Method and device for producing stator of electric motor

Abstract

The invention relates to a method and a device for manufacturing a star yoke stator of an electric motor with distributed windings, and to a stator obtained by means of said method. A two-component stator is provided with a central star element provided with radial stator teeth and stator slots between the teeth, and a yoke in which the star element is inserted, and windings are received in the stator slots. The assembling method comprises the following steps of: positioning the star-shaped piece on the rotating main shaft; a linear portion of a coil formed of a wire pre-formed on a winding tool and preferably pressed and carburized is inserted into a stator slot to maintain an ordered arrangement of the wire. Winding is completed by alternating actions of inserting coils into stator slots and rotating stars. When the yoke is integrally formed, the yoke may be coupled to the star in a final step, or the yoke may be constructed by coupling sectors of the yoke around the star when the winding is completed. An apparatus configured for implementing the described method is also described. The invention further relates to a stator obtained directly by said method, and to an electric motor incorporating such a stator. According to the invention, a larger filling coefficient, higher efficiency, smaller leakage current and lower stator height are realized.

Description

Technical Field

[0001] The present invention relates to a method and apparatus for manufacturing a stator for an electric motor, particularly a dual-component stator (also known as a star and yoke stator), and a stator manufactured by such method. Background Technology

[0002] As is well known, the stator of an electric motor is typically cylindrical and comprises multiple poles formed by stator teeth arranged along the inner circumference of the cylinder, with the stator teeth projecting toward a common central main axis. With the outer side coaxial with the stator and the inner side coaxial with the rotor, the central main axis coincides with the rotation axis of the rotor, which is combined with the stator in the completed electric motor.

[0003] One or more wires are wound (also called coils) and placed in a sector consisting of the space between stator teeth (more often called stator slots).

[0004] In stators, there are centralized winding stators and distributed winding stators. In a centralized winding stator, the wire is wound on a single stator tooth, while in a distributed winding stator, the wire is wound on two or more teeth. This invention particularly relates to the manufacture of distributed winding stators.

[0005] In known technologies, to manufacture a distributed winding stator, the stator cylinder is made by first assembling teeth and one or more wire coils on the outside of the stator body, and then inserting these coils into the stator slots of the already formed cylinder.

[0006] The ends of stator teeth are usually called pole shoes. In a conventional stator, there is an opening called a slot opening between the pole shoes of two adjacent teeth, and the size of the opening is sufficient to allow the insertion of a coil.

[0007] However, there are stators in which coils cannot be inserted in the manner just described because these stators lack slot openings. An example is a stator consisting of a star-yoke. These stators are two-component stators: an outer cylindrical body, usually called the yoke, and an inner body, typically composed of stacked metal laminations, called the star element. The star element derives its name from its geometry and the stator teeth themselves, which provides an inner cylindrical surface defined by the pole shoes of all the stator teeth, extending radially outward from this surface. The inner cylindrical surface of the star element is essentially continuous, except for small windows or openings made to reduce stator weight and minimize electromagnetic short-circuiting. Therefore, the coil cannot be inserted between the pole shoes of adjacent stator teeth, but rather from the outside into the stator slot before the star element is inserted into the yoke.

[0008] In a dual-component or star-shaped yoke stator, the yoke is a cylinder whose inner surface is appropriately machined to form a seat for accommodating the stator teeth of the star-shaped element, and is locked once the connection between the yoke and the star-shaped element (by interference) is completed. Thus, in a star-shaped yoke stator, the stator slot is limited circumferentially by two stator teeth and radially by the inner cylindrical surface of the same star-shaped element, which is defined by the pole shoes of the stator teeth and the inner surface of the yoke.

[0009] US2015 / 0054378 describes an example of a star-yoke stator, mentioning in paragraph 29 that different techniques can be used to fabricate windings on the stator teeth according to the desired fill factor. This document shows a star-yoke stator with concentrated windings, i.e., coils wound on each stator tooth. In this configuration, windings can be formed on the stator teeth using a pin winding machine. If the windings are distributed, the coils are made on a winding tool outside the stator and later manually inserted onto two stator teeth.

[0010] Typically, as in conventional stators, it is desirable to maximize the sector fill factor in star-yoke stators as well, i.e., to be able to insert as many wires as possible, or the same number of wires of different diameters, into the same sector, as this will translate into improved motor performance. The fill factor is defined as the ratio between the cross-sectional area occupied by the wires in the stator slots and the total usable area in the stator slots (always considered in terms of cross-section).

[0011] Maximizing the fill factor also allows for minimizing the stator height, all other things being equal, resulting in a more compact motor.

[0012] Another limitation is the fact that after the coil has been inserted into the stator, the individual loops that make up the coil are arranged such that some loops are always oriented toward the center of the stator, while others are always oriented toward the outside of the stator. This involves an increase in the leakage current of the motor and thus a decrease in the efficiency of the motor itself.

[0013] WO 2022 / 084760, under the applicant's name, describes a method that allows maximizing the fill factor in different types of stators relative to a star-yoke stator. The method provides pre-forming the coil on a suitable winding tool outside the stator before inserting it into the stator slot. The method includes:

[0014] - A coil manufacturing step in which one or more wires are wound around a winding tool to form at least one coil, the coil including at least one linear portion, the linear portion including a plurality of separate linear wire portions, and intended to be inserted into a sector of a stator;

[0015] The coil receiving step involves inserting the linear portion of the coil into a stator component comprising a subset of the plurality of side-by-side teeth, particularly between two side-by-side stator teeth.

[0016] - A forming step in which the stator component housing the linear portion of the coil is deformed so that the side-by-side stator teeth are moved closer together, thereby achieving a complete stator portion including two teeth that together define a sector in which the linear portion of the coil is contained and constrained.

[0017] - Assembly step, in which multiple completed stator parts, achieved via corresponding receiving and forming steps, are assembled together to form the body of a stator with windings.

[0018] Following the forming step, and thus with the coil already accommodated in the stator slot, the method further provides a rotational translation R1 of the first completed stator portion relative to the second completed stator portion. The first completed stator portion and the second completed stator portion engage the same coil. The rotational translation is performed until the relative position that the first completed stator portion will have within the completed body of the stator relative to the second completed stator portion is reached, and the coil is thus deformed.

[0019] As an alternative to step R1, prior to the forming step and therefore before inserting the coil into the stator slot, the method provides to perform a rotational translation R2 of the first stator component relative to the second stator component until the first stator component reaches the relative position that the second stator component will have in the completed body of the stator. According to the method of the invention, the coil is deformed corresponding to the arrangement of the rotationally translated first and second stator components, and then a coil receiving step is performed.

[0020] The method described in WO 2022 / 084760 is not applicable to star-shaped yoke stators because no deformation of the star-shaped part is provided in this type of stator for moving the stator teeth closer and confining the coils in the slots, and no sector is provided for making the star-shaped part deformable and assemblable: in the star-shaped part, the stator teeth extend radially to the final position of each tooth in the finished stator.

[0021] JP 2022137412A, published by Mitsubishi Electric Corporation, describes a method for assembling a stator starting from a linear (flat) support. The coils are preventatively wound onto a winding tool, and all coils are inserted onto the linear support together in a single rotation before the linear support is wound onto the cylindrical element. Therefore, due to the winding of the linear support, coil deformation occurs simultaneously for all coils.

[0022] The applicant's patent application IT 102021000011564 describes a method for manufacturing a stator, the method comprising:

[0023] - A step of manufacturing a coil on a winding tool, the step of forming at least one coil including at least one linear conductor portion intended to be inserted into a corresponding stator sector;

[0024] - A pressing and carburizing step, wherein at least one linear portion of the coil is subjected to hot carburizing and pressed to compact the linear conductor portion;

[0025] - Coil receiving step, wherein the linear portion of the coil is inserted between two side-by-side stator teeth of the stator assembly;

[0026] - A forming step in which the stator component is deformed so that the two side-by-side teeth move closer together to surround the linear portion of the coil and obtain a complete stator portion;

[0027] - Assembly step, in which multiple completed stator parts are assembled together to form the body of the stator. Summary of the Invention

[0028] The purpose of this invention is to provide a method and apparatus for manufacturing a star-shaped yoke stator for an electric motor, which overcomes the limitations of existing solutions and thereby maximizes the fill factor.

[0029] Another object of the present invention is to provide a method and apparatus for manufacturing a star-shaped yoke stator, such that, under the same conditions, the stator manufactured by the method and apparatus is more compact (with a smaller stacking height) compared to a stator manufactured using a known solution.

[0030] This invention relates to a method for manufacturing a star-shaped yoke stator for an electric motor according to claim 1, and more particularly to a dual-component stator having distributed windings. The dual-component stator comprises:

[0031] - The outer body, called the yoke, and

[0032] - A main body, located inside the yoke, referred to as a star-shaped component, having an inner cylindrical surface defining a receiving cavity for the rotor of an electric motor and a plurality of radial stator teeth extending from the cylindrical surface toward the yoke, and stator slots for receiving windings formed by conductors are provided between the plurality of radial stator teeth.

[0033] The method includes:

[0034] A) Manufacturing a coil by means of conductors, wherein one or more conductors are wound on a winding tool to form a coil comprising at least one linear portion, the linear portion further comprising a plurality of individual conductor segments arranged in an orderly manner, and the linear portion being adapted to be inserted into a stator slot;

[0035] C) The star-shaped component is supported on the axis of rotation, wherein at least one first stator slot is operable by the coil operator;

[0036] D) Insert the first linear portion of the coil into at least one first stator slot using the manipulator, and constrain the second linear portion of the coil to the outside of the star-shaped member;

[0037] E) Rotate the star-shaped member about the axis of rotation by a predetermined angle, thereby deforming the coil in the portion between the linear portions and making at least one second stator slot accessible (i.e. operable by the operator) and ready for insertion into the corresponding linear portion of the coil;

[0038] F) Insert the second linear portion of the coil into at least one second stator slot using an operator;

[0039] G) Repeat steps D, E and F until the star-shaped piece is wound, thereby inserting the linear portion of the coil into each stator slot;

[0040] H) Constrain the star-shaped component to the yoke using one of the two methods described below.

[0041] Step E of rotating the star-shaped component is repeated until the stator is complete, with a linear portion of the coil inserted into the corresponding stator slot each time the star-shaped component stops. Therefore, the rotation step E is intermittent and ends when all stator slots are filled with the linear portion of the coil. Thus, in the claimed solution, the linear portions of the coil are inserted into the corresponding stator slots one at a time, and the precise intermittent rotation E of the star-shaped component is synchronized with the insertion actions D and F; specifically, the rotation E of the star-shaped component alternates with the insertion actions D and F of the actuator. Therefore, the deformation of the coil also occurs intermittently, rather than all coils occurring simultaneously.

[0042] Therefore, the rotation step involves rotating the star-shaped component by an angle corresponding to the included angle between the first stator slot and the second stator slot (which are not necessarily adjacent to each other), but this angle is less than 360°, and preferably less than 180°, and then stopping the star-shaped component and continuing to step F: during step F, the star-shaped component remains stationary.

[0043] Steps D, E, and F are performed in sequence, and step G specifies that these steps be repeated in the same order until the stator is completed, that is, until the stator is equipped with all the necessary windings.

[0044] The above methods can achieve different advantages.

