twisting", in which case a "step-like" shape of the protruding portions of the legs 255a and 255b can be introduced, wherein, for example, the leg 255a has a first straight portion 255a1, a stepped portion 255a2 and a second straight portion 255a3 (roughly corresponding to portion 255aE in Figure 1).

[0016] With reference to FIG. 3 , for a molded hairpin, the shape of the protruding portion on the insertion side, i.e. the shape of the bridge-like connection 255 c, may include three portions 255 c 1 , 255 c 3 and 255 c 2 , starting from the connection with the second leg 255 b and ending at the connection with the first leg 255 a (not visible in FIG. 3 ). The portion 255 c 1 has a main extension direction B and a radius of curvature RB, the portion 255 c 3 has a main extension direction A and a radius of curvature RA, and the portion 255 c 2 has a main extension direction C (and a possible curvature, not shown). Hereinafter, the portion 255 c 2 is referred to as a “layer-changing bend”; in fact, due to this, the head and leg portions of the hairpin are located on different layers when they are inserted into corresponding slots of a stator pack. The reference α 1 denotes the angle between directions A and C, the reference α 2 denotes the angle between directions A and B, and the reference α 3 denotes the angle between directions B and C, α 3 being equal to the sum of the angles α 1 and α 2. This is only one of the final possible shapes of the hairpin, all other shapes with different parts and shapes of the bridge and the legs can be used with the device and method according to the present description.

[0017] There are also conductors defined as "reverse" conductors (not shown), which are hairpins that bend in the bridge-like connection in the opposite direction to the majority of hairpins forming the same winding. They are used to go from the last layer of one crown to the first layer of the next crown.

[0018] Furthermore, with reference to FIG. 4A , there is a layered (“twisted”) hairpin having an opposite cross section at the bending point ( FIG. 4A (a) ), which results in an exchange of the positions occupied by the layers. As can be seen from the type of shading of the cross section in FIG. 4A (a) , due to this reversal or exchange of positions, the upper layer of a pair of layers in the left slot is located below the other layer in the right slot. In another hairpin form, the position can be continuously transposed along multiple parts of the hairpin accommodated in the slot ( FIG. 4A (b) ), US3837072 ). The variation shown in FIG. 4B is a layered hairpin without reversal shown in US8552611B2 (a layered hairpin 4 having multiple hairpins 42 , each having a foot 41 and a curved head end 42a ). FIG. 4C (from patent US6894417B2 Figure 6 ) shows a variation of the arrangement of the legs of the layered hairpins in the double crown winding at different positions in the slots. The reference letters A and B indicate the crown to which the legs shown in the slots belong (belonging to different hairpins).

[0019] Likewise, there are pins known as "I-pins", i.e., the pins are housed in a single slot and, when in the slot, have free end portions that protrude from two flat faces of the stator core. FIG. 4D shows an example of an I-pin, which does not necessarily have to have all the directional changes shown; it can also have no directional changes and be bent on the output side of the hairpin winding assembly drum. The ends of the I-pins can be welded to the ends of other conductors protruding from the slots, or to a third element (e.g., a busbar, an eyelet), or they can be used as phase terminals. These portions can be subjected to a "weld side" type of bend. An example of an I-pin can be found in the hairpins indicated by reference numerals 81-83 in document US7622843B2. "W-conductors" are also known, for example, see again patent US7622843B2, and FIG. 4E, in which the distance between the legs is N slots. A W-conductor can be formed by welding a molded hairpin with one I-pin or by welding a fourth conductor to three I-pins. Likewise, the W-pin does not necessarily have to have all the directional changes shown; it may also have no directional changes and be bent on the output side of the hairpin winding assembly bobbin.

[0020] With reference to FIG. 4F (obtained from US10749399B2), there is also a so-called "inverted hairpin" 255-IVP, i.e. a hairpin that can be formed by spreading out the legs (without using the above-described insertion side twisting method), or molded with a "punch and die" system, characterized in that the legs in the corresponding slots occupy the same radial position, i.e. they belong to the same layer. Therefore, their ends on the twisting side will bend in the same direction. In fact, the protruding parts of the sides of the bridge-like connection can be bent in the same tangential direction, or they can be V-shaped. At least two layers of varying bends may be required on this connection.

[0021] Finally, there are pairs of hairpins whose corresponding legs belong to different layers (Figure 4G) or to the same layer (Figure 4H), and which are configured and dimensioned to nest.

[0022] For the remainder of this article, all “hairpin” types as well as I-type leads and W-type leads will be included in the definition of “basic conductor.”

[0023] After undergoing the first type of twisting or after they have been moulded, the basic conductors are usually pre-assembled in a winding set as described above. The pre-assembly device has a set of slots, usually equal to the number of slots of the stator associated with the winding, into which the legs of each hairpin will be inserted, and is usually different from the twisting device.

[0024] The winding group is then inserted as a whole into these slots of the stator core through a first side of the stator core (the so-called "insertion side" or "insertion face"), and the corresponding free parts protrude from a second side of the core opposite to the first side (the so-called "welding side" or "connection side" or "welding face" or "escape face").

[0025] Based on the specific winding style to be obtained, the free part of the basic conductor protruding from the side opposite to the insertion side can then be subjected to a second type of twisting, also called "twisting on the welding side", for example after having been inserted into a cavity made in a suitable twisting device. Here, the purpose of the twisting device is to bend or twist the free part of the conductor in order to properly shape it so as to allow obtaining a suitable electrical connection between the conductors to complete the winding. Patent application with publication number US2009 / 0302705 describes an example of a twisting method on the welding side of the above type.

[0026] Electrical winding assembly systems for stators and / or rotors are known. Systems for transferring windings and inserting them into stator packages are also known.

[0027] For example, international patent application WO2019207448A1 describes a device for preassembling a stator winding of an electric motor, the device comprising a plurality of basic conductors (see FIG. 5 of this specification). However, this device is configured to process and insert only one type of hairpin into the stator package at a time. Therefore, the problem of having to manually modify the insertion system according to the type of hairpin to be inserted significantly increases the cycle time of the device, thereby reducing the overall efficiency of the system.

[0028] Patent document US2020336054 describes an alignment device, which is provided to align multiple winding segments to form an aligned winding, including a cylindrical container for hairpins, the cylindrical container being provided with a slot. The container has radial teeth that can rotate relative to the cylindrical body. The cylindrical container also has an internal entrance arranged in the inner cylinder, an external entrance arranged in the outer cylinder, and some guide walls between these openings. Such guide walls are below the plane of the rotatable radial teeth. A device for inserting hairpins into slots above the plane of the rotatable teeth is described, the device being configured to insert the hairpins into predetermined slots one by one at a predetermined time to allow the teeth to rotate between one insertion and another insertion. The morphological configuration of such an insertion device is not described. This device has the same problem as described above, that is, it is configured to process and insert only one type of hairpin at a time in the stator package. Therefore, the problem of having to manually modify the insertion system according to the type of hairpin to be inserted greatly increases the cycle time of the device, thereby reducing the overall efficiency of the system.

[0029] Patent document EP3700071A1 describes a system for the simultaneous preassembly of hairpins in stator windings. The system comprises a housing with hairpin slots formed by radially retractable teeth. The hairpins are first inserted in their respective positions in all necessary slots, and then the radial teeth are rotated about the housing axis so that the same hairpins are rotated and simultaneously position themselves in the assembled crown. Here too, the insertion means are not described in detail, and the simultaneous assembly of hairpins does not allow the insertion and inclusion of different types of hairpins in the same preassembly process.

[0030] Patent document JP2004072839 describes a system with slotted housings in which all the hairpins of the crown are inserted before the rotation that brings them to their position. However, in this case, no radial teeth are provided and the system is subject to the same limitations as the other documents mentioned above.

[0031] Patent document WO2018039806A2 describes a method and system for assembling hairpins in a stator core. The slot container is divided into three parts, and the hinge allows the three parts to rotate relative to each other. The hairpins are inserted independently into the three container parts, which are then closed to form a complete winding. Obviously, due to the insertion into three container parts that are far apart and due to the rotation of these parts, this arrangement is very complex and has a high cycle time. Although different types of hairpins can theoretically be used, the system is inefficient and costly. In addition, due to the complexity of the system, it will be subject to significant wear.

[0032] The need is felt to have the windings all assembled in one system to make it easier to insert them into the stator package, while pursuing time cycle and accuracy specifications, as well as pursuing cost and easy maintenance specifications, which are becoming increasingly stringent today. Summary of the invention

[0033] The object of the present invention is to provide an apparatus for loading and handling elementary conductors which solves all or part of the problems and overcomes the disadvantages of the prior art.