[0045] One of the achievable advantages is increasing the fill factor of the stator sectors. The applicant has calculated that, all other things being equal, this method can increase the fill factor by at least 20% compared to a star-yoke stator manufactured using known techniques (i.e., inserting the windings into the stator slots in a standard manner).

[0046] The method according to the invention can also produce stators with lower winding losses, which reduce losses by about 30% at low speeds and by about 20% at high speeds compared to stators assembled by inserting coils into slots between teeth in a standard manner.

[0047] In terms of efficiency, all other things being equal (same size / power, same number of poles, same slot size between teeth, same wire diameter, same rotor, and same stack height), the stator manufactured by the above method can improve the motor efficiency by about 1-1.4% at low speeds compared to the stator manufactured using the standard slot filling technique.

[0048] Furthermore, under the same conditions (same size / power, same number of poles, same slot size between teeth, same wire diameter, same rotor, and same stack height), at low speeds, the power output of a motor equipped with a stator manufactured according to the method of this application is about 4-5% higher than that of a motor equipped with a standard stator; while at high speeds, the power output increase is even greater, reaching up to 20%.

[0049] The method described in this application also offers advantages in terms of the axial dimensions of the finished motor. When the motor size is fixed (e.g., 55kW), the stack height of the stator and corresponding windings can be significantly reduced because this method can manufacture a stator with a higher slot fill factor. Compared to a standard stator, the stator manufactured using this method can reduce the stack height by up to 35%.

[0050] Another advantage is that the individual loops (or turns) that make up the coil are arranged such that the first linear portion of the coil faces the center of the stator, and the second linear portion of the same coil faces outward; this reversed position configuration helps to minimize the leakage current of the motor.

[0051] The method described in this application can also economically and easily manufacture motor stators equipped with corresponding windings, the details of which will be described in detail below.

[0052] Another advantage of the proposed solution is that the deformation is applied to each individual coil individually (i.e., applied to a single coil each time the star-shaped component undergoes an angular displacement, rather than simultaneously to all coils). This results in higher structural accuracy and better tolerances compared to the case described in, for example, JP2022137412 A, where one or more coils are deformed substantially simultaneously. The rotation of the star-shaped component mentioned here refers to its rotation between two consecutive stop positions of the star-shaped support, which correspond precisely to the angle between the first and second slots, and should not be confused with the rotation of the star-shaped support described in JP 2022137412 A.

[0053] More specifically, in step E, the star-shaped member rotates about the rotation axis by an angle corresponding to the electrical phase of the completed stator and stops at this angular position, thereby accommodating another linear portion of the coil (or multiple other linear portions of the coil) in the corresponding stator slot. Thus, the periodic rotation applied to the star-shaped member is intended to provide new stator slots for the manipulator to fill the straight portions of the coil previously formed on the winding tool.

[0054] In a preferred embodiment, the method further includes a pressing or carburizing step B (otherwise optional). In this step, at least one linear portion of the coil undergoes a pressing step, hot carburizing, or both pressing and hot carburizing in a desired order or simultaneously, thereby pressing the individual line segments according to the ordered arrangement achieved in coil forming step A. Advantageously, the conductors of the pressed and carburized linear portions of the coil remain clustered, without separating or shifting relative to each other. This detail allows the winding to maintain the optimal geometry achievable for each stator slot size to be filled (to maximize the fill factor) and avoids unwinding during coil movement. Furthermore, the line segments can be shaped to be completely complementary to the shape of the stator slot to be inserted.

[0055] Preferably, step B lasts from 15 seconds to 2 minutes.

[0056] Preferably, during the pressing and / or carburizing step B, the linear portion of the coil is pressed with one or more pressing elements and heated by one or more heating devices integrated into or connected to the pressing elements, while the coil is wound on a winding tool, i.e., before the coil is removed from the winding tool.

[0057] In one possible method, during the pressing and / or carburizing step B, a thermal carburizing process is performed by inserting one or more heating elements between the linear portions of the coils to heat them to a predetermined carburizing temperature, typically in the range of 170°C to 210°C.

[0058] In one possible method, during the carburizing and pressing step B, the linear portion is pressed by a pressing device inserted between the linear portions of the coil after the heating element is removed, while the coil is held in the winding tool.

[0059] In one possible approach, during coil manufacturing step A, a complementary and thinner conductor with a cross-sectional area smaller than that of the main conductor is added to the conductor (referred to as the main conductor); the complementary conductor occupies the free space between the side-by-side main conductors.

[0060] Preferably, the method further includes the step of insulating the wire. Electrical insulation layer:

[0061] - After the optional pressing and / or carburizing step B, at least applied to the linear portion of the coil, or

[0062] - Apply between the teeth of the stator component before coil insertion step D.

[0063] Preferably, coil manufacturing step A is carried out by manufacturing a series of multiple coils on the same winding tool, specifically ensuring that a linear portion of one coil is spaced apart from the linear portion of a subsequent coil by a predetermined pitch distance corresponding to the pitch between the star-shaped stator slots.

[0064] Preferably, before step E and during coil insertion step D, the first linear portions of a series of coils are simultaneously inserted into the corresponding stator slots of the star-shaped member. At a later time, subordinate to step E, the second linear portions of the same series of coils are simultaneously inserted into the corresponding stator slots of the star-shaped member, such that the corresponding windings are distributed across multiple stator slots. The non-linear portions of the coils deform due to the rotation of the star-shaped member; this deformation causes the coils to take on the desired shape, thereby ensuring that the linear portions are correctly inserted into the corresponding stator slots according to the pitch defined by the electrical phase.

[0065] This method can be implemented in two modes.

[0066] In the first mode for manufacturing a stator with an integrally formed yoke, between steps D and E, and between steps F and G, the following are provided:

[0067] Steps D') and F') involve temporarily closing the stator slot containing the corresponding linear portion of the coil using a closing device that is movable between a retracted position and a forward position. In the retracted position, the stator slot is radially open and accessible by an operator, allowing insertion of the linear portion of the coil. In the forward position, the stator slot is radially closed, preventing the linear portion of the coil from dislodging. This detail is designed to prevent the coil from accidentally dislodging from the star-shaped component during rotation.

[0068] Initially, whenever the coil manipulator approaches the star-shaped component after removing a coil from the winding tool, and during step D, when the first linear portion of the coil is inserted into the corresponding stator slot of the star-shaped component, these first linear portions remain coplanar with the second linear portion of the coil. In other words, the coil initially maintains its shape as it was removed from the winding tool; that is, the coil remains undeformed. Conversely, during step E, when the first linear portion of the coil has been inserted into the corresponding stator slot, and the second linear portion remains constrained by the manipulator while the star-shaped component rotates, the coil deforms: in this case, the portion of the coil connecting the first and second linear portions deforms.

[0069] Preferably, steps C to G are performed by supporting the star-shaped member on the main shaft (e.g., a drum) and placing it within the inner cylindrical surface of the winding device. In practice, the star-shaped member is coaxially mounted on the main shaft, with the stator teeth arranged radially and protruding toward the inner cylindrical surface of the winding device. This design precisely closes the stator slots radially within the inner cylindrical surface of the winding device. This inner cylindrical surface has a longitudinal opening that provides a radial passage for the coil manipulator to enter the first stator slot of the star-shaped member. Therefore, only those stator slots that require periodic insertion of the linear portion of the coil are moved to this longitudinal opening and made externally accessible, while the remaining stator slots and the rest of the star-shaped member are confined between the main shaft and the inner cylindrical surface of the winding device.

[0070] In a first embodiment of the method, steps D and F are performed by bringing the stator slot intended to accommodate the linear portion of the coil to the longitudinal opening by rotating the star-shaped member, while keeping the star-shaped member stationary during the insertion of the linear portion.

[0071] Therefore, the rotation of the star-shaped component and the insertion of the coil manipulator are performed alternately. The winding on the star-shaped component is completed by repeatedly rotating the star-shaped component and inserting the linear portion of the coil through the manipulator.

[0072] In this first embodiment of the method, the yoke is made substantially cylindrical and integral, and step H is performed by pulling out the star-shaped piece on the spindle and inserting it into the yoke along with all the windings.

[0073] In a second embodiment of the method, the yoke is made into a set of sectors, and step H is performed by constraining the sectors of the yoke to the star at the stator slot of the linear portion of the inserted coil using a specific operating system for sequentially operating the sectors of the yoke between steps E and F and between steps F and G, thereby achieving external closure of the stator slot.

[0074] Therefore, in a first embodiment of the method, the stator slot is closed by a closing device, and in a second embodiment of the method, the stator slot is closed by a sector of a yoke applied to the star-shaped member.

[0075] Preferably, step H is performed by temporarily constraining the sector of the yoke to the star and the spindle supporting the star by a removable fastening element, and holding the completed yoke together (i.e., once completed) by a gripper system.

[0076] Another aspect of the invention relates to a dual-component or star-yoke stator according to claim 18, which is obtained directly using the methods described herein. Under the same conditions, a stator obtained directly by the methods described herein can be distinguished from a stator manufactured using known techniques for the following reasons:

[0077] -Considering the case of conductors with circular cross-sections, the fill factor should be at least 20% larger;

[0078] - The conductors of the linear portion of the coil contained in the slots of the stator sector are arranged in an ordered, repeatable matrix layout, rather than in a tight but random layout as in the prior art.

[0079] - The cross-section of the stator slot is roughly rectangular, unlike the trapezoidal slot of known solutions; and the cross-sectional shape of the linear portion of the coil is complementary to the cross-sectional shape of the stator slot.

[0080] The present invention also relates to an electric motor that integrates the stator described above, including a version with the yoke integrally formed and a version with the yoke formed by assembling sectors of the yoke.

[0081] Another aspect of the present invention relates to an apparatus for manufacturing a star-shaped yoke stator of the type described above, as claimed in claim 20. The apparatus comprises:

[0082] - At least one winding tool, the winding tool being configured to perform step A, wherein one or more wires are wound around the winding tool to form a coil comprising at least one linear portion, the linear portion further comprising segment portions of a plurality of individual wires, and the linear portion being adapted to be inserted into one of the stator slots;

[0083] - A spindle, which is rotatable about a rotation axis and can be locked in multiple angular positions, the spindle being configured such that:

[0084] - During step CG, the star-shaped member is supported such that at least one first stator slot of the star-shaped member can be approached and accessed by the coil manipulator, and

[0085] - Rotate the star-shaped component by an angle corresponding to making at least one second stator slot accessible to the coil manipulator, and possibly deform the coil at a portion between the linear sections during step E.

[0086] - A coil operator configured to perform step D by inserting a first linear portion of the coil into a corresponding stator slot and constraining a second linear portion of the same coil, and to perform step F by inserting the second linear portion of the coil into a corresponding stator slot.

[0087] The main shaft coaxially supports the star-shaped component on the axis of rotation. The rotation of the star-shaped component alternates with the insertion action of the coil manipulator, such that after the linear portion of the coil is inserted into the corresponding stator slot, the star-shaped component rotates to bring another stator slot into the manipulator's trajectory, so as to insert another linear portion of the coil or the linear portion of the same coil.

[0088] Preferably, the winding tool includes a support frame that supports a series of corner elements, wherein each corner element in the series is arranged approximately along the edge of an ideal parallelepiped, and wherein each series of corner elements is spaced apart from each other to define a corresponding series of winding chambers to accommodate the wires or wire bundles forming the coil. The winding chambers are spaced apart by a pitch corresponding to the desired pitch to be formed between the linear portions of the coil.