[0034] According to the appended claims, the invention relates to an apparatus for loading and handling elementary conductors for stator or rotor winding assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The invention will now be described by way of non-limiting illustration, with particular reference to the figures of the accompanying drawings, in which:

[0036] - Figure 1 shows in (a) a preformed flat U-shaped hairpin according to the prior art and in (b) a formed hairpin;

[0037] - Figure 2 shows in (a) a moulded hairpin and in (b) the hairpin after having been subjected to welding side twisting;

[0038] - FIG. 3 shows the hairpin in FIG. 2 (a) according to the prior art from above;

[0039] - FIG. 4A shows in (a) a layered ("twisted") hairpin according to the prior art, with opposite cross-sections at the bending point, and in (b) a continuous transposition along the portion of the hairpin housed in a slot;

[0040] - Figure 4B shows a hairpin of layered type;

[0041] - FIG. 4C shows a variant of the arrangement of the legs of the layered hairpins in different positions in the slots in a double-crown winding according to the prior art;

[0042] - FIG. 4D shows an example of an I-type pin according to the prior art;

[0043] - FIG. 4E shows an example of a "W-shaped pin" according to the prior art;

[0044] - FIG. 4F shows an example of an “inverted hairpin” according to the prior art;

[0045] - FIG. 4G shows an example of nested hairpins on different layers according to the prior art;

[0046] - FIG. 4H shows an example of nested hairpins on the same layer according to the prior art;

[0047] - FIG. 5 shows a device for preassembling windings according to international application WO2019207448A1;

[0048] - Figure 6 According to one aspect of the invention, means for inserting a reverse hairpin are shown;

[0049] - Figure 7 According to one aspect of the invention there is shown an apparatus for inserting a first substantially counter conductor into a winding;

[0050] - Figure 8 According to one aspect of the present invention, a molding scheme with a plurality of circular receiving parts is shown;

[0051] - Fig. 9 One aspect of the method according to the invention shows the situation in the step of forming a spiral widening profile;

[0052] - Fig.10 According to one aspect of the invention, possible movements of a circular container are shown;

[0053] - Fig.10a Shows Fig.10 A variation of the invention wherein the containment system includes a retractable radial element;

[0054] - Fig.10b An embodiment similar to the previous figures is shown, but the insertion and manipulation device 400 is reversed, i.e., the tip 410 points in a clockwise direction rather than a counterclockwise direction;

[0055] - Fig.11 According to the invention, an embodiment of a removable insertion and handling device is shown, specifically for inserting a first of two nested elementary conductors;

[0056] - Fig.12 According to one aspect of the present invention, in (a) a standard basic conductor is shown positioned, in (b) an insertion of a nested basic conductor is shown, and in (c) a top view of the insertion in (b) is shown;

[0057] - Fig.13 Two views showing the inserted nested base conductor, still inside the inserter;

[0058] - Fig.14 A front view of an inserter is shown according to one aspect of the present invention;

[0059] - Fig.15 According to one aspect of the invention, a system for loading and handling a primary conductor having a container volume within which the primary conductor must be located for proper handling and subsequent insertion into a slot is shown;

[0060] - Fig.16 According to one aspect of the invention, the positioning of a basic conductor through a loading and handling device is shown;

[0061] - Fig.17 The asymmetry of the infeed and positioning rollers of the basic conductor is shown;

[0062] - Fig.18 According to one aspect of the invention, an inserter is shown in which the infeed and positioning rollers are free to rotate in an unloaded area of ​​the counter-mold;

[0063] - Fig.19 According to one aspect of the invention, a basic conductor is placed in the movement of the infeed and positioning rollers;

[0064] - Fig. 20 A cross section of a leg of a base conductor is shown;

[0065] - Fig.21 According to one aspect of the invention, different modes for positioning the elementary conductor during the action of the infeed and positioning rollers are shown;

[0066] - Fig. 22 According to an embodiment of the present invention, Fig.15 A top view of the volume of the container;

[0067] - Fig.23 shows the calculation of the basic conductor oscillation and determination Fig.15 The geometry of the volume of the container;

[0068] - Fig.24 According to one aspect of the invention, positioning of a base conductor without a tip portion is shown;

[0069] - Fig.25 Solutions 2-4 described in the embodiments according to the present invention show the cycle time in the case of positioning;

[0070] - Fig.26 A possible embodiment of a counter-mold is shown according to one aspect of the present invention for inserting an opposing elementary conductor ((a) perspective view and (b) top view);

[0071] - Fig. 27 According to one aspect of the invention an insertion and handling system for standard and reverse base conductors is shown;

[0072] - Fig.28 According to one aspect of the present invention, a blade system having two different terminals is shown;

[0073] - Fig.29 According to one aspect of the present invention, Fig.28 The contact point between the blade and the hairpin;

[0074] - Fig.30 According to one aspect of the invention, a possible embodiment of an inserter is shown, the inserter having a blade and a dual body counter-mold;

[0075] - Fig.31 According to one aspect of the invention, a possible embodiment of an inserter is shown, the inserter having a blade and a dual body counter-mold;

[0076] - Fig.32 A top view of a possible embodiment of an inserter having a blade and a dual body counter-mold, wherein one body is fixed and the other is movable, is shown according to one aspect of the present invention;

[0077] - Fig.33 shows a basic conductor processed in a single interposer with associated accommodation errors;

[0078] - Fig.34 According to one aspect of the invention, the effect of the reverse base conductor on the feed and registration rollers is shown;

[0079] - Fig.35 ((a) perspective view and (b) top view) shows a possible embodiment of a two-piece insertion and manipulation device (and loading and manipulation device) according to one aspect of the present invention;

[0080] - Fig.36 According to one aspect of the invention a possible embodiment of an insertion and manipulation device consisting of two parts is shown;

[0081] - Fig.37 A base conductor holder is shown according to one aspect of the invention wherein the nested conductors have a smaller pitch and subsequent rotation for inserting a conductor having a larger pitch is indicated;

[0082] - Fig.38 According to one aspect of the present invention, Fig.37 The housing for the conductors at the end of the rotation shown, wherein the conductor spacing is greater than the nested conductor spacing;

[0083] - Fig.39 According to one aspect of the invention, different possible directions of movement of the counter-mold are shown (the latter not shown);

[0084] - Fig.40 According to one aspect of the present invention, a two-piece insertion and handling device is shown for insertion into a nested base conductor;

[0085] - Fig.41 An overall view of loading, inserting and operating the system is shown according to one aspect of the present invention;

[0086] - Fig.42 A top view of a loading, inserting and operating system is shown according to one aspect of the present invention;

[0087] - Fig.43 A rear view of a loading, inserting and operating system is shown according to one aspect of the present invention;

[0088] - Fig.44 Details relating to the movement of the lower rod of the chute are shown according to one aspect of the invention;

[0089] - Fig.45 The circumferential position of the joint is shown from above according to one aspect of the invention;

[0090] - Fig.46 According to one aspect of the invention, a moving entity in the system is shown for the correct accommodation of the legs of the various elementary conductors;

[0091] - Fig.47 A diagram showing another embodiment of loading, inserting and operating the system according to one aspect of the present invention;

[0092] - Fig.48 A top view of another embodiment of a loading, inserting and operating system is shown according to one aspect of the present invention;

[0093] - Fig.49 A rear view of another embodiment of a loading, inserting and operating system is shown according to one aspect of the present invention;

[0094] - Fig.50 According to one aspect of the invention, different forms of movement of the counter-mold of the loading and handling device are shown;

[0095] - Fig.51 Shows Fig.50 The accommodation error of the innermost basic conductor of the equipment;

[0096] - Fig.52 Details of a loading, insertion and handling system are shown according to one aspect of the invention, wherein an auxiliary tip portion is present;

[0097] - Fig.53 According to one aspect of the invention, a base conductor is inserted into the innermost layer;

[0098] - Fig.54 According to one aspect of the invention, a base conductor is inserted into the outermost layer;

[0099] - Fig.55 A diagram showing a possible embodiment of loading, inserting and operating a system according to one aspect of the present invention;

[0100] - Fig.56 A possible embodiment of handling a base conductor in a load is shown according to an aspect of the invention; and

[0101] - Fig.57 According to one aspect of the present invention, a tip movement mechanism is shown according to a possible embodiment of processing a base conductor in a load.

[0102] It is provided herein that by respecting the technical concept of the present invention, elements of different embodiments may be combined together to provide further embodiments without limitation, which will be easily understood by ordinary technicians from the description.

[0103] Furthermore, the present description also refers to the prior art for its implementation, with regard to detailed features not described, such as less important elements that are usually used in solutions of the same type in the prior art.

[0104] When an element is introduced, it is always understood that there may be "at least one" or "one or more".

[0105] When a list of elements or features is given in the present specification, it should be understood that the invention “includes” or optionally “consists of” such elements.

[0106] When features are listed in the same sentence or bullet list, one or more individual features may be included in the present invention without being linked to other features in the list.

[0107] According to the present invention, two or more components (elements, devices, systems) described below can be freely combined and regarded as a set of components. DETAILED DESCRIPTION

[0108] Insert and operate the system

[0109] According to the definition of the invention, the stator or rotor winding 100 may consist of one or more sectors 100-CI, 100-CIN extending circumferentially around the winding axis 50, each sector comprising one or more layers, each layer consisting of a circumferential arrangement (or even part) of elementary conductors (see Figure 7-10b ).

[0110] A first embodiment of the present invention includes a removable insertion and operation device 400 (e.g., Figure 6 , 7 -10, 29, 30), the insertion and manipulation device 400 includes a wedge-shaped circumferential end 410, an opposite circumferential receiving end 420 and an inner bevel (or "tapered portion") 430, the inner bevel 430 serving as a guide for inserting the base conductor into the winding. The removable insertion and manipulation device 400 can be configured to insert all types of hairpins except I-type pin hairpins. For base conductors, such as W-type pins and parallel hairpins, the removable insertion and manipulation device 400 can have a suitable shape and a recess for the insertion of the base conductor. The base conductor is inserted into the insertion area and then moved to the destination area in the winding.

[0111] The wedge-shaped end or wedge 410 or "guide and receiver end" is an example of one or more elements with which the removable insertion and handling device 400 is equipped, which are configured to generate a camming movement of the elementary conductor in the radial direction towards the inside and / or outside of these sectors when the associated rotating device is actuated. This guide and receiver end narrows in a plane perpendicular to the axis of rotation 50, in a direction opposite to the relative rotation direction of the circumferential receiver device 300. The guide and receiver end 410 is placed at a predetermined distance from the axis of rotation 50 of the circumferential receiver device 300 in order to guide and receive the elementary conductor that has been inserted into a sector of the winding 100-CI and is fed towards the removable insertion and handling device 400 when the circumferential receiver device 300 is relatively rotated.

[0112] In all embodiments, the removable insertion and manipulation device 400 of the elementary conductors is a means for insertion, displacement and / or orientation (usually movement) and not for elastic bending: it is not possible to exploit the elasticity of the elementary conductors because there would be problems of friction with other elementary conductors. The removable insertion and manipulation device 400 can also be different for each sector, due to the different dimensions of the elementary conductors belonging to the different sectors, or it can be unique but with the ability to vary in size.

[0113] In fact, although the removable insertion and operating device 400 is shown in some figures as consisting of a single block, it will be seen that it can be made into several independently movable blocks for processing basic conductors of different sizes. In this case, the various blocks are moved and then blocked so that the overall geometry of the removable insertion and operating device 400 is fixed during the operation of the device itself. As will be seen, the mutual fixing can be carried out in different ways, by mutual fixing elements or by different elements, which keep the different blocks in a mutually fixed position. As described below, the dimensional configurability of the removable insertion and operating device does not change its function.

[0114] The removable insertion and handling device may be configured to insert a base conductor along the slot of the housing device and to displace the base conductor inserted into the sector being assembled in a radial direction towards the inside and / or outside of the sector.

[0115] The removable insertion and operating device 400 is configured (element 430, see below) so that the basic conductor previously gradually inserted is radially moved from a first angular position relative to the winding axis, wherein the basic conductor already inserted into the winding does not interfere with the basic conductor being inserted, to a second angular position relative to the winding axis corresponding to the corresponding target area.

[0116] According to one aspect of the invention, once the last elementary conductor has been inserted into a sector, the removable insertion and operating device 400 is removed. If the size is adjusted, these elementary conductors can be inserted into the corresponding area of ​​the new sector; otherwise another removable insertion and operating device of different size is used in such an area.

[0117] In this step, it is advantageous to ensure that the intermediate crown is positioned so that the free reverse space SLR required to accommodate the reverse hairpin is aligned with the axis of this reverse hairpin: this is called the so-called "initial crown alignment". In other words, the circumferential housing means and the removable insertion and manipulation device are positioned relative to each other so as to define in these slots a minimum insertion area for the reverse elementary conductor.

[0118] When the device 400 is made in a single piece, the bevel or "tapered portion" 430 is part of the formed bridge portion 480 (see Figure 7 , view on a plane perpendicular to the axis 50), the shaped bridge 480 connects the two circumferential ends of the removable insertion and operation device 400 and is located between the two grooves or through holes for insertion in the case of a hairpin. According to one aspect of the invention, the tapered portion 430 is located at the foot of the rear base conductor with respect to the relative rotation direction of the circumferential housing device, the tapered portion 430 widening in the relative rotation direction. This positioning of the tapered portion can be maintained even in embodiments in which the device 400 is not integral.

[0119] Typically, the reverse base conductor is placed first (optional), which can be done using, for example, Figure 6 and Fig. 27 The same device as in the example above starts with the insertion of a basic conductor of standard type 255 into the inner crown 100-CI. The first thing to do is to correctly position the hairpin at the through-holes 440U+440S of the insertion and operation device. As shown in the figure, the through-hole can be bifurcated to have the possibility of inserting a standard conductor (into the through-hole 400S) and a reverse conductor (into the through-hole 400R). There is a first single through-hole portion 440U from which two through-holes 440S and 440R, respectively dedicated to the standard conductor and the reverse conductor, leave. Note that in both cases 440S and 440R follow the bending direction of the bridge-like connection of the basic conductor.

[0120] like Figure 8-10 As shown, once the reverse basic conductor is inserted, the standard basic conductor continues to be inserted, gradually rotating the circumferential container until the first conductor inserted into the crown contacts the wedge-shaped guide and container end 410, which extends the assembled crown and also contains the bridge portion 255RT of the reverse basic conductor 255-R. Fig.10a To better illustrate this, an optional variant of the different circumferential housing system 600 comprises retractable radial elements 610, which are also known from international patent application PCT / IB2023 / 052123. Fig.10b Shown is a similar situation, but the insertion and operation device 400 is reversed, that is, the wedge-shaped guide and receiving member end 410 points in the clockwise direction instead of the counterclockwise direction. In fact, the process can also be operated in the opposite direction.

[0121] According to the use according to Figure 11-13 According to a particular embodiment of the invention of the nested hairpins, the standard basic conductor 255 can be positioned at a through hole 465 in an upper part 460 of the removable insertion and handling device 400'. Such an upper part can have a (flat) sleeve shape.

[0122] Note that the through-holes of the insertion and handling device are sized to accommodate elementary conductors with a larger opening angle (nested conductors, in the example case of nested conductors, but similar grooves are provided for any other conductors, see above). In order to make the process repeatable and safe, it is advantageous to provide movable housing elements (or devices) 470, which have the unique function of accommodating the standard elementary conductors 255 (with smaller spacing) passing through the sleeve 460 during the insertion step. In some cases, their absence can lead to the elementary conductors being inserted into incorrect "equivalent stator slots". The mobile housing system can include different elements other than 470, not shown here. A person skilled in the art understands from what has been described that they can have any shape that helps to laterally accommodate elementary conductors with smaller spacing during their insertion.

[0123] The nested basic conductors may also include more than two hairpins, i.e., a group of hairpins with increasing spacing, wherein the group of hairpins includes a hairpin with a larger spacing and one or more basic conductors with gradually decreasing spacing, wherein the one or more basic conductors with gradually decreasing spacing are also nested, i.e., these spacings allow nesting.

[0124] refer to Fig.12 (a), in which step the basic conductor 255 (with a smaller pitch) is inserted and then the movable receiving element 470 is moved back, ie before the basic conductor with a larger pitch. A stop element 466 with a smaller pitch may be provided for the head of the hairpin.

[0125] refer to Fig.12 (b) and (c), once the standard base conductor has been inserted and the movable receiving member has been retracted, the nested base conductor 255A can be positioned.

[0126] refer to Fig.13 The nested base conductor 255A is then inserted, where it stops above the base conductor at a smaller distance (head-on) in the insertion and handling device.

[0127] Loading and handling equipment

[0128] The removable insertion and handling device 400 described above is part of a larger complex system referred to herein as a device for loading and handling elementary conductors.

[0129] Fig.14The loading and handling device 500 shown in is a system that allows loading, positioning and then moving a single elementary conductor in a removable insertion and handling device 400 or 400' (hereinafter reference will always be made to the device 400 to denote both embodiments in combination with this loading and handling device). The device 500 may also comprise the removable insertion and handling device 400 (401, 402) described herein, which is responsible for the actual insertion and handling of the elementary conductors of the winding.

[0130] These elementary conductors, after a 2D-3D formation process known per se, pass through a transport system 530 (in one possible embodiment) to a housing volume 500R formed as described below.

[0131] The loading and handling device 500 is configured to:

[0132] 1. Move the basic conductor from a well-defined spatial region, which is the region of the end volume 500F (see below). Typically, with the aid of a conveyor system 530 and brushes ( Fig.14 With the help of a positioning element (not shown in the figure), it can be ensured that the basic conductor reaches a defined and reproducible position within a certain tolerance range. This receiving area or volume 500R of the basic conductor is Fig.15 The presence of the primary conductor in this area is preferably communicated to all other system components, for example by means of inductive presence sensors, in order to ensure automation of the overall system.