[0089] Preferably, the device further includes a wire guiding device comprising an axial guide along which multiple wire guide tubes are capable of sliding independently of each other in a controlled manner. Each wire guide tube passes through and guides one or more layers of wires intended to form a loop (or coil). The conductors may be a main conductor with a nominal cross-section and a finer complementary conductor (i.e., with a cross-section smaller than the nominal cross-section).

[0090] Preferably, the device includes a pressing device for performing step B (i.e., pressing the linear portion of the coil). The pressing device includes a plate with a series of inclined planes adapted to contact the linear portion to be pressed.

[0091] Preferably, the apparatus includes a heating device for performing step B (i.e., for performing thermal carburizing of the linear portion of the coil). The heating device includes one or more heating elements (preferably induction type) shaped and arranged to be inserted between the linear portions of the coil.

[0092] In a preferred embodiment, the coil manipulator includes a first clamp or upper clamp and a second clamp or lower clamp. The lower clamp is configured to remove a first linear portion of the coil from the winding tool, hold it for a necessary time, and spring it into a first stator slot; the upper clamp is configured to remove a second linear portion of the coil from the winding tool, constrain it for a necessary time, and spring it into a second stator slot.

[0093] The upper gripper and the lower gripper are movable relative to each other between the following positions:

[0094] - Initial coplanar position, at which the coil remains unchanged relative to its initial configuration on the winding tool, and

[0095] - Multiple staggered positions, at which the clamp is in different planes and / or at different heights, to allow the linear portion of the coil to be inserted into the stator slot at different angular positions of the star-shaped part of the stator being assembled.

[0096] In other words, the clamps move relative to each other and relative to the spindle and star-shaped component to allow insertion of the linear portion of the coil and allow deformation of the coil in the non-linear portion.

[0097] Preferably, the holder is provided with a pop-out element operable to eject the linear portion of the coil from the holder itself, thereby inserting it into the stator slot. In other words, the holder has jaws for restraining the linear portion of the coil during the time required for movement from the winding tool to the spindle and star-shaped member, and furthermore, the holder has an operable pop-out element for pushing the linear portion of the coil out of the holder's jaws and into the stator slot.

[0098] In a first embodiment suitable for manufacturing a stator with an integrally formed yoke, the device includes a support structure and a carriage, to which the main shaft is constrained. The carriage is movable relative to the main shaft and / or relative to the support structure, for example, along a track, between the following positions:

[0099] - In the first position, the carriage does not obstruct the main shaft, and the star-shaped member supported on the main shaft is not restricted by the carriage, i.e., the carriage does not surround the star-shaped member, and

[0100] - Second position, in which the carriage extends around the main shaft and surrounds the star-shaped member supported on the main shaft.

[0101] The carriage has an inner cylindrical surface complementary to the star-shaped member supported on the main shaft. Specifically, the available clearance between the stator teeth and the inner cylindrical surface is minimal, sufficient to allow the star-shaped member to rotate while preventing the coil from dislodging from the stator slots. The inner cylindrical surface opens outward at a longitudinal opening through which the coil manipulator is inserted to accommodate the linear portion of the coil in the corresponding stator slot of the star. In effect, the carriage encloses the star-shaped member supported on the main shaft, and the longitudinal opening allows the linear portion of the coil to be inserted radially from the outside.

[0102] In this embodiment, a closing device is provided, which is configured to temporarily and responsively close the longitudinal opening. In practice, the closing device intervenes to temporarily close the longitudinal opening and prevent the coil from accidentally dislodging from the stator slot before the star-shaped member rotates and the linear portion is displaced by the carriage into the confined area.

[0103] Preferably, the closing device is a sliding, drawer-type, or louver-type device mounted on a carriage, and is provided with a panel that can move between two positions:

[0104] - Retracted position, in which the panel does not obstruct the longitudinal opening, thereby allowing the manipulator to be inserted through the longitudinal opening into the stator slot of the star-shaped component supported on the spindle, and

[0105] - Forward position: In this forward position, the panel blocks the longitudinal opening, thereby preventing the linear portion of the coil from coming out of the stator slot.

[0106] In a second embodiment suitable for manufacturing a stator having a yoke formed by assembling sectors, the apparatus includes a system for operating the sectors of the yoke. The operating system is provided with at least one gripper having jaws movable to grip / release the sectors of the yoke; the gripper is movable to a position for releasing the sectors, where the sectors are anchored to the star and close one or more stator slots already equipped with linear portions of coils.

[0107] In this second embodiment, the device includes one or more fastening elements that can be transported by the operating system along with each sector of the yoke. The fastening elements are configured to constrain the sectors of the yoke to the spindle during stator assembly and are removable after assembly is complete.

[0108] Preferably, the fastening elements are fork-shaped, engaging the two longitudinal ends of the yoke sector and capable of being inserted into corresponding recesses on the spindle. The fork shape causes these fastening elements to span the linear portion of the coil inserted into the stator slot of the star-shaped member.

[0109] More specifically, the fork-shaped element engages with the corresponding sector of the yoke and has at least one tooth that can be inserted into a recess in the spindle. The spindle, in turn, includes at least one lever, and the tooth of the fork-shaped element snaps into the corresponding lever. The lever is movable to release the tooth of the fork-shaped element, and allows the fork-shaped element to be released when it is no longer needed, i.e., when the yoke has been assembled.

[0110] Preferably, the recesses for inserting the fork-shaped elements are circumferentially arranged on the main shaft at a pitch proportional to or corresponding to the pitch between the sectors of the yoke. The main shaft includes at least one lever for each recess, each lever oscillating about a pin and counteracted by a spring. The levers are also provided with teeth designed to engage the teeth of the corresponding fork-shaped element. By controlling the oscillation of all levers, all fork-shaped elements are disengaged and disengaged from the main shaft.

[0111] Preferably, the main shaft is cylindrical, and the levers are arranged radially on the main shaft; the pins are arranged tangentially, that is, orthogonally to the corresponding lever arrangement.

[0112] In both versions, the described apparatus is capable of assembling the stator according to the invention, thereby achieving the described advantages, and the assembly process is fast, accurate and fully automated. Attached Figure Description

[0113] Further features and advantages will become clearer from the description of some preferred but non-exclusive embodiments of the method for manufacturing the stator, which are depicted by way of example rather than limitation with the aid of the accompanying drawings, wherein:

[0114] - Figure 1 This is a flowchart depicting a method for manufacturing a star-shaped yoke stator according to the present invention;

[0115] - Figure 2 These are front and elevation views of a winding machine used to manufacture coils that can be used in the stator according to the method and in the present invention.

[0116] - Figure 3 yes Figure 2 The details of the machine;

[0117] - Figure 4 , Figure 5 and Figure 6 yes Figure 2 Cross-sectional details of the machine;

[0118] - Figure 7 and Figure 8 Is with Figure 2 An exploded view of the winding tool of the machine assembly;

[0119] - Figure 9 and Figure 10 yes Figure 7 A perspective view of the winding tool in successive steps;

[0120] - Figure 11 yes Figure 7 The side and elevation views of the winding tool shown;

[0121] - Figure 12 , Figure 13 and Figure 14 yes Figure 7 The winding tool along the cross-sectional views of different planes;

[0122] - Figure 15 Is Figure 2 In the machine and Figure 7 A perspective view of a single coil made on a winding tool;

[0123] - Figure 16 Is Figure 2 In the machine and Figure 7 A perspective view of multiple coils made on a winding tool;

[0124] - Figure 17 It is a perspective view of the apparatus used for pressing and carburizing coils;

[0125] - Figure 18 and Figure 19 yes Figure 17 A cross-sectional view of the device during continuous coil pressing and carburizing time.

[0126] - Figure 20 and Figure 21 This is a perspective view of an alternative embodiment of the wire winding tool;

[0127] - Figures 22a, 22b and 22c are cross-sectional views of the loops of different possible types of windings;

[0128] - Figures 23a, 23b and 23c are cross-sectional views of the rings with different types of windings according to the alternative solutions;

[0129] - Figure 24 This is a perspective view showing details of another embodiment of the winding tool;

[0130] - Figure 25 yes Figure 24 The main view of the winding tool;

[0131] - Figure 26 yes Figure 24 Side view of the winding tool;

[0132] - Figure 27 yes Figure 24A top view of the winding tool;

[0133] - Figure 28A and Figure 29 It is a description of the containment Figure 24 A perspective view of two consecutive steps of the heat treatment process performed on the coil of the winding tool;

[0134] - Figure 30 It is a cross-sectional view of an electric motor with a star-shaped yoke stator based on known technology;

[0135] - Figure 31 It is a perspective view of a star-shaped component based on known technology;

[0136] - Figure 32 This is a perspective view of the stator star-shaped portion according to the present invention;

[0137] - Figure 33 This is a cross-sectional view of a first embodiment of the star-shaped yoke stator according to the present invention, wherein there are no windings;

[0138] - Figure 34 yes Figure 33 The isometric view of the star-shaped yoke stator shown, but the windings are complete;

[0139] - Figure 35 This is a cross-sectional view of a second embodiment of the star-shaped yoke stator according to the present invention, wherein there are no windings;

[0140] - Figure 36 yes Figure 35 The isometric view of the star-shaped yoke stator shown, but the windings are complete;

[0141] - Figure 37 This is a perspective view of a clamping system used in the device according to the invention, the clamping system being used to manipulate coils to manufacture respectively in Figures 33-34 And the star-shaped yoke stator of the two embodiments shown in 35-36;

[0142] - Figure 38 yes Figure 37 Cross-sectional view of the clamping system shown;

[0143] - Figures 39-61 It is according to the invention for manufacturing according to Figure 33 and Figure 34 A perspective view of the first device of the star-shaped yoke stator of the first embodiment shown in the figure during different steps of inserting the coil into the stator slot;

[0144] - Figures 62-63 and Figures 66-91 It is according to the invention for manufacturing according to Figure 35 and Figure 36A perspective view of the second device of the star-shaped yoke stator of the second embodiment shown in the figure, during the different steps of inserting the coil into the stator slot;

[0145] - Figure 64 This is a perspective view of components according to a second embodiment of the device based on the present invention;

[0146] - Figure 65 yes Figure 65 A sectional (vertical) view of the component shown;

[0147] - Figure 92 It is a cross-sectional schematic diagram of the layout for winding a star-shaped yoke stator based on known technology, and a table of the corresponding technical requirements for the winding;

[0148] - Figure 93 This is a cross-sectional schematic diagram of five possible layouts for winding a star-shaped yoke stator according to the present invention, and a table of corresponding technical requirements for the windings;

[0149] - Figure 94 It is a cross-sectional view of a portion of a hypothetical star-shaped yoke stator, which has stator slots filled in a conventional manner compared to the same stator slots filled using the method according to the invention;

[0150] - Figure 95 It is a graph showing the relationship between losses and rotational speed of an electric motor made with a star-shaped yoke stator according to known technology and an electric motor made with a star-shaped yoke stator according to the present invention, all under the same conditions.

[0151] - Figure 96 It is a graph showing the relationship between the efficiency and rotational speed of an electric motor made with a star-shaped yoke stator according to known technology and an electric motor made with a star-shaped yoke stator according to the present invention, all under the same conditions.

[0152] - Figure 97 It is a graph showing the relationship between the output power and the rotational speed of an electric motor made with a star-shaped yoke stator according to known technology and an electric motor made with a star-shaped yoke stator according to the present invention, all under the same conditions. Detailed Implementation

[0153] To achieve a high fill factor, in the star-shaped yoke stator according to the invention, a winding is formed by manufacturing a coil in a suitable tool outside the stator and then inserting the coil into the stator slot, the coil being characterized by an extremely orderly distribution of conductors.

[0154] Figure 1 This is a flowchart outlining the main steps of a method for manufacturing a star-shaped yoke stator with distributed windings according to the present invention.

[0155] Step A includes manufacturing coil 4. The method optionally and preferably includes step B of pressing and / or carburizing the coil, wherein step B provides pressing only, or carburizing only, or pressing and carburizing in a desired order or simultaneously.

[0156] In step C, the star-shaped members 100 of stators S1 and S2 are coaxially mounted on the main shafts 501 and 601, wherein the stator teeth 104 extend radially outward from the main shafts 501 and 601 and the first stator slot 106 can enter from the outside.

[0157] Step D provides to operate the coil 4 previously made by step A and possibly also by step B, to insert the first linear portion 4b of the coil 4 into the first stator slot 106 and to constrain or lock the second linear portion 4a of the same coil 4.

[0158] Step E provides to rotate the spindles 501 and 601 by an angle, thereby causing the star-shaped component 100 to rotate by that angle, which in turn causes the coil 4 to deform simultaneously. This angle is useful for allowing the second stator slot 106 to be accessed from the outside.

[0159] Step F involves inserting the second linear portion 4a of coil 4 into the second stator slot 106.

[0160] Step G provides the yoke to repeat steps D, E and F until the winding is completed, that is, until the linear portions 4a, 4b of coil 4 are inserted into each stator slot 106.

[0161] The yokes 101' and 101" are assembled on the star-shaped part 100 in step H, which can be performed during the previous steps.

[0162] In the first embodiment, the star-shaped member 100 of the stator S1 is mounted on a spindle 501 that rotates within a cylindrical surface 508, and the straight portions 4a and 4b of the coil 4 are constrained in corresponding stator slots 106 via the cylindrical surface 508. In the second embodiment, the yoke 101” of the stator S2 is made of sectors 110, and the straight portions 4a and 4b of the coil 4 are constrained in corresponding stator slots 106 via at least one sector 110 coupled to the yoke 101” of the star-shaped member 100.

[0163] In the first embodiment, step H' provides to complete stator S1 by removing the star member along with the windings from the spindle 501 and inserting it into the corresponding yoke 101'. In the second embodiment, step H" provides to complete stator S2 by, for example, locking all sectors 110 of yoke 101" with a claw system 700.

[0164] refer to Figures 2-29As described above, the method initially includes step A of manufacturing a coil 4, wherein one or more wires 14 are wound around a winding tool 20 to form at least one coil 4 comprising at least one, and preferably two, linear portions 4a, 4b, each linear portion comprising a plurality of individual wire segments 14. Each linear portion 4a, 4b of the coil 4 is intended to be inserted into a stator slot defined in a star-shaped member of the stator. The coil 4 thus produced is actually formed of multiple turns of wire 14.

[0165] In this step, the coil 4 is preferably made of at least one first linear portion 4a and at least one second linear portion 4b, which are parallel to each other and connected by a non-linear portion, and then the first linear portion 4a and the second linear portion 4b are each inserted into different stator slots 106.

[0166] As shown in the figure, the coil 4 is preferably made in series on the winding tool 20, such that the series connection includes a plurality of first linear portions 4a and corresponding second linear portions 4b, for example, three, and the plurality of first linear portions 4a and corresponding second linear portions 4b are appropriately spaced according to the spacing corresponding to the slot spacing between the stator slots 106 of the star member 100.

[0167] like Figure 15 As shown, according to the design decision, only one coil 4 or as... Figure 16 The multiple coils 4 connected in series shown can be wound onto the winding tool 20.

[0168] The winding is made of one or two or more parallel lines to realize coil 4, which includes, for example, one hundred loops made of only one line 14, or fifty loops made of two parallel lines, or ten loops made of ten parallel lines 14, etc.

[0169] exist Figure 2 The text describes a possible embodiment of a winding machine 200 that can be used to manufacture coil 4.

[0170] The winding machine 200 includes a support structure 201, which supports:

[0171] - Multiple wire tensioning devices 203 (known type) for tensioning the wire 14 to be wound,

[0172] - A wire guide device 206, which is provided with a wire guide tube 204 and is movable along a wire guide guide 205 (preferably composed of a rod).

[0173] - A winding spindle 244, which is rotated by a motor 214 and adapted to rotate a winding tool 20, which will be described below, is actually coupled to a sleeve to hook onto a spindle 25.

[0174] Such a winding machine 200 can therefore be configured to run a winding configuration in which the wire 14 to be wound is pulled taut and exits from the wire tensioning device 203 toward the wire guide device 206, which in turn keeps the wire 14 rotating toward the winding tool 20.

[0175] Optionally, the winding machine 200 also includes a tailstock 215, which is coaxially positioned with the spindle 244 and adapted to be coupled to the removable wall 24' of the winding tool 20.

[0176] Figure 3 The wire guide device 206 is shown in detail, which includes a base 217, wire guide elements 216 (preferably a pair of wheels) fixed on the base 217 and guiding the wire 14 into the wire guide tube 204, which is positioned at the end of the base 217 facing the winding tool 20.

[0177] exist Figure 4 and Figure 5 Details of the winding member 218 are shown, which is preferably present in the winding machine 200 and positioned coaxially with the spindle 244, wherein the wire 14 coming out of the wire guide tube 204 is aligned into a loop before being wound onto the winding tool 20.

[0178] Figure 6 A cross-section of a wire guide 204 is shown, which comprises multiple segments defining multiple individual conduits 251 for the wires 14, such that a layer of wires 14 intended to form a loop is secured in place within each conduit 251. In the depicted example, there are three conduits 251, and the wires are arranged in a 5-4-5 sequence across three levels (five wires on the first level, four wires on the second level, and five wires on the third level), with a total of fourteen parallel wires in each loop, each wire 14 originating from... Figure 2 It is one of the fourteen visible conductor tensioning devices 203 and is managed by it.

[0179] Obviously, the number of parallel wound wires 14 in each loop (and consequently the number of wire tensioning devices 203), the number of layers (and consequently the number of pipes 251 in the wire guide tube 204), and the number of wires 14 in each layer can vary and be selected according to project requirements.

[0180] The first embodiment of the winding tool 20 is in Figures 7 to 14 It is shown in the middle; while Figures 20-21 and Figures 24-29 The second embodiment is shown in the figure.

[0181] refer to Figures 7 to 14The winding tool 20 preferably includes a plurality of movable walls 22, which are included between the anchoring wall 23' and the removable wall 24'.

[0182] Anchor wall 23' is configured to be operatively coupled to winding spindle 244 in order to drive rotation of movable wall 22, and for this purpose, anchor wall 23' may optionally include a hook to spindle 25.

[0183] The removable wall 24' can be detached from the anchoring wall 23' to release the movable wall 22 and allow displacement of the already wound coil 4.

[0184] The movable wall 22 forms one or more winding chambers 24, and the wire 14 is wound inside the winding chambers 24 to form a coil 4.

[0185] More specifically, the anchor wall 23 also includes a wire clamping element 26 configured to clamp the wire 14 entering the winding (already arranged in a suitable configuration).

[0186] Conveniently, the anchoring wall 23' is also provided with a centering pin 27 to center the movable wall 22, the centering pin protruding toward the removable wall 24' and engaging the tunnel formed by the center hole 28 obtained at the center of each movable wall 22.

[0187] The hook end 271 for hooking the anchor wall 23' to the removable wall 24' is located at the end of the centering pin 27.

[0188] The anchoring wall 23' is also provided with a plurality of (four in the example shown) axial locating pins 231, which also protrude toward the removable wall 24', and the task of the axial locating pins 231 is to maintain the proper axial position of the removable wall 22 during winding by occupying the corresponding locating holes 29 obtained in the removable wall 22, thereby ensuring the proper size of the winding chamber 24.

[0189] As can be seen in the figure, the axial locating pin 231 is formed by multiple longitudinal portions with different diameters that decrease toward the removable wall 24', and the locating hole 29 has a different diameter in each movable wall 22 that decreases toward the removable wall 24', such that each movable wall 22 is locked onto the corresponding longitudinal portion of the axial locating pin 231.

[0190] Therefore, the movable walls 22 ensure axial dimensions (determined by the thickness of the walls 22 and the distance between the walls 22 themselves) during the step of winding (manufacturing the coil 4) the wire 14, but can approach each other under the thrust of the press during the pressing step, as will be described below. This axial dimension is conveniently ensured by mechanical reference element 291, which ensures the repeatability of the process and the consistency of the final dimensions of the pressed coil 4. In practice, the winding tool 20 is configured such that the movable walls 22 can move closer to each other under pressure until the distance defined by the mechanical reference element 291, which serves as a limit to the abutment.

[0191] The number of movable walls 22 in the winding tool 20 is determined by the number of coils 4 to be manufactured in series (equal to the number of coils per electrode, and thus equal to the number of coils per sector 3) + 1; therefore, by the formula Np = nm + 1, where Np is the number of movable walls 22 and nm is the number of coils. In fact, nm coils are coils 4 that will become part of a single electrode.

[0192] The movable wall 22 is generally rectangular in plan view, both in vertical and horizontal sections. Preferably, the movable wall 22 has an operating seat 249 on its side extending outside the winding tool 20.

[0193] In a preferred embodiment, each movable wall 22 is formed by a central support 221 and two wound cheek plates 222 fixed to both sides of the central support 221, in which case the operating seat 249 is obtained within the wound cheek plates 222. In practice, in these embodiments, the winding chamber is defined between the winding cheek plates 222.

[0194] Preferably, a thermal insulator is inserted between the central support 221 and the winding cheek plate 222 to limit heat loss during the hot carburizing process, as will be described below.

[0195] The removable wall 24' is removable because it can be separated from the fixed wall to allow the movable wall 22 to be pulled out.

[0196] In a preferred embodiment, the removable wall 24 is further provided with a corresponding wire clamp element 261 configured to clamp the wires 14 coming out of the winding, thereby keeping them in a proper construction arrangement.

[0197] Then, the removable wall 24' includes a connecting device 241 for direct or indirect connection to the anchor wall 23', for example, the hook end 271 of the centering pin 27 of the anchor wall 23' is hooked in the connecting device 241.

[0198] Preferably, the removable wall 24' also includes a clamping element 242 adapted to be gripped or hooked to allow its movement.

[0199] In a preferred embodiment, the winding tool 20 includes a plurality of corner elements 245 coupled to the removable wall 24', which slide on corresponding appropriately angled guides 246. These guides 246 extend from the removable wall toward the anchoring wall 23', and preferably all the way to the anchoring wall 23'. The corner elements serve as supports for the wire 14 during winding, and particularly provide support for the wire portions 14 that are not part of the straight portions 4a, 4b (i.e., the wire portions 14 forming the heads of the coil 4).

[0200] In the example shown, there are at least four corner elements 245, one at each corner.