[0133] 2. Positioning the basic conductor in vertical correspondence with the through hole or recess of the removable insertion and operation device 400 by radial movement relative to the winding, such as Fig.16 As shown, the basic conductor reaches the end area or volume 500F again and again. This step can be performed by using a cross-feed and positioning roller 540 and / or an adjacent tip 535 moving from the opposite side of the counter-mold, which has a tip that moves along the inserter axis 70 (such as when the conductor leaves the guide or chute of the conveying system 530). Fig.14 As shown, the function of supporting the basic conductor is actually parallel to the axis 50).

[0134] 3. Insert (or slide) the base conductor into the removable insertion and handling device 400. Once the base conductor has been positioned, it can be inserted using the blade 510 as a presser and accommodating the infeed and positioning rollers 540 and the counter-mold 520, see Fig.14 The blade may also have the function of controlling the delivery of the conductor, since in the event that the base conductor falls due to gravity but is still blocked, the blade may release the conductor or even remain blocked, thereby signaling a fault. Furthermore, during this step, the tip 535 (if present) is rotated downwards by 90 degrees ( Fig.14The gear 545 can be moved by the motion of the blade or for example by utilizing the rotational motion of the infeed and positioning rollers. Usually, the tip can be retracted in various ways, even linearly retracted.

[0135] like Fig.17 As shown, the rollers 540 can be arranged so that the straight line through the respective centers is not perpendicular to the radial direction, but has an inclination angle α. This inclination corresponds to the curvature of the head of the elementary conductor. Thus, the rollers push the elementary conductor uniformly during the processing step. This ensures that the rollers can be identical to each other. In contrast, the arrangement of the centers on a horizontal line would result in two different geometries.

[0136] In a particular embodiment of the loading and handling device, the infeed and positioning rollers can rotate independently of the position of the blade 510, due to the presence of ventilation holes 525 on the counter-mold (see Fig.26 ). The vent refers to a transverse hollow portion in the counter-mold for rotatable positioning of the roller. In the illustrated embodiment, the roller has continuous fins 541 at 180° to each other.

[0137] For example, by choosing a roller of about 50 mm in length, the counter-mold has at least the same degree of hollowness in the vertical direction (parallel to the axis 70 which, in use, is generally parallel to the winding axis 50). Although this solution is feasible, a problem that may arise when inserting the elementary conductor is that the elementary conductor may be deformed as the blade pushes. The blade 510 works only after the elementary conductor has reached the end volume 500F above the removable insertion and handling device 400, to allow it to then be housed in the winding by rotation of the circumferential housing means.

[0138] To avoid this problem, it may be useful to use roller fins of different geometries. Fig.18 , there may be four fins at 180° in pairs, each pair of fins being separated by an empty central space 542. The empty space 542 may have a corresponding raised element on the counter-mold 520, thereby improving the accommodation of the basic conductor and increasing the strength of the counter-mold itself. It can be noted that in the region of the empty space between the fins of the infeed and positioning rollers, a protrusion 526 is provided on the counter-mold.

[0139] Positioning of the base conductor in the presence of a pointed end

[0140] refer to Figure 16-21As shown, once the basic conductor is brought into the container volume (which can be defined as having or not having a tip portion, see below), it is conveniently guided at the through hole or groove of the removable insertion and operation device 400, so that the initial theoretical position 500I and the final position 500F (also called the "final volume" occupied by the basic conductor ready to slide down) can be confined within the container volume.

[0141] In the presence of the tip 535, the positioning of the elementary conductor from the initial theoretical position 500I to the final position 500F can take place according to a rotational and non-translational movement (using the transverse feed and positioning rollers); in fact, it is thus possible to increase the speed of the entire system, increasing the angular position of the feed roller fins and the positioning of the elementary conductor. Different positioning modes can be designed, which are different for different contacts between the roller fins and the strip 255z. In general, the term "strip" means a part of one leg of the elementary conductor, such as Fig. 20 , 21 As shown, it includes, for example, connecting spokes or connecting edges 255y that extend or parallel surfaces 255x.

[0142] In a first positioning mode, for example, the first contact of the primary conductor or inlet takes place by means of the connecting spokes of the strip 255y, while the outer containment is ensured by the physical contact of the roller fins 541 with the larger surface 255x of this strip, as shown Fig.21 , which shows the final position of the basic conductor.

[0143] In the second positioning mode, the first contact or entry of the basic conductor occurs by exploiting the largest surface 255x of the strip, while allowing accommodation by the "point" contact of the roller fins 541 with the connecting spokes 255y of the strip, as Fig.21 , which shows the final position of the basic conductor.

[0144] In the third positioning mode, the uniform contact between the roller fin 541 and the extended surface 255x of the strip is located midway between the final position and the initial position, as shown in FIG. Fig.21 , which represents the final position of the basic conductor.

[0145] There may be advantages and disadvantages in each of the situations just described, but a fundamental advantage of the invention is the ability to position the rollers so that initial contact of the strip may be of any kind, but ensuring that the final containment position is always on the long or short side of the strip.

[0146] Initial theoretical position and uncertainty region

[0147] As described above, the basic conductor is conveniently positioned in a position that may coincide with the initial theoretical position 500I before being positioned in the through holes 440U, 440S, 440R of the removable insertion and operating device 400. The positioning of the basic conductor in the initial theoretical position is made possible by the presence of a suitably dimensioned conveyor system 530 and by means of a braking system, for example of the brush type.

[0148] In practice, the basic conductor can occupy different positions, always within a (containment or processability) volume based on the possible maximum deviation defined by the conveying system. Therefore, the maximum deviation and the various initial positions that the basic conductor can take can be known and defined to ensure its processability in subsequent operations.

[0149] The possible positions that a basic conductor can take at the beginning can be associated with a bunch of straight lines passing through a single point, which is equal to the midpoint of the conductor in this initial theoretical position when viewed from above.

[0150] according to Fig. 22 The height h of the middle rectangle, the size of the volume portion of the accommodating member is related to the difference in distance D relative to the quantity Δ, where distance D is the distance between the centers of the feet of the strip in the theoretical initial position, and Δ is equal to the distance between the centers of the two lower guides 530b and 530c of the conveying system 530.

[0151] Thanks to this schematic representation, the dimensions of the runner can be determined which allow the correct positioning of the elementary conductor in the initial theoretical position 500I. In the details of the schematic representation, the size of D is influenced by the forming process and the length of the elementary conductor and generally has errors.

[0152] like Figure 23-24 As shown, another type of variability exists due to the vibration of the base conductor along the slideway supporting the head of the conductor. However, these oscillations can be controlled by appropriately selecting the dimensions of the upper guide, the schematic diagram of which is similar to the one provided. This variability can be taken into account when defining the volume of the container.

[0153] Positioning of the base conductor without the tip

[0154] In a possible embodiment of the present invention, loading and handling of the base conductor may be performed without using the tip portion 535 .

[0155] In the absence of a tip, it is preferred that the transfer system 530 is positioned adjacent to the counter-mold 520 so that the elementary conductors do not fall due to gravity before being positioned on the removable insertion and manipulation device 400 .

[0156] In the case of using a tip, the minimum distance x between the tip and the counter-mold mincan conveniently be equal to the height H of the strip 255z piattina (i.e., thickness is smaller than the cross section), such as Fig.24 As shown. It can be seen that:

[0157] x m i n =H p i att i na

[0158] In practice, it is convenient to leave a safety margin ε, for example:

[0159] x=H piattina +εconε>0

[0160] In contrast, without the tip, the elementary conductor is not supported in the vertical direction over a feed section equal to x, but is merely accommodated laterally and guided by the movement of the transverse feed and positioning rollers 540 .

[0161] As regards the mode for locating the elementary conductor and assessing the volume of the housing, the same considerations made above for the device 500 are valid in the presence of the tip.

[0162] Cycle time for loading and operating equipment

[0163] The cycle time for loading and operating the device 500 may vary according to different possible embodiments of the invention:

[0164] I. In a first embodiment, referred to as case 1, the transverse feed and positioning rollers 540 allowing the feeding of the elementary conductor perform a unidirectional and opposite rotational movement relative to each other; in other words, the transverse rollers rotate 360° (ending the rotation after the elementary conductor has slid vertically);

[0165] II. In a second embodiment, referred to as case 2, the rollers 540 that allow the feed of the basic conductor perform alternating and opposite rotational movements relative to each other; in other words, the transverse rollers rotate in intervals of less than 180°;

[0166] III. In a third embodiment, referred to as case 3, the blade 510 ensuring the vertical movement of the basic conductor (insertion into the device 400) pushes on about 2 / 3 of the upper surface of the basic conductor, so that the movement of the transverse roller and the blade can always occur simultaneously without any obstacles;

[0167] IV. In a fourth embodiment, referred to as case 4, the blade 510 ensuring the insertion of the basic conductor pushes over its entire upper surface; in this case, due to mechanical interference problems, the movement of the transverse roller and the movement of the blade cannot always occur simultaneously.

[0168] The preferred embodiment of the present invention provides Fig.25 The cycle times shown above assume the following, with basic conductor feed steps F1 and F2, basic conductor positioning step F3, blade lowering step F4, idle lateral roller rotation step F5 and blade raising step F6. This embodiment combines cases 2-4, i.e., cases where the rollers rotate less than 180° (both roller positioning and idle rotation are performed by sweeping the same angle). The blade pushes only 2 / 3 of the upper surface of the elementary conductor, so that the movement of the blade and the roller can occur simultaneously. This embodiment is advantageous in terms of a shorter duration of the cycle time of the device 500 and in terms of a smaller surface in contact with the elementary conductor during guidance and insertion, reducing the risk of possible damage to the elementary conductor and its coating. The following values ​​were obtained in laboratory tests (see Fig.25 ):

[0169]

[0170] Management of reverse basic conductors

[0171] As previously described, the removable insertion and operating device 400 is configured to insert the standard base conductor 255 and the reverse base conductor 255R. We now describe how the base conductor loading and insertion system 500 is configured to direct the standard and reverse base conductors to the removable insertion and operating device 400.

[0172] In order to completely contain the standard and reverse elementary conductors (ie, over the entire opening angle of the elementary conductors), the counter-mold 520 may include two bodies that are configured to move relative to each other, such as Fig.30 The first body 521 can be, for example, fixed in space (the body associated with the common part of the two standard and reverse basic conductors, corresponding to the through hole 440U of the removable insertion and operation device 400), while the second body 522 is removable (the body corresponding to the through holes 440S and 440R of the removable insertion and operation device 400, again as shown in FIG. Fig. 27 ) and can be moved forward or backward depending on whether a standard or reverse elementary conductor is being processed. It is also possible that both bodies 521, 522 can be moved independently to form the housing volume required to accommodate elementary conductors again and again. Such a housing volume can be defined between the counter-molds 521, 522 and their side walls 520l1 and 520l2, which in corresponding embodiments can be walls of a single block counter-mold 520. The housing volume is defined relative to the legs of the elementary conductors, and the bridge-like connection can extend from the housing volume.

[0173] In this embodiment, the blade 510 of the loading and handling device may be configured to push two basic conductors into the corresponding grooves 440U, 440S, 440R, and may include a fixed blade portion 511 and a movable blade portion 512, such as Fig.30 Here, the blade 510 may also include two movable parts 511,512.

[0174] Some possible embodiments of the invention are shown below, which combine different solutions for guiding and inserting standard and counter-basic conductors.

[0175] Solution 1

[0176] Reference again Figure 26-29 , we now describe a first embodiment for guiding and inserting standard and reverse basic conductors. Such a first embodiment may include:

[0177] -520 is reverse molded into a single body, the shape of which conforms to the shape and curvature of the basic reverse conductor (so for standard conductors there is a non-contained part PNC);

[0178] - The blade 510 has two parallel ends 512 and 511, one for the reverse base conductor and one for the standard base conductor, so as not to interfere with the insertion system, not even with each other. Fig.28 The blade reinforcement element is indicated by 515 .

[0179] In a first possible embodiment, the portion of the blade that pushes the counter-base conductor has a greater length than the portion that is inserted into the standard base conductor, so that when the blade system is fully raised and the standard base conductor must be inserted, the blade itself has the function of accommodating the standard base conductor for about half of the conductor opening angle. In addition, the vertical length of the blade portion common to both base conductors is equal to the blade end associated with the insertion of the standard base conductor; therefore, the insertion of the standard base conductor is not hindered by anything.

[0180] Obviously, while the reverse base conductor is contained over the entire opening angle along its entire length, the standard base conductor is only fully contained within half of the opening angle; in the other half, it will be contained by the blade, but not along the entire length of the base conductor (e.g., for the first 20-30mm, measured from the head of the base conductor).

[0181] like Fig.29 As shown, in this first embodiment, due to the choice of the blade structure, the counter-base conductor is only pushed through half the angle of the conductor itself, instead of being pushed through the entire surface of the head like a standard base conductor.

[0182] In other advantageous embodiments, the blade has a shape with a certain thickness in order to be inserted into one or more points of each type of elementary conductor.

[0183] Solution 2

[0184] Figure 30-32 A second possible embodiment of the invention for guiding and inserting standard and reverse elementary conductors is shown. This embodiment may include:

[0185] - a counter-mold 520 comprising two separate bodies: a fixed body 521 and a movable body 522;

[0186] - a blade 510 comprising two separate bodies 511, 512 (see Fig.30 ) or alternatively, a body having a geometry so as to enter between the two bodies 521 and 522 and simultaneously push the basic conductor at the tip of the head during the insertion step.

[0187] In this possible second embodiment, the movable part of the counter-mold, and therefore also of the blade, is actuated in relative motion with respect to a fixed, removable insertion and manipulation device 400 .

[0188] The blade can insert the base conductor by pushing a portion of the base conductor's head or by pushing the base conductor along the entire arc of the base conductor's head, which is applicable to both standard base conductors and reverse base conductors.

[0189] This solution allows the correct and complete accommodation of both basic reverse and standard conductors thanks to the double body counter-mold system and the presence of double body or single body blades.

[0190] Solution 3

[0191] Fig.35 A third possible embodiment of the invention for guiding and inserting standard and reverse elementary conductors is shown, wherein the counter-mold is in two bodies 521, 522 which are movable independently of one another in order to accommodate various elementary conductors (even with different crowns) to be repeatedly loaded and manipulated. An insertion and manipulation device 400 is also shown.

[0192] Fig.33 It is shown how all the crowns of a winding can be processed by a single loading and handling device with two independent bodies. This innovative solution avoids the use of several loading and handling devices, introducing a specific movement of the entire loading and handling device so that they are positioned instantaneously on the several layers of the crowns to be formed. For the same opening angle of the elementary conductors, the elementary conductors located in the outermost layer will tend to have greater circumferential dimensions: it is these dimensions that determine the dimensions of the counter-mold. Fig.33The reverse elementary conductors of different layers contained inside the counter-mold 520 are shown. Note that the elementary conductors located at the outermost layers are well contained laterally by the counter-mold, while the elementary conductors located further inside have greater instability. There is therefore an error ε that depends on various factors, including: the height of the strips, the number of strips in a single slot, the height of the stator slots, and the opening angle of the elementary conductors.

[0193] In such an embodiment, Fig.34 As shown, infeed and registration rollers may be used, as described above and below, adapted to move the loaded elementary conductors toward the counter-die, capable of moving both standard and reverse elementary conductors.

[0194] Back to Fig.33 According to one aspect of the invention, the counter-mold or loading and handling device can be divided into two separate parts. In this possible embodiment, the loading and handling device translates radially relative to the center of the stator package. In other cases, it can translate along an axis passing through the center of the loader 500 and perpendicular to the axial direction. The various movements are better illustrated below with reference to nested basic conductors (see below), but it should be understood that they can be applied separately to various situations when necessary.

[0195] It should be noted that the elementary conductors are thus well accommodated and all types of elementary conductors (with the same angular opening) can be processed for each crown.

[0196] Dual-body insertion and manipulation device

[0197] refer to Fig.35 , Fig.36 and Fig.40 , with respect to the removable insertion and handling device 400, it may also comprise two separate bodies which are integral with the loading and handling device, such as Fig.35 The same elements as above are provided, such as a wedge-shaped guide and receiving end 410, an opposite receiving end 420, a ramp 430 for moving the base conductor when the circumferential receiving element is rotated, and optionally, if the device is made in a more symmetrical manner, a ramp 430' similar to ramp 430, capable of acting in both directions of circumferential movement. In this case, the end 420 will be shaped in a functionally similar manner to the wedge-shaped guide and receiving end 410.

[0198] In this case, the pusher blade 510 also includes two independent bodies (not shown), which extend in the axial direction of the winding, and each blade body is configured to push the basic conductor at least on a portion of the head and can be configured by independently rotating around the axial direction or moving radially as described above.

[0199] Obviously, the geometry of the portion of the end 410 (towards the winding) of the removable insertion and manipulation device 400 is linked to the geometry of the strip and the opening angle of the basic conductor. Furthermore, the geometry of the removable insertion and manipulation device 400 can be such that it allows to accommodate the basic conductor during the rotation of the air gap, rotating simultaneously with the basic conductor.

[0200] In this case, there may be interference between the base element and the conductor, which can be conveniently avoided by providing one or more suitable bevels relative to the cross section of the device. Fig.36 In (b) it can be seen how the chamfer 450 is used to avoid jamming of a sector that has already been inserted and moved radially.

[0201] Management of nested basic conductors

[0202] We now describe several possible embodiments of managing nested elementary conductors 255A in the presence of a single loading and handling device 500 comprising two separate bodies 521 and 522 .