[0201] Due to sliding along the guide 246, the corner element 245 slides toward the center of the winding tool 20 as the removable wall 24' disengages from the hook wall (as shown in the image). Figure 9 and Figure 10 (as shown), thereby eliminating stress from the wire 14 forming the coil 4, and thus allowing the coil 4 to be removed without scratching, thereby preventing damage to the wire 14.

[0202] Following the coil forming step A, the method provides an optional but preferred pressing and / or carburizing step B, wherein at least one linear portion 4a, 4b of at least one coil 4 is pressed and subjected to hot carburizing to compact the respective linear conductor portions 1 together.

[0203] In practice, the coil 4 already formed on the winding tool 20 is moved and positioned together with the winding tool 20 in the pressing and / or carburizing apparatus 300, such as, for example, in Figure 17 The device shown.

[0204] In a preferred embodiment, the device 300 performs both pressing and carburizing 300, and includes a receiving seat 301 configured to receive the winding tool 20 and one or more pressing elements 30 configured to apply pressure to at least one linear portion 4a, 4b of the coil 4 wound on the winding tool 20.

[0205] Preferably, there are two pressing elements 30, which are coaxially positioned on opposite sides of the receiving seat, and one pressing element 30 applies pressure in the other direction (preferably in the horizontal direction) to press each of the two opposite linear portions 4a, 4b of each coil 4.

[0206] The pressing element 30 is provided with at least one heating device 31 (preferably including one or more inductors) which is configured to heat the linear portions 4a, 4b before, after or during the pressing, so as to perform hot carburizing while the coil 4 is wound on the winding tool 20, and thus perform hot carburizing while the arrangement of the wires 14 is completely orderly.

[0207] The pressing element is actuated by a pressure motion system 304, which in the illustrated embodiment includes a piston and a spring coaxial therewith.

[0208] In some embodiments, a heating device 31 (clearly visible in FIG. 28) is included in or coupled to the pressing element 30, more specifically, is included in or coupled to the head 32 of the pressing element 30, which constitutes the end of the pressing element 30 itself that contacts the linear portions 4a, 4b during pressing.

[0209] Conveniently, the number of heating devices 31 is equal to the number of movable walls 22.

[0210] Optionally, the pressing and / or carburizing device 300 includes a thermal probe 34 and / or a pyrometer 35, which are preferably coupled to the pressing element 30 to allow feedback control of the carburizing process via a control system that controls the heating element 31.

[0211] More specifically, the pressing and / or carburizing apparatus 300 includes a fixed support 311 at the receiving seat 301, on which the winding tool 20 rests. This fixed support 311 has a support surface made of heat-insulating material, on which the winding tool 20 rests to limit heat dissipation.

[0212] Preferably, the pressing and / or carburizing apparatus 300 further includes a pressure head 302 that moves orthogonally relative to the pressing element 30, and in the illustrated example, vertically, to compress the winding tool (and thus the coil 4) in a direction orthogonal to the pressing element 30. This causes the movable wall 22 to move closer to further press the linear portions 4a, 4b of the coil 4 and determine their thickness with reference to the mechanical reference element 291, which serves as a limiting support. In practice, the pressure head 302 presses the winding tool 20 (and thus the coil 4) against the fixed support 311.

[0213] Therefore, the linear portions 4a and 4b of each coil 4 are preferably subjected to two pressures in mutually orthogonal directions, such as Figures 17-19 As shown.

[0214] Conveniently, only the linear portions 4a and 4b of coil 4 are pressed and heat-treated, while the non-linear portions (i.e., the portions of coil 4 that connect the linear portions 4a and 4b, which are mainly bent and form the head of coil 4) are not treated, so that they can be easily shaped in successive steps.

[0215] Once the predetermined carburizing temperature is reached (depending on the characteristics of the line 14 used), the pressing element 30 and possibly the vertical pressing element 302 maintain pressure for the time required for cooling, assisted by a cooling device (e.g., using air, not shown) in order to stabilize the linear sections 4a, 4b to their final dimensions.

[0216] In the example shown in the figure, the applied pressure is in the range of 140 bar to 300 bar, and the temperature reached by the heating element 31 is in the range of 170°C to 210°C. The duration of step B is from 15 seconds to 2 minutes.

[0217] Optionally, the pressing and / or carburizing apparatus 300 includes a loading slide 330 configured to bring the winding tool 20 with the coil 4 into the receiving seat 301 and place it on the fixed support 311. (As in...) Figure 17 As can be seen, the loading slider can slide along the horizontal track 331, and a platform that can move vertically and is suitable for raising the winding tool 20 is provided.

[0218] Advantageously, the pressing and / or carburizing step B conforms to the dimensions of the linear portions 4a and 4b of coil 4 and makes the dimensions of the linear portions 4a and 4b of coil 4 repeatable, and compacts them by maximizing the fill factor. Furthermore, the linear portions 4a and 4b thus treated are solidified together so that the arrangement of the wires 14 remains unchanged throughout the process; the wires 14 are arranged and maintained in an ordered, repeatable matrix configuration, and are not grouped in a random order, but rather maintain the ordered arrangement given during the initial winding.

[0219] In the described example, the linear portions 4a and 4b of coil 4 are first subjected to pressing and then carburizing. However, in general, the method can be implemented by performing pressing or carburizing alone; or by performing both in the order described; or by performing both in reverse order; or even by performing pressing and carburizing simultaneously.

[0220] After pressing and / or carburizing step B, once the coil 4 has cooled and thus solidified in the linear portions 4a, 4b, the coil itself is removed from the winding tool 20. The coupling device 241 is locked (pneumatically) by means of a sleeve and / or clamping element 242 for hooking onto the spindle 25.

[0221] The wire clamp elements 26, 261 are thus opened, for example by means of two external controls, to release the wires 14 entering and exiting the winding. At this time, the manipulator (not shown) of the removable wall 24' guiding the winding tool begins to move axially away from the anchor wall 23'. During the first step of this movement, the corner element 245, which slides on the corresponding guide 246, begins to move toward the center of the winding tool 20, thereby relieving the stress on the wires and allowing the coil 4 to be pulled out.

[0222] Therefore, the manipulator guiding the removable wall 24' continues to move axially away from the anchored wall 23', and the second manipulator, by means of the manipulator seat 249, drives and moves the removable walls 22 until they are pulled out from the anchored wall 23' (pulling them out from the pins 27, 231).

[0223] At this point, remove one or more coils 4 from the winding tool 20.

[0224] Figures 22a, 22b, and 22c show three different examples of loops that can be made using the described winding tool 20, wherein:

[0225] - In Figure 22a, each ring S1, S2 is formed by two layers: a first layer with five lines and a second layer with four lines;

[0226] -In Figure 22b, each ring S1', S2' is formed by two layers, and each layer has five lines;

[0227] - In Figure 22c, each ring S1”, S2” is formed by three layers: a first layer of five lines, a second layer of four lines, and a third layer of five lines.

[0228] These examples help to understand how to distinguish a star-shaped yoke stator manufactured according to the present invention from a star-shaped yoke stator manufactured according to known techniques by visually analyzing the arrangement and density of wires in sectors or slots.

[0229] It can be noted that circular lines tend to leave free space; to overcome this problem, alternative solutions depicted in Figures 23a, 23b, and 23c can be used.

[0230] According to this optional and advantageous solution for the fill factor, during the coil manufacturing step, and more precisely, during winding, complementary conductors 14' with smaller cross-sections are added to each loop S1, S2. These complementary conductors 14' occupy the space left by the tangential contact of the conductors 14 with larger cross-sections (i.e., the free space between the aforementioned conductors 14 with larger cross-sections). In this way, during the winding step, each loop S1, S2 will be formed by layers of wires with different cross-sections, which alternate with each other, and once wound, this allows for even larger fill factors to be achieved.

[0231] Figure 20 and Figure 21 A variation of the winding machine 200 and a second embodiment of the winding tool 20 are shown, which can be used as an alternative to the first embodiment. Instead of the separate wire guide tube 204 of FIG. 206, the wire guide device 206 is replaced by a wire guide device 150, which automatically allows for the management of the distance between the individual layers of the wire 14 entering through the controlled axis.

[0232] The wire guiding device 150 includes an axial guide 151, along which a plurality of wire guide tubes 152 slide in a controlled manner and independently of each other.

[0233] The axial guide 151 slides along the vertical guide 153, allowing the line guide tube 152 to move along at least two axes.

[0234] Each wire guide tube 152 is passed through a layer of wire 14 and actually guides a layer of wire 14.

[0235] During each winding step, the wire guide tubes 152 can move closer to each other until the layers of wire come into contact, or they can move further away from each other so that each layer of wire enters the winding independently and at a different time than the other layers.

[0236] This allows each layer to be deposited on the winding tool 20 independently of the others, preventing them from interfering with each other.

[0237] Whenever needed, the wire guide tubes 152 move closer to each other again to facilitate operations that require bringing all the wires 14 together.

[0238] Optionally, in this embodiment, the winding tool 20 rotates by a winding spindle 244', which is integrated with the motor assembly 157, which is fixed to a carriage 158 that can move along a track 159 (guide or track, etc.).

[0239] Considering Figures 20-21 The winding machine 200 and corresponding winding tool 20 shown herein, after the coil forming step A, the method provides a pressing and / or carburizing step B, as previously described and now referred to. Figures 24 to 29 B is described.

[0240] Figure 28A and Figure 28B The heating device 30' shown includes one or more heating elements 31, preferably by induction. These heating elements 31 are shaped and arranged to be inserted between, in contact with or adjacent to, the linear portions 4a and 4b of the coil. Because the linear portions 4a and 4b remain free, the operation can be performed while the coil 4 is still housed on the winding tool 20.

[0241] Therefore, these heating elements 31 have a longitudinal range that is substantially equal to the longitudinal range of the linear portions 4a, 4b to be heated.

[0242] It should be noted that in the depicted embodiment, the heating element 31 is formed substantially as a comb-shaped element parallel to each other.

[0243] In practice, heating element 31 is inserted between the linear portions 4a and 4b of the coil to heat them to the carburizing temperature, such as... Figure 28B As shown.

[0244] Therefore, there is time to remove the heating element 31 and insert the pressing device 300 at the location of the heating element 31, which presses the winding by utilizing the thermal inertia of the material.

[0245] exist Figure 29 In the illustrated embodiment, regarding the installation Figures 20 to 21 The winding tool 20 on the winding machine 200 shown includes a pressing device 300 comprising a plate 301 to which a series of inclined planes 303 adapted to contact the linear portions 4a, 4b to be pressed are coupled. The plate 301 is inserted into or mechanically coupled in any way to complementary plates 302' located on opposite sides of the linear portions 4a, 4b, which effectively function as support elements.

[0246] Plate 301 is pushed against complementary plate 302' by a thrust device (not shown). Inclined plane 303 is configured such that the movement of plate 301 toward complementary plate 302' causes the linear portions of coils 4a and 4b to be pressed together through direct mechanical interaction.

[0247] Therefore, by utilizing the force of the thrust device and the appropriately manufactured inclined plane 303, the linear portions 4a and 4b of the winding are compacted to the desired dimensions.

[0248] These carburizing and pressing operations can be performed alternately or simultaneously on both sides of the winding tool 20, depending on the cycle time required by the device during production.