[0203] First case

[0204] In the first embodiment of the device 500, the independent bodies 521 and 522 can rotate, in particular can perform a rotation relative to each other, such as Fig.37 and 38 As shown, it is used to accommodate standard / reverse base conductors and to accommodate different layers of standard / reverse base conductors. This type of movement allows the base conductors to be accommodated in a safe and repeatable manner.

[0205] Second case

[0206] exist Fig.39 In the second embodiment shown, the independent bodies 521 and 522 of the device 500 (not shown for simplicity) can be moved by two linear movements along a first straight line 61 and along a second straight line 62, the first straight line 61 and the second straight line 62 forming equal angles with the central straight line 60 perpendicular to the axis 70 and coinciding with the radial direction, with the same displacement obtainable by the associated displacement means.

[0207] The third case

[0208] In the third embodiment, still referring to Fig.39 and Fig.37 , the movement lines 61 and 62 of the independent bodies 521 and 522 can be at the opening angle of the selected nested non-standard basic conductor. The two inserter bodies 521 and 522 thus have the possibility of moving along these two straight lines (the two elements are in Fig.37The rotation in the tube also has the effect of accommodating the internal basic conductor).

[0209] The insertion of the two basic conductors can be carried out individually, thus sequentially or simultaneously, depending on the standard sequence of the nesting.

[0210] The simultaneous insertion of two basic conductors is advantageous because the legs of the nested basic conductor above the standard basic conductor are accommodated at an angle.

[0211] Fig.40 An example of a removable insertion and handling device 400 is provided in two parts for inserting a nested basic conductor. Stop elements 466A, 466B are provided in two parts for two bodies, which are used to stop the head of the conductor, but have suitable bevels that allow the basic conductor to slide radially during the rotation of the circumferential housing.

[0212] Final Assembly

[0213] By combining all of the above concepts, the loading and handling device 500 can be Figures 41-45 and Figures 47-49 The loading and handling equipment 500 may include:

[0214] - a base plate 550 oriented perpendicularly to the axis 70 , allowing the entire inserter 500 to translate axially relative to the stator package. This movement is advantageous whenever the shaping of the winding crown begins and ends;

[0215] - the device does not have the aforementioned tip 535, but may be provided with a delivery system 530;

[0216] - The two bodies 521 , 522 of the inserter, which can be moved in radial and circumferential directions by means of a radial electrical axis 551 of a pneumatic cylinder 555 and a curved guide 556 , allow the machining of standard, reversed and nested basic conductors on all crowns in a single system.

[0217] Further details are provided below.

[0218] Basic conductor transmission system

[0219] We will now describe how a universal base conductor delivery system 530 can be created, for example to accommodate and handle standard, reversed and nested base conductors, regardless of which crown they belong to.

[0220] The basic conductor transport system 530 may comprise three bars: an upper guide 530a and two lower guides 530b, 530c, appearing for example in cross section at the vertices of a triangle.

[0221] The upper guide 530a is integral with the base plate and supports the elementary conductor from its tip. The other two lower chutes are always integral with the base plate, but are allowed to translate by a guide system 534 if it is necessary to process a product comprising nested elementary conductors.

[0222] Fig.44 It is shown how the operation (i.e. the horizontal movement in the plane XY) of the two lower guides 530b, 530c takes place, which guide the foot of the elementary conductor. A ball joint 534 is provided to perform this movement. Furthermore, a system can be provided which allows the distance between the two lower bars of the chute to be adjusted, at least in the transition from a standard elementary conductor to a nested elementary conductor. In fact, it should be noted that the further the ball joint is from the center of the stator package, the greater the amplitude of the movement.

[0223] from Fig.45 It can be seen that the value of D depends on the circumference of the mounting joint 536. Fig.45 As shown, in the transition from a standard basic conductor to a nested conductor, the two innermost circumferences must be taken into account to calculate this value. Joints should potentially be installed on these curves; if they are installed on larger diameters, it is inevitable to consider restrictions on movement for space reasons, for example through a system with supports and springs.

[0224] It should be noted that if Fig.46 As is evident from the figure, for a static configuration of the system, the transport system 530 does not undergo any movement from one crown to another, more outer crown and therefore, the greater the displacement from the axis towards the outermost layer (SE) towards the proximal diameter (SI), the lower guides 530b, 530c will contain fewer legs of the basic conductor.

[0225] In a particular configuration according to the invention, the elementary conductor transport system 530 can be integral with the base plate and, regardless of the type of elementary conductors being processed (standard, reversed or nested), the bars of the chute can be chosen to have a length that does not hinder the insertion of the outermost elementary conductors of the winding (those belonging to layers 1-2). Thus, the elementary conductors belonging to the innermost layers (layers n and n-1) will leave the chute faster; in this case, the elementary conductor is not vertically constrained or supported and is therefore free. However, the presence of feed and positioning rollers prevents it from falling towards a larger outer diameter.

[0226] An alternative embodiment of the first solution for conveying and operating the elementary conductors can be devised as follows:

[0227] A first alternative embodiment consists in compensating the distance by movement of the slide along a radial axis.

[0228] A second alternative embodiment consists in introducing a tip 535 actuated by a two-position pneumatic cylinder or, by a suitable mechanism, by an actuator actuating the blade, so that the substrate moves only in direction 70 .

[0229] Compensation by movement of the slide

[0230] Figure 53-57 Another embodiment of the delivery and operation of a base conductor is shown.

[0231] As the basic conductor transport system 530 slides relative to the base plate, each basic conductor can be brought arbitrarily and by the same amount closer to the counter-mold, regardless of the crown being formed, which helps to feed the basic conductors into the body of the individual loading and handling devices via the lateral feed and positioning rollers without hindering the conductors themselves from falling into the removable insertion and handling device 400.

[0232] The pneumatic cylinder 555 used to move the plate 560 may be replaced by an electric actuator.

[0233] In this case, unlike what happens in the previous solution, the device 500 is positioned by positioning the counter-mold using two movements instead of just one: in the previous case, as in Fig.42 As can be seen in the figure, with two electrical axes, once the opening angle of the basic conductor to be processed is fixed, it can be correctly positioned on each crown; on the contrary, with this new configuration, this displacement can be reproduced by using translation and rotation, as Figures 49-50 shown.

[0234] In fact, in order to position the counter-mode at the base conductor CB3-4, a first translation in the direction of the axis 60 is used, such as Fig.50 shown.

[0235] At this time, using two electric cylinders 555, the rotation shown by the arrows can be achieved, thereby correctly containing the basic conductors 3-4.

[0236] The same procedure applies for inserting base conductors CB5-6.

[0237] It may be noted that, unlike the case where the counter-mold moves in radial directions 61 , 62 , in contrast, in this alternative embodiment, small errors ε in the accommodation of the basic conductor may be expected.

[0238] In this embodiment, it is convenient to model the inverse mold with reference to the innermost elementary conductors (conductors belonging to layers n and n-1), but to position them correctly with respect to the outermost elementary conductors (conductors associated with layers 1-2) so as to always have good accommodation of all elementary conductors at the foot.

[0239] By first performing a linear movement along the central axis 60 and then a rotation, the elementary conductors belonging to the innermost layer (in this case, layers 5-6) are obtained, see Fig.51 .

[0240] Another solution may consist in mounting one of the two inserter bodies on a carriage (not shown) driven by a two-position pneumatic cylinder.

[0241] Another aspect to be evaluated in this case is the following: each time a crown is changed, the body of the loading and handling device is repositioned (through two movements as described above). This is also the case with the two lower bars of the chute, which are integral with the base plate: any support-spring system must therefore be "modular" according to the type of crown being formed and / or base conductor being processed (standard or nested).

[0242] The presence of an auxiliary tip for the hairpin delivery system

[0243] In a second alternative embodiment for transmitting and operating a basic conductor ( Fig.52 ), the presence of the pointed portion 535 allows the basic conductors (especially those belonging to the innermost layer) not to fall off before terminating at the counter-mold 520, and thus to be supported in the last section.

[0244] For example, the tip can be driven according to two different logics:

[0245] - by means of a two-position pneumatic cylinder 555: once the basic conductor has arrived, it is advanced by means of the infeed and positioning rollers 540 and supported in this section by the tip 535 which moves back once the rollers have completed their travel, as Fig.52 The tip is moved backwards by means of a cylinder (or a retracting device, not shown in the figure), and the base conductor can fall freely and / or fall by means of a pushing blade 510;

[0246] - The tip 535 can be rotated downward 90° (as described above and Fig.18 545) so that it can be returned to the appropriate base 535S without interfering with other components.

[0247] A third alternative solution for managing the transport and operation systems of basic conductors is Figure 53-55 This solution provides:

[0248] - the upper guide or rod 530a of the transfer rod is integral with the base plate 550, which is free to move only along the axis 70;

[0249] - The lower guides or rods 530b and 530c are integral with the two electrical axes that respectively move the two inserter bodies 521 and 522. Thus, the presence of a ball joint can be omitted, while ensuring in any case a good guidance of the elementary conductors belonging to the different crowns and of any nested elementary conductors.

[0250] Fig.54 The radial displacement of the two counter modes is shown to operate the base conductor CB1-2 of layer 1-2 and the base conductor CB3-4 of layer 3-4.

[0251] An advantage of this solution is that it does not have the foot accommodation error ε emphasized previously.

[0252] Note that the nested base conductor 255A is also manufacturable since the two lower rods are integral with the electrical axis of the body of the mobile loading and handling device.

[0253] However, as far as the upper rod is concerned, it remains integral with the lower plate; and the tip 535 may be as Fig.55 shown.

[0254] Movement of the rod

[0255] The movement of the two lower guides 530b and 530c of the basic conductor transport system 530 can be performed, for example, by means of two electric axes.

[0256] By positioning the two lower guides 530b and 530c of the conveyor system integral with the two electric axes that move the two bodies of the loading and handling device, the desired movement, ie translation along the axes 61 , 62 , is obtained.

[0257] In order to process elementary conductors with different opening angles on the same crown (for example nested elementary conductors 255A), a specific movement of the two lower guides 530b and 530c of the elementary conductor transport system 530 can be introduced.

[0258] For simplicity, the following discussion is provided for one of the two lower bars.

[0259] In the case of machining standard elementary conductors, the lower rods or guides can be fed by two electric cylinders as described above so as to position themselves on the layer associated with the elementary conductor being processed.

[0260] blade

[0261] With respect to the above, the blade system may be made with alternative geometries and configurations, such as Fig.56 and Fig.57 Optional blade systems include:

[0262] - a tip portion 535 for supporting the elementary conductor as described above;

[0263] - An upper pusher 517 (similar to the blade pattern 510) which ensures the insertion of the base conductor by pushing on the upper ridge of the conductor if it does not fall naturally.

[0264] In this configuration, the tip is synchronized with a mechanism that allows the upper pusher to advance vertically.

[0265] When the pusher allows the base conductor to be inserted, the tip moves without hindering its insertion. In fact, in other embodiments, the pusher replaces the blade. In general, the pusher can be included in the term "blade".

[0266] Advantages of the present invention

[0267] The basic conductor loading and insertion system 500 and the associated removable insertion and handling device 400 have several advantages over prior art techniques and methods.

[0268] Firstly, the system according to the invention allows processing of different types of elementary conductors, such as standard, reversed, nested elementary conductors, in a sequential and automatic manner on a single device without having to resort to the intervention of an external operator. The system reduces the size of prior art systems due to its compact configuration.

[0269] The cycle time for stator winding assembly is thus reduced relative to the prior art, while increasing the efficiency of the system and reducing production costs. The cycle time is reduced due to the flexibility of the system to adapt to various windings and due to the fact that the structure of the device according to the invention itself quickly implements the same flexibility.

[0270] Another advantage of the system according to the invention is the high precision of handling and inserting the elementary conductors. In fact, when entering the system, the elementary conductors are guided and pushed into the winding without undergoing deformations or changes from their initial shape. This ensures that the stator winding has a high level of precision, limiting as much as possible defects and frictions between the elementary conductors, which often cause electrical faults.

[0271] Reference numerals list

[0272] Electrical axis, radial direction 100-CI – inner crown

[0273] CB1-2 – Basic Conductor Layer 1-2 100-CIN-Intermediate Crown

[0274] CB3-4 – Base conductor layer 3-4 SLR – space in the winding to accommodate the reverse base conductor

[0275] CB5-6 – Basic Conductor Layer 5-6

[0276] CR2-3 – Reverse Basic Conductor Layer 2-3 255 – Standard Basic Conductor

[0277] CB4-5 – Reverse Basic Conductor Layer 4-5 255 1 -Standard basic conductors inserted

[0278] 255A-Nested Basic Conductor

[0279] T-Tangent 255R-Reverse Basic Conductor

[0280] 50 - winding axis 255RT - bridge portion of the opposite basic conductor

[0281] 60-Central counter-mold motion axis 255z-Strip

[0282] 61- inclined reverse mold movement axis 255x- extended edge of the strip

[0283] 62- inclined counter-mold movement axis 255y- connecting edge or spoke of the strip

[0284] 70-Inserter Axis 255-IVP-Inverted Hairpin

[0285] 255-IP – Type I pinout

[0286] 100-Winding

[0287] 300 - Circumferential housing for basic conductor 521 - First counter-mold body

[0288] 350 - Circumferential receiving member slot 522 - Second counter mold body

[0289] 530-Basic Conductor Conveyor System or "Chute"

[0290] 400 - Insertion and operation of the device or "device" 530a - Upper guide

[0291] 400' - Insertion and handling equipment or "device" for nested basic conductors 530b - Lower guide

[0292] 401 - First independent body of the insertion and operation device 530c - Lower guide

[0293] 402 - Second independent body of the insertion and operation device 534 - Ball joint

[0294] 410-wedge-shaped circumferential end 535-tip

[0295] 420- Circumferential receiving member end 540- Roller

[0296] 541-Roller Fin

[0297] 430- wedge-shaped or beveled inner circumferential end 542- roller vent

[0298] 440U - Single recessed section 545 - Wheel

[0299] 440S - Standard Base Conductor Recessed Section 550 – Base Plate

[0300] 440R - Reverse Base Conductor Recessed Section 551 - Electrical Axis

[0301] 460 - Upper part of the insertion system 555 - Pneumatic cylinder

[0302] 465 - Insertion and operation device recess 556 - Curved guide

[0303] 466-Stop element 560–Moving plate

[0304] 470-Movable Container Device

[0305] 480 - Profiled bridge 600 - Different circumferential accommodation of the basic conductor

[0306] 610 – retractable radial element

[0307] 500-Basic Conductor Loading and Insertion System or "Insertor"

[0308] 500I-theoretical initial position SLR – reverse hairpin destination region

[0309] 500F - Final position of the basic conductor before vertical sliding (end body PFR – Final position of the reverse hairpin

[0310] SE – Outermost layer

[0311] 500R - Volume SI of container – innermost layer

[0312] 510-Blade F1, F2 – Steps for feeding basic conductors

[0313] 511-First Blade Body F3-Step of Positioning the Basic Conductor

[0314] 512- Second blade body F4- Blade lowering step

[0315] 517 - Upper pusher (similar to blade style 510) F5 - Steps for idling transverse rollers

[0316] 520-Reverse mold F6-Blade rising step

[0317] 520l1-First reverse mold sidewall PNC——Unenclosed part of reverse hairpin

[0318] 520l2- second reverse mold side wall

[0319] Preferred embodiments have been described above, and some variations of the present invention have been proposed, but it should be understood that modifications and changes may be made by those skilled in the art without departing from the relevant scope of protection defined by the appended claims.

Claims

1. A removable device (500) for loading and handling elementary conductors (255, 255-R, 255-IP, 255-IVP), the device being configured to load, handle and insert elementary conductors into circumferential receiving means (300, 600), each elementary conductor comprising a head end and one or more legs, the legs having respective free insertion ends, the removable loading and handling device (500) being configured to assemble a stator or rotor winding (100), the stator or rotor winding (100) being composed of one or more sectors (100-CI), the one or more sectors (100-CI) extending circumferentially around a winding axis (50), each sector comprising one or more layers, each layer being composed of a circumferential arrangement of elementary conductors, the device comprising: a first counter-mold (521) and a second counter-mold (522), the first counter-mold (521) and the second counter-mold (522) being configured to define a housing volume (52011, 52012, 521, 522) for a basic conductor, the first counter-mold and the second counter-mold each having an extension along an axial direction which, in use, is parallel to the winding axis (50); a loading device (530, 540) for the base conductor, the loading device (530, 540) being located in the receiving volume; The container volume (500R) comprises an end volume (500F) of a base conductor, the end volume (500F) resting against the first counter-mold and the second counter-mold, the end volume (500F) being configured to slide the base conductor along the axial direction (z) until inserted into the circumferential container device (300, 600) within a sector being assembled (100-CIN) of the one or more sectors (100-CI).

2. The device according to claim 1, wherein: One or more pushing blades (510, 511, 512, 515, 517) for the base conductor are configured to slide along the axial direction and push the base conductor into the end volume (500F) along the axial direction until it is substantially located outside the first counter-mold and the second counter-mold.