[0249] Conveniently, only the linear portions 4a and 4b of coil 4 are pressed and / or subjected to heat treatment, while the nonlinear portions (i.e., the portions of coil 4 that connect the linear portions 4a and 4b, which are mainly bent and form the head of coil 4) are not treated, so that they can be easily shaped in successive steps.

[0250] After pressing and / or carburizing step B, when coil 4 has cooled and thus solidified in linear portions 4a, 4b, coil 4 or multiple coils 4 can be removed from winding tool 20 (any of those described herein).

[0251] Optionally, whenever a series of more coils 4 are manufactured on the same winding tool 20 in coil manufacturing step A, such that the linear portions 4a, 4b of coil 4 are spaced apart from the linear portions of subsequent coils 4 by a predetermined pitch distance, a step of correcting the pitch between the coils 4 is performed before accommodating the coils 4 in the stator slots. Pitch correction is achieved in the following manner:

[0252] - Take a series of coils 4 from the winding tool 20 and bring them to the pitch correction device (not shown), which is configured to correct the pitch distance between the linear portions 4a, 4b of the different coils 4.

[0253] - By means of, for example in Figure 37 and Figure 38 The clamps shown remove coil 4 from the pitch correction device, and are configured to maintain the pitch distance between the linear portions 4a and 4b of coil 4 after pitch correction has been achieved. These clamps insert coil 4 between the stator teeth of the star-shaped member.

[0254] Alternatively, during the pitch correction process, insulating paper can be introduced inside the coil 4 (preferably around the linear portions 4a, 4b) to protect the coil 4 itself from damage inside the stator slots.

[0255] By forming the coil 4 in step A described above, a coil 4 with straight portions 4a and 4b is obtained, and the cross-section of the coil 4 has a shape complementary to the shape of the stator slot 106 into which the coil 4 must be inserted. Therefore, the entire area of ​​the stator slot 106 can be fully utilized while keeping the conductors 14 and 14' ordered and maximizing the fill factor.

[0256] Figure 30 The diagram shows a schematic cross-section and plan view of an electric motor M based on known technology. The motor M includes a star-shaped yoke stator S' and a rotor R, which is rotatably and coaxially arranged on its axis of rotation and located inside the stator S'. The stator S' is of a two-component type, consisting of an outer cylindrical body 101', a yoke, and an inner body 100' referred to as a star-shaped element, the inner body 100' being composed of stacked metal laminations.

[0257] Figure 31The star-shaped member 100' is shown in perspective, extending from an inner cylindrical surface 102' defined by the pole shoes 103' of all stator teeth 104' and the stator teeth 104' themselves, which extend radially outward from the inner cylindrical surface 102'. The inner cylindrical surface 102' of the star-shaped member 100' is substantially continuous, except for small windows or openings 105', which are designed to reduce stator weight and minimize electromagnetic short-circuiting. Stator slots 106' for accommodating conductor coils are defined between the stator teeth 104', the inner cylindrical surface 102', and the yoke 101'.

[0258] To simplify the illustration, Figure 30 Only one stator slot is shown, containing the wire winding 107'. A conventional electric motor M (e.g., Figure 30 The electric motor shown is characterized by the disordered distribution of wires in its winding 107', or the possibility of improvement.

[0259] The object of this invention is to provide a method and apparatus for precisely maximizing the fill factor, which allows for the automated assembly of a stator having perfectly ordered coils 4, as referenced above. Figures 2-29 The obtained, and better occupy the stator slots with complementary shapes and orderly arrangement.

[0260] Figure 32 This is a perspective view of the star-shaped member 100 of the stator S1, S2 according to the present invention, which differs from the star-shaped member 100' of the stator S' of the prior art in that the stator teeth 104 point to the end 108 opposite to the pole shoe 103. In practice, the end 108 of the stator teeth 104 is pointed to stabilize its coupling with the yoke, as will be described below.

[0261] Another difference between star-shaped component 100 and star-shaped component 100' lies in the shape of the stator slots. A simple visual comparison highlights that the stator slots 106' of the stator S' according to the prior art are sliced, i.e., they are widened in the outer diameter direction, while the stator slots 106' of the stator S according to the invention are basically rectangular, thus having greater compatibility with the coil 4 in terms of shape.

[0262] Figure 33This is a cross-sectional view of the stator S1 according to a first embodiment of the invention: for simplicity, a separate winding consisting of the linear portions 4a or 4b of the coils 4 is shown. The star member 100 is forced into the yoke 101', in which sense, the connection between these elements is achieved by an interference fit. As will be explained below, after all the coils 4 are correctly positioned, the yoke 101' is fitted onto the star member 100 by an interference fit such that the tips 108 of the stator teeth 104 are inserted into corresponding longitudinal grooves 109 formed in the inner surface of the yoke 101'. The pointed shape of the stator teeth 104, together with the shape coupled to the corresponding grooves 109, ensures the mechanical seal of the stator S manufactured in the two parts 100, 101'.

[0263] Figure 34 This is a perspective view of the stator S1 with all windings completed, i.e., the stator slots 106 are all joined by the linear portions 4a or 4b of the coils 4. As can be observed, the inner surface 102 of the star-shaped member 100 is continuous except for the window or opening 105. In this configuration, the stator S1 is prepared to accommodate the rotor R to complete the motor.

[0264] It can be noted that the first embodiment of the stator S1 is provided with a yoke 101' integrally made of a mechanical cylinder.

[0265] Figure 35 This is a cross-sectional view of the stator S2 according to a second embodiment of the invention: for simplicity, a separate winding consisting of the straight portions 4a or 4b of the coil 4 is shown. The star member 100 is forced into the yoke 101”, in which sense, the connection between these elements is achieved by an interference fit. As described below, when the coil 4 is correctly inserted into the stator slot 106, the yoke 101” is configured to surround the star member 100 by fixing the sectors 110 of the yoke 101”, such that the tips 108 of the stator teeth 104 are inserted into corresponding longitudinal grooves 109 formed in the inner surface of each sector 110 of the yoke 101”. The pointed shape of the stator teeth 104, together with the shape coupled to the corresponding grooves 109, ensures the mechanical seal of the stator S manufactured in the two parts 100, 101”.

[0266] Figure 36 This is a perspective view of the stator S2 with all windings completed, i.e., the stator slots 106 are all joined by the linear portions 4a or 4b of the coils 4. As can be observed, the inner surface 102 of the star-shaped member 100 is continuous except for the window or opening 105. In this configuration, the stator S2 is prepared to accommodate the rotor R to complete the motor.

[0267] It can be noted that the second embodiment of stator S2 differs from the first embodiment S1 in that the yoke 101 is not integrally made, but is formed by assembling sector 110 on the outside of star-shaped member 100.

[0268] The methods and apparatus for manufacturing stators S1 and S2 will now be described.

[0269] First, refer to Figure 37 and Figure 38 The following will describe a clamping system for removing coils 4 of wires 14 from the winding machine 200 or from the pressing and / or carburizing device 300 and positioning them in the stator slots 106 of the star member 100.

[0270] Figure 37 A perspective view of a clamping system 400 is shown, which includes two clamps, namely an upper clamp 401 and a lower clamp 402, both of which are used to handle the coil 4. Figure 38 The system 400 is shown in cross-section (in different planes) and elevation view. The coil 4 is shown arranged in a vertical plane: the linear portion 4a is constrained by the upper clamp 401, and the linear portion 4b is constrained by the lower clamp 402.

[0271] Clamps 401 and 402 are provided with jaws 403 for constraining linear portions 4a and 4b, with the middle jaw mounted to float on pin 404, and the first and last jaws fixed to pin 404; pin 404 is connected to a pneumatic linear actuator 405, for example, operated using compressed air, such that pin 404 can be translated in two directions along a horizontal direction 406 that is transverse to the linear portions 4a and 4b of coil 4, to open and close the jaws 403 on the linear portions 4a and 4b of coil 4, respectively.

[0272] With this configuration, the clamps 401 and 402 maintain the pitch between the first linear portion 4a and the second linear portion 4b of the coil 4 taken from the winding tool.

[0273] The grippers 401 and 402 are also provided with a pop-out element 407, which is movable in two directions along a vertical direction 408 orthogonal to the horizontal direction 406, to pop out the linear portions 4a and 4b of the coil from the grippers 401 and 402 themselves. For this purpose, the pop-out element 407 is fixed to a plate 409, which is vertically movable in response to a thrust applied by an external actuator. The movement of the plate 409 is caused by… Figure 38 The visible pin 410 guides the movement of the pin within the hole 411.

[0274] The operation of the clamping system 400 is as follows:

[0275] - Whenever coil 4 must be removed, clamps 401 and 402 engage the linear portions 4a and 4b of coil 4, wherein the linear portions 4a and 4b are inserted between the jaws 403;

[0276] - Pneumatic actuator 405 is operated to clamp linear portions 4a and 4b;

[0277] - At this time, the clamp system 400 can move together with the coil 4, and the coil 4 remains integrated with the clamps 401 and 402 without the possibility of relative movement;

[0278] - Whenever it is necessary to pop out the linear portion 4a or linear portion 4b of coil 4, the jaws 403 of the upper clamp 401 or the lower clamp 402 open respectively, and the plate 409 is pushed down to make the pop-out element 407 insert between the jaws 403, thereby popping out the linear portion 4a or 4b.

[0279] The popping of linear portions 4a and 4b can occur and is expected to occur at different times: the upper gripper 401 and the lower gripper 402 are selectively operable.

[0280] The clamping system 400 just described can be used to manufacture embodiments S1 and S2 of the stator according to the invention.

[0281] Figure 39 This is a perspective view of a first apparatus 500 for manufacturing a stator S1 according to a first embodiment. The apparatus 500 includes a main shaft 501 mounted on a shaft 504 extending cantilevered from a support structure 502, thereby enabling rotation relative to the support structure 502 itself about a horizontal rotation axis 503, with respect to which a longitudinal, transverse, or radial direction is defined. The main shaft 501 is rotatable and is rotated by a motor housed in the support structure 502, which is not visible in the drawing.

[0282] The device 500 also includes a carriage 505, which is provided with a slider 507 and mounted on a coplanar track 506 parallel to the rotation axis 503 of the main shaft 501. With this configuration, the carriage 505 can move translationally on the track 506 and on the slider 507 between a first position and a second position.

[0283] - In the first position, near the support structure 502, the carriage 505 extends around the shaft 504 but does not obstruct the main shaft 501, as... Figure 39 As shown, and

[0284] - In the second position, as shown in other figures, carriage 505 extends around main shaft 501, but does not completely block shaft 504 and only partially blocks shaft 504.

[0285] The longitudinal displacement of the carriage 505 on the track 506 is achieved by a dedicated actuator (e.g., a linear or rack-and-pinion type actuator) mounted on the support structure 502 or directly on the carriage 505.

[0286] The carriage 505 has a longitudinal range considered along the axis of rotation 503, which is at least equal to the longitudinal range of the main shaft 501. The carriage 505 is hollow inside: it has an inner cylindrical surface 508 that is coaxial with the axis of rotation 503 and therefore with the shaft 504 and the main shaft 501.