3. The device according to claim 1 or 2, wherein: At one end of the first counter-mold and the second counter-mold in the axial direction, on the side opposite to the circumferential receiving member device in use, a corresponding first device (401) and a corresponding second device (402) are arranged in a manner integral with the first counter-mold and the second counter-mold, the first device (401) and the second device (402) being used to insert and operate the basic conductor in the circumferential receiving member device, wherein the first insertion and operation device (401) comprises a first through hole (440U) for a part of the basic conductor, the first through hole being configured to accommodate and guiding the basic conductor (255, 255R) until the basic conductor (255, 255R) is inserted into the circumferential container device (300, 600) in an axial direction parallel to the winding axis (50) in an insertion area of ​​the circumferential container device, and a first wedge-shaped guide and container end (410) which narrows in a direction transverse to the axial direction, the guide and container end (410) being placed at a predetermined distance from the winding axis (50) and being configured such that: In use, when the circumferential housing device is rotated relative to the removable insertion and operation device, one or more layers (2551) of the sector (100-CIN) being assembled are radially moved according to the circumferential position of one or more layers (2551) of the sector (100-CIN) being assembled in the sector being assembled, so that in the insertion area there is a free space between the elementary conductors of the sector (100-CIN) for inserting the last elementary conductor of the sector; and The inserted elementary conductor is guided and received, and is fed into the sector towards the first insertion and handling device (401) during the relative rotation.

4. The device according to claim 3, wherein: The second insertion and manipulation device (402) comprises a second through hole (440R, 440S) for a portion of a basic conductor and a second receiving piece end (420), the second through hole (440R, 440S) being used for a portion of a basic conductor, the second receiving piece end (420) being circumferentially opposite to the first guide and receiving piece end (410), the second guide and receiving piece end (420) being configured to receive the basic conductor that has been inserted into the sector (100-CIN) being assembled of the one or more sectors (100-CI).

5. The device according to claim 3 or 4, wherein: The first wedge-shaped guide and receiving member end (410) is configured so that, in use, a base conductor gradually inserted into the sector (100-CIN) being assembled follows a helical profile around the winding axis (50), thereby causing the first base conductor inserted into the sector to move radially outward.

6. The device according to any one of claims 1 to 5, wherein: The first insertion and manipulation device (401) and / or the second insertion and manipulation device (402) comprises a stop element (466A, 466B, 466) for the head end.

7. The device according to any one of claims 1 to 6, wherein: The first insertion and manipulation device (401) and / or the second insertion and manipulation device (402) are fixed to each other.

8. The device according to claim 7, wherein: The first insertion and manipulation device (401) and / or the second insertion and manipulation device (402) are formed as a single piece (400, 400').

9. The device according to any one of claims 1 to 6, wherein: The first counter-mold (521) is configured as a single counter-mold (520), the second counter-mold (522) is configured to be movable in a direction perpendicular to the axial direction, and the blade (510) includes a body whose geometry is capable of entering between the first counter-mold and the second counter-mold, and the blade is simultaneously configured to push the basic conductor at the tip of the head.

10. The apparatus according to any one of claims 1 to 6, wherein: The first counter-mold (521) and the second counter-mold (522) are configured to rotate around the axial direction and move independently relative to each other, thereby changing the volume of the container.

11. The device according to claims 2 and 10, wherein: The advancing blade (510) includes a first independent body (511) and a second independent body (512) extending along the axial direction, each of the two independent bodies being configured to advance the basic conductor on at least a portion of the head, and the first independent body and the second independent body are respectively integrated with the first counter-mold and the second counter-mold.

12. The device according to claim 10 or 11, wherein: The first counter-mould and the second counter-mould are configured to move in a radial direction relative to the winding axis in use.

13. The apparatus according to claim 10 or 11, wherein: The first counter-mold and the second counter-mold are configured to rotate in opposite directions, each rotating about the axial direction.

14. The apparatus according to any one of claims 1 to 13, wherein: The corresponding first device (401) for inserting and operating the basic conductor includes one or more first elements (430), which are configured to cause the one or more basic conductors (255, 255R) to be cammed in a radial direction toward the sector (100-CIN) being assembled inside the first insertion and operating device (401) when the circumferential container device (300, 600) is rotated relative to the first removable insertion and operating device (401) in use, until they leave the first insertion and operating device (401) and are positioned in the sector (100-CIN) being assembled.

15. The device according to claims 3 and 14, wherein: The basic conductor is a double-legged hairpin (255, 255-R, 255-IVP, 255-P), the first through hole (440U) and the second through hole (440R, 440S) are shaped such that the first leg inserted into the first through hole is at the front relative to the relative rotation direction of the circumferential accommodating member device (300, 600), while the second leg inserted into the second through hole is at the rear relative to the relative rotation direction, and wherein the one or more first elements include a tapered portion (430), the tapered portion (430) widens in the relative rotation direction corresponding to the second leg on a plane perpendicular to the winding axis (50).

16. The device according to claim 3 and one or more of claims 1 to 15, wherein: The first insertion and manipulation device (401) and the second insertion and manipulation device (402) extend along the axial direction from the insertion end (460, 465) to an end opposite to the insertion end, wherein: The insertion end (460, 465) includes a guide sleeve shaped to receive, laterally receive and guide the one or more elementary conductors; The end opposite to the insertion end is dimensioned to receive the head end of the elementary conductor and is open on the side facing the winding sector (100-CIN) when in use.

17. Apparatus according to one or more of claims 1 to 16, wherein: The subset of elementary conductors comprises one or more nested elementary conductors (255, 255A), each nested elementary conductor having a spacing between two legs, each nested elementary conductor comprising an elementary conductor (255A) having a larger spacing and one or more elementary conductors (255) having corresponding spacings that gradually decrease, wherein: Additional movable receiving member means (470) are provided to receive the one or more elementary conductors (255) with gradually decreasing spacing, The additional movable receiver means (470) is configured to be operated to position the one or more elementary conductors having progressively smaller pitches and to be removed immediately prior to inserting the elementary conductors (255A) having larger pitches.

18. The apparatus according to claim 17, wherein: The end opposite to the insertion end comprises a stop element (466) for the head of the elementary conductor having a smaller spacing.

19. Apparatus according to claim 3 or according to claim 3 and one or more of claims 4 to 18, wherein The first insertion and operation device (401) comprises a through hole (440U) configured for the second leg of a standard or reverse basic conductor, and the corresponding second insertion and operation device (402) comprises a first through hole (440S) for the first leg in the case of a standard basic conductor and a second through hole (440R) for the first leg in the case of a reverse hairpin.

20. The apparatus according to claims 1 to 19, wherein: The loading device (530, 540) comprises a conveying system (530) configured to slide the head end of the elementary conductor from a loading station to the receiving volume.

21. The apparatus according to claim 20, wherein: The loading device comprises one or more transverse feed and positioning rollers (540), which are arranged at the end of the container volume, transverse to the axial direction, can rotate around the axial direction, and comprise fins (541), which are perpendicular to the axial direction so as to push the basic conductor into the container volume each time when the one or more transverse feed and positioning rollers rotate, and press against the first counter-mold (521) and the second counter-mold (522).

22. The apparatus according to claim 21, wherein The first counter-mold and the second counter-mold have transverse grooves configured to allow the fin (541) to continue rotating after advancing the base conductor.

23. The apparatus according to claim 21 or 22, wherein: The one or more infeed and positioning rollers (540) are identical on both sides of the counter-mold and are arranged so that a straight line passing through the respective centers of rotation is not perpendicular to a radial direction relative to the winding axis (50) in use, but has an inclination angle α that is proportional to the curvature of the head of the basic conductor.

24. Apparatus according to any one of claims 21 to 23, wherein: The basic conductor has a quadrilateral strip cross-section (255z), the quadrilateral strip cross-section (255z) having two long sides (255x) and two short sides (255y), and wherein the one or more transverse feed and positioning rollers (540) are arranged so that, in a position of the transverse feed and positioning rollers corresponding to the position of the basic conductor in the end volume (500F), the fins (541) are in contact along the entire long side (255x).

25. Apparatus according to any one of claims 21 to 24, wherein The basic conductor has a quadrilateral strip cross-section (255z), the quadrilateral strip cross-section (255z) having two long sides (255x) and two short sides (255y), and wherein the one or more transverse feed and positioning rollers (540) are arranged so that, in a position of the transverse feed and positioning rollers corresponding to the position of the basic conductor in the end volume (500F), the fins (541) are in contact along the entire short side (255y).

26. Apparatus according to any one of claims 21 to 25, wherein: The one or more infeed and positioning rollers (540) are arranged to rotate through an angle of less than 180° in use, wherein the blade (510) is shaped to advance over only approximately 2 / 3 of the surface area of ​​the head of the base conductor so that the movement of the blade and the rollers is synchronized.

27. Apparatus according to any one of claims 21 to 26, wherein: The conveying system (530) includes a first upper guide (530a, 535) and two lower guides (530b, 530c), wherein the first upper guide (530a, 535) is used to support the head end of the basic conductor, and the lower guides (530b, 530c) are used to slide within the supporting feet of the fed basic conductor.

28. The apparatus of claim 27, wherein: The upper guide member terminates continuously at a removable support member (535) for the head end of the basic conductor, the removable support member (535) being retractable so as to allow the basic conductor to slide along the axial direction.

29. Apparatus according to claim 27 or 28, wherein The upper guide (530a) is fixed, while the two lower guides (530b, 530c) are configured to be moved away from or toward each other by translation means (534) of the lower guides in order to load and move the nested elementary conductors.

Images