[0287] The inner cylindrical surface 508 of the carriage 505 breaks at a longitudinal opening 509 (i.e., an opening parallel to the generatrix of the inner cylindrical surface 508). The longitudinal opening 509 gives the carriage 505 an almost horseshoe shape and allows the clamping system 400 to enter the interior of the carriage 505 from the outside. In particular, the longitudinal opening 509 provides the clamping system 400 with the possibility of interacting with the star member 100, provided that the star member 100 is mounted on the spindle 501 and the carriage 505 is in the second position, as will be described below.

[0288] The longitudinal opening 509 has a width measured circumferentially relative to the inner cylindrical surface 508 of the carriage 505, sufficient to allow the coil 4 to be inserted from the outside of the carriage 505, specifically the linear portions 4a and 4b of the coil 4, into the space enclosed by the inner cylindrical surface 508. In the example shown, since the coil 4 comprises three linear portions 4a and three linear portions 4b, the width of the longitudinal opening 509 is at least equal to the circumferential length of the three stator slots 106 of the star member 100. When only one linear portion is present, the width of the longitudinal opening 509 will be significantly smaller, at least equal to the circumferential length of a single stator slot 106 of the star member 100.

[0289] The device 500 also includes a closing device 510 configured to temporarily and upon command close the longitudinal opening 509. In the example shown, the closing device 510 is mounted on and moves with the carriage 505.

[0290] In the embodiment shown in the figure, the closing device 510 is a sliding or drawer-type device, which is provided with a panel 511, which is mounted on a track 512 by a slider 513 acting as an actuator. The tracks 512 are arranged parallel to each other and inclined relative to the axis of rotation 503, such that the panel 511 can move between a retracted position and a forward position, and always remain tangent to the inner cylindrical surface 508 of the carriage 505. Specifically:

[0291] -exist Figure 39 In the retracted position shown, panel 511 does not obstruct longitudinal opening 509, and longitudinal opening 509 can still be used normally for inserting linear portions 4a and 4b of coil 4 through clamp system 400.

[0292] - In the forward position shown in other figures, panel 511 blocks and closes the longitudinal opening 509, thereby preventing the linear portions 4a, 4b from dislodging from the interior of carriage 505 through the longitudinal opening 509.

[0293] As will be noted with reference to other figures, the longitudinal length of panel 511 (parallel to axis 503) corresponds to the longitudinal length of longitudinal opening 509 so as not to interfere with the head (non-linear portion) of coil 4.

[0294] Initially, such as Figure 40 As shown, the star-shaped component 100 of the stator S1 is mounted on the main shaft 501, such that the stator teeth 104 point radially outward, and the stator slots 106 are also arranged radially relative to the rotation axis 503. Figure 40 In the configuration shown, the carriage 505 is in the first position, and the closing device 510 holds the panel 511 in the retracted position, thereby keeping the longitudinal opening 509 open.

[0295] Figure 41 It shows relative to Figure 40 The configuration shown is a successive configuration over time. The carriage 505 is pushed to a second position on the track 506. The carriage 505 surrounds the spindle and the star member 100; more specifically, the star member 100 is held with minimal clearance between the outer surface of the spindle 501 and the inner cylindrical surface 508 of the carriage 505. The clearance is minimal, but sufficient to allow rotation of the spindle 501 and the star member 100 integral therewith without interfering with the inner cylindrical surface 508 of the carriage 505.

[0296] The spindle 501 rotates sufficiently to bring the stator slot 106 of the star-shaped component 100 to an angle at the longitudinal opening 509, and... Figure 41 In the position shown, the spindle 501 stops: the upward-facing stator slot 106 remains accessible to the gripper system 400, and this access is achieved precisely through the longitudinal opening 509.

[0297] The rotation of the spindle 501 is intermittent and is used to rotate the star-shaped member 100 by an angle corresponding to the angular distance between the two stator slots that must accommodate the linear portions 4a, 4b of the coil. At the end of the rotation, the spindle 501 stops and remains stationary until a new rotation is required. Thus, the rotation of the spindle 501 alternates with the insertion of the linear portions 4a, 4b of the coil 4.

[0298] Figure 42 It shows relative to Figure 41The configuration shown is a successive configuration over time. The gripper system 400 is displaced at the longitudinal opening 509. Specifically, the lower gripper 402 of the linear portion 4b of the constraint coil 4 is brought to or abuts against the boundary of the longitudinal opening 509. The other components of the device 500 remain stationary, just as the star-shaped member 100 remains stationary. In the example shown, the coil 4 includes three linear portions 4b (and three corresponding linear portions 4a), as... Figure 37 and Figure 38 The configuration shown.

[0299] Figure 43 It shows relative to Figure 42 The configuration shown is a successive configuration over time. The spindle 501 remains stationary together with the star-shaped member 100. The lower gripper 402 is relative to... Figure 42 The position shown remains stationary. The ejector element 407 of the lower gripper 402 passes through plate 409 ( Figure 38 The upper clamp 401 is lowered vertically to eject the three linear portions 4b of the coil 4 from the clamp 402 and insert them into the corresponding three stator slots 106 through the longitudinal opening 509. The height at which the upper clamp 401 is lowered corresponds to the stroke of the ejection element 407 of the lower clamp 402 to facilitate the radial displacement of the coil 4.

[0300] Figure 44 It shows relative to Figure 43 The configuration shown is a continuous configuration over time. The spindle 501 remains stationary together with the star-shaped member 100. The lower clamp 402 moves away from the carriage 505 by lateral movement relative to the receiving plane of the coil 4. Simultaneously or immediately after the lower clamp 402 moves away, the closing device 510 is operated, and the panel 511 is pushed and held in a corresponding forward position, in which the longitudinal opening 509 is kept closed by the panel 511, which serves as an external temporary closing element for the stator slot 106. With this arrangement, the linear portion 4b of the coil 4 cannot disengage from the corresponding stator slot 106.

[0301] Figure 45 It shows relative to Figure 44 The configuration shown is a successive configuration over time. The stator S1 being manufactured is of the distributed winding type. The spindle 501 rotates (counterclockwise when viewed in the diagram) by an angle corresponding to the phase of the stator S1, and the upper clamp 401 simultaneously lowers and reaches or abuts against the panel 511. The simultaneous rotational motion of the spindle 501 about the rotation axis 503 and the vertical translational motion of the first clamp 401 cause deformation of the coil 4.

[0302] The linear portion 4b is initially constrained in a corresponding stator slot 106 between the star member 100 and the panel 511. Due to the presence of the inner cylindrical surface 508 of the carriage 505 (which surrounds the star member 100 from the outside), the linear portion 4b is properly accommodated in the stator slot 106, thereby rotating integrally with the star member 100.

[0303] The lowering of the upper clamp 401 will bring the linear portion 4a, which is still constrained in the upper clamp 401, to the panel 511, and thus bring the linear portion over the longitudinal opening 509 aligned with the panel 511.

[0304] Figure 46 It shows relative to Figure 45 The configuration shown is a successive configuration over time. Panel 511 is retracted, i.e., brought to its retracted position so that the longitudinal opening 509 can be accessed by the upper clamp 401, which is further lowered to abut the boundary of the longitudinal opening 509. The linear portion 4a of coil 4 remains constrained by the upper clamp 401.

[0305] Figure 47 It shows relative to Figure 46 The configuration shown is a successive configuration over time. By lowering the plate 409 to operate the pop-out element 407 of the upper clamp 401, the linear portion 4a of the coil 4 is pushed into the corresponding stator slot 106, which becomes accessible due to the rearward movement of the panel 511 described in the previous paragraph.

[0306] Figure 48 It shows relative to Figure 47 The configuration shown is a successive configuration over time. When the clamp system 400 is removed from the device 500, the panel 511 is pushed to the forward position to close the longitudinal opening 509 again and prevent the linear portion 4a of the coil 4 from emerging from the stator slot 106. In this configuration, the coil 4 is fully inserted into the star member 100: the three linear portions 4b and three linear portions 4a are angularly offset upwards by an angle corresponding to a single electrical phase. The spindle 501 is stationary.

[0307] Figure 49 It shows relative to Figure 48 The configuration shown is a successive configuration over time. The gripper system 400 is brought to the panel 511, where the new coil 4 is locked in the grippers 401 and 402.

[0308] Figure 50 It shows relative to Figure 49The configuration shown is a successive configuration over time. The spindle 501 rotates by an angle corresponding to moving the stator slot 106 in the star member 100 to the longitudinal opening 509, which corresponds to the new electrical phase. The panel 511 remains stationary in the forward position, just as the clamping system 400 remains stationary.

[0309] Figure 51 It shows relative to Figure 50 The configuration shown is a successive configuration over time. Spindle 501 in... Figure 50 The previous configuration shown remains stationary. Panel 511 is brought to the retracted position, and longitudinal opening 509 is opened and accessible by lower clamp 402, thereby keeping the three stator slots 106 in the star structure 100 into which the linear portion 4b of the new coil 4 is inserted accessible.

[0310] Reference Figures 44-50 The described steps are repeated on the new coil 4, thereby arranging two coils 4 on the star-shaped piece 100.

[0311] Figure 52 The diagram shows the continuous configuration of the first and second coils 4 over time, and the third coil 4 is ready to be operated.

[0312] Figure 53 It shows relative to Figure 52 The configuration shown is a successive configuration over time. Three coils 4 are already housed on the star-shaped piece 100, and a fourth coil 4 is about to be moved.

[0313] Figure 54 It shows relative to Figure 53 The configuration shown is a successive configuration over time. Four coils 4 have already been housed on the star member 100, and a fifth coil 4 is about to be operated to insert the linear portions 4a and 4b into the stator slot 106.

[0314] Figure 55 It shows relative to Figure 54 The configuration shown is a successive configuration over time. Five coils 4 have already been housed on the star member 100, and a sixth coil 4 is about to be operated to insert the linear portions 4a and 4b into the stator slot 106.

[0315] Figure 56 It shows relative to Figure 55 The configuration shown is a successive configuration over time. Six coils 4 have already been housed on the star member 100, and a seventh coil 4 is about to be operated to insert the linear portions 4a and 4b into the stator slot 106.

[0316] Figure 57 It shows relative to Figure 56The configuration shown is a successive configuration over time. Eight coils 4 have already been housed on the star member 100, and a ninth coil 4 is about to be operated to insert the linear portions 4a and 4b into the stator slot 106.

[0317] Figures 58-61 The final steps of the method for manufacturing stator S1 are shown.

[0318] In particular, Figure 58 The device 500 shows the completed configuration of the windings on the star member 100. Nine coils 4 are constrained to the star member 100. The panel 511 is brought to a forward position for closing the longitudinal opening 509.

[0319] The integrally formed yoke 101' moves closer to the carriage 505. The yoke 101' is cylindrical: a longitudinal groove 109 is formed on its inner surface, into which the tip 108 of the stator tooth 104 of the star-shaped member 100 will be inserted.

[0320] yoke 101' in Figure 59 The slide 505 is shown as abutting against the main shaft 501. The yoke 101' is supported coaxially with the axis of rotation 503 of the main shaft 501 by a suitable means (not shown). In this step, the main shaft 501 remains stationary, just as the panel 511 remains stationary in the forward position. The yoke 101' and the star member 100 are angularly aligned in the sense that the tip 108 of the stator tooth 104 is aligned with the longitudinal groove 109 of the yoke 101'.

[0321] Figure 60 The diagram illustrates a continuous time sequence in which the carriage 505 moves backward, from a second position to a first position, where it remains stationary. In the first position, the carriage 505 does not obstruct the semi-finished product, which is composed of the completed-winding star member 100. Simultaneously with the carriage 505's movement on the track 506, the yoke 101' moves forward and follows the carriage 505 by fitting onto the semi-finished product, i.e., onto the wound star member 100. The yoke 101' is pressed into the star member 100; in this sense, the connection employs an interference fit.

[0322] Figure 61 The final step is shown: the stator S1 has been completed and pulled off the spindle 501. The panel 511 of the closing device 510 moves backward to release the longitudinal opening 509; the device 500 is now ready to begin a new work cycle to manufacture another stator S1.

[0323] The spindle 501 is preferably a variable geometry spindle, which can change its diameter, thereby enabling the star member 100 to be locked and also allowing the stator S1 to be pulled out.

[0324] In summary, the star-shaped component 100 is thus assembled onto the main shaft 501, and the carriage 505 is brought to a second position in which the carriage 505 surrounds the star-shaped component 100, but one or more stator slots 106 remain accessible. The closing device 510 is operable to close the accessible stator slots left by the carriage 505. According to the desired electrical layout, the insertion of the linear portions 4a, 4b of the coils 4 is achieved by synchronizing the movement of the clamping system 400 with the rotation of the main shaft 501 and the movement of the closing device 510. Once all the coils 4 are accommodated, the yoke 101' is assembled onto the star-shaped component 100, and the stator S1 is manufactured.

[0325] refer to Figures 62-91 The method and apparatus 600 for implementing the second embodiment of the stator S2 will now be described. The clamping system 400 is the same as the clamping system described above with reference to the first embodiment S1.

[0326] Figure 62 This is a perspective view of device 600, which includes a support structure 602 that cantileverly supports a main shaft 601 on a shaft 604. The shaft 604 and the main shaft 601 are rotatable about a rotation axis 603, the direction of which is defined as longitudinal, transverse, or radial relative to the rotation axis 603. Rotation is provided by an actuator (not shown) within the support structure 602. The function of rotating the main shaft 601 is to support the star-shaped member 100 during the insertion of the straight portions 4a and 4b of the coil 4 into the stator slot 106.

[0327] The device 600 also includes a sector 110 for operating the yoke 101” (in Figure 35 , Figure 36 , Figure 63 and Figure 75 The system 610 (shown in the figure) operates using multiple fork-shaped elements 611. Insert the spindle 601 ( Figure 66 All fork-shaped elements 611 in the corresponding radial seat 605 Figure 62 The image shows a temporary configuration preview, which will be explained in more detail below.

[0328] The device 600 also includes a system 700 consisting of grippers 701, which can move toward and away from the spindle 601 to constrain the sector 110 of the yoke 101” and allow unloading of the completed stator S2.

[0329] Figure 63This is a perspective view of a partial axisymmetric section of the device 600 and the main shaft 601, with the stator S2 already completed on the main shaft 601. This figure helps to understand the operation of the fork-shaped elements 611. For each sector 110 of the yoke 101', two fork-shaped elements 611 are provided at each of its axial ends. The radially outer end 611' of each fork-shaped element 611 has teeth that engage with the edge 110' of the corresponding sector 110 of the yoke 101'. Figure 65 Together, they form a notch for constraining sector 110 to the main shaft 601 during stator S2 assembly. The opposite ends of the fork-shaped elements 611 also have teeth 611", which are designed to engage corresponding teeth of levers 612 present on the main shaft 601. In fact, the main shaft 601 is provided with as many levers 612 as there are fork-shaped elements 611 to be engaged. The levers 612 extend radially from the hub of the main shaft 601 and are hinged to pins 613 arranged circumferentially along the main shaft 601. The levers 612 are subjected to the counterforce of springs 613': when engaged by the ends 611" of the fork-shaped elements 611, they initially move backward and then engage in a constrained position where the teeth 612' of the levers 612 engage the teeth 611" of the fork-shaped elements 611". To achieve the opposite effect, i.e., to disengage the fork-shaped element 611, simply apply a pushing force from the outside to the lever 612 along the rotation axis 603 to drive the lever 612 to rotate, which will disengage the teeth 611".

[0330] Element 611 is fork-shaped because whenever the linear portions 4a, 4b of coil 4 are inserted into stator slot 106, fork teeth 614 extend from opposite sides of the linear portions 4a, 4b of coil 4; in other words, fork-shaped element 611 straddles the linear portions 4a, 4b of coil 4 to engage lever 612 of main shaft 601.

[0331] Figure 64 This is a perspective view of a system 610 for operating sector 110 of yoke 101”, and Figure 65 These are longitudinal and elevation views of system 610 itself. Both views show the operating system 610 while simultaneously constraining sector 110 of yoke 101". In practice, operating system 610 includes a gripper 620 with two jaws 621 and 622 that can move closer to and further away from each other to constrain and release individual sectors 110 of yoke 101". The operation of jaws 621 and 622 can be electric or pneumatic.

[0332] As in Figure 64 and Figure 65As can be seen, each sector 110 of the yoke 101” is moved by the system 610 at this time, the fork element 611 is already in the connected state (i.e. pre-installed in place), the pre-installation in place causes the upper teeth 611' of the fork element 611 to engage the upper edge 110' of the sector 110 of the yoke 101”, and the fork teeth 614 of each fork element 611 extend downward in a cantilever manner, with its teeth 611” remaining exposed and accessible.

[0333] Initially, such as Figure 66 As shown, the star-shaped member 100 of the stator S2 moves closer to the main shaft 601 along the rotation axis 603, such that the stator teeth 104 point radially outward, and the stator slots 106 are arranged radially relative to the rotation axis 603. The main shaft 601 is stationary, and the radial seat 605 is visible thereon, with the fork-shaped element 611 precisely inserted radially into the radial seat 605. The clamping system 400 prepares the coil 4. The operating system 610 is also prepared and equipped with the sector 110 of the yoke 101” and two corresponding fork-shaped elements 611 pre-positioned on the sector 110.

[0334] Figure 67 It shows relative to Figure 66 The configuration shown is a successive configuration over time. The star-shaped element 100 is mounted on the spindle 601. It should be noted that the radial opening 605 remains at least partially uncovered, i.e., not blocked by the star-shaped element 100, so as to allow for the insertion of the fork-shaped element 611.

[0335] Figure 68 It shows relative to Figure 67 The configuration shown is a successive configuration over time. The gripper system 400 is held stationary beside the star member 100 by the spindle 601. The lower gripper 402 has been lowered to the height of the tip 108 of the stator teeth 104. Figure 32 ), which may come into contact with it. In this position, the linear portion 4b of coil 4 is ready to be inserted into the radially arranged stator slot 106.

[0336] Figure 69 It shows relative to Figure 68 The configuration shown is a continuous configuration over time. The lower gripper 402 is operated to push the linear portion 4b of the coil 4 into the corresponding stator slot 106 of the star-shaped member 100. Specifically, the vertically movable plate 409 is lowered, thereby lowering the ejector element 407. Simultaneously, the upper gripper 401 is lowered by a length corresponding to the stroke of the ejector element 407 to prevent deformation of the coil 4. The spindle 601 and the star-shaped member 100 remain stationary.

[0337] Figure 70 It shows relative to Figure 69The configuration shown is a continuous configuration over time. The spindle 601 and star-shaped member 100 remain stationary. The upper gripper 401 moves backward, still maintaining the same height, to make room for the operating system 610, which must move above the lower gripper 402. The displacement of the upper gripper causes the coil 4 to deform at its head (i.e., at the nonlinear portion 4c), while the linear portions 4b remain unchanged within the stator slots 106 into which they are inserted, and the linear portions 4a remain unchanged between the jaws of the upper gripper 401. The linear portions 4b of the coil 4 are prevented from dislodging from the stator slots 106 by temporarily closing the same lower gripper 402.

[0338] Figure 71 It shows relative to Figure 70 The configuration shown is a successive configuration over time. The spindle 601 and the star-shaped component 100 remain stationary. The upper gripper 401 is relative to a reference... Figure 70 The described retracted position remains stationary. The lower gripper 402 also retracts and moves outward through the coil 4, passing beneath the upper gripper 401. In this configuration, there is no risk that the linear portion 4b of the coil 4 might dislodge from the stator slot 106, because the coil 4 has already deformed at the nonlinear portion 4c and is not subjected to stress that could cause the linear portion 4b to return toward the linear portion 4a.

[0339] Figure 72 It shows relative to Figure 71 The configuration shown is a successive configuration over time. Spindle 601 and star-shaped component 100 remain stationary; grippers 401 and 402 are also relative to each other. Figure 71 The position shown remains stationary. At this time, the operating system 610 moves above the stator slot 106 of the linear portion 4b of the star-shaped component 100 that accommodates the coil 4.

[0340] Figure 73 It shows relative to Figure 72 The configuration shown is a successive configuration over time. The spindle 601 and star-shaped element 100 remain stationary. The operating system 610, previously aligned with the stator slots 106 into which the linear portion 4b of the coil 4 is inserted, is lowered until the sector 110 of the yoke 101" abuts against the tips 108 of the stator teeth 104 of those stator slots 106. Simultaneously, the fork-shaped element 611 is inserted into the radial seat 605 (…). Figures 62-65 This causes the lever 612 to engage. More specifically, the fork teeth 614 of the fork element 611 are inserted into the corresponding radial seats 605 present in the main shaft 601, and the lower teeth 611” engage with the teeth 612' of the lever 612 present on the main shaft 601. Figure 63 This causes lever 612 to swing around the corresponding pin 613.

[0341] Figure 74 It shows relative to Figure 73 The configuration shown is a successive configuration over time. The spindle 601 and the star member 100 remain stationary. The operating system 610, which was previously lowered until the sector 110 of the yoke 101” abutted against the tip 108 of the stator tooth 104 of the stator slot 106 that accommodates the linear portion 4b of the coil 4, remains stationary. The sector 110 of the yoke 101” is constrained to the spindle 601 by the fork element 611. The grippers 621 and 622 of the operating system 610 open to release the sector 110 of the yoke 101”, at which point the sector 110 of the yoke 101” is no longer constrained to the system 610, but is held hooked to the star member 100 by the fork element 611.

[0342] Figure 75 It shows relative to Figure 74 The configuration shown is a successive configuration over time. The spindle 601 and star member 100 remain stationary. The operating system 610, previously unconstrained by the sector 110 of the yoke 101", moves away from the gripper system 400 and the spindle 601. The upper gripper 401 of the gripper system 400 still holds the linear portion 4a of the coil 4, while the linear portion 4b is finally enclosed in the stator slot 106, which is now closed by the sector 110 of the yoke 101".

[0343] Figure 76 It shows relative to Figure 75 The configuration shown is a continuous configuration over time. The spindle 601 rotates (counterclockwise in the figure), thereby dragging the star member 100 by an angle corresponding to the electrical phase of the stator S2. Simultaneously, the upper clamp 401 is lowered to facilitate the deformation of the nonlinear portion 4c of the coil 4, and the operating system 610 acquires a new sector 110 of the yoke 101” via the corresponding pre-arranged fork elements 611. In particular, the upper clamp 401 reaches or abuts against the tip 108 of the stator tooth 104, preparing to release the linear portion 4a of the coil 4.

[0344] Therefore, the rotation of the spindle 601 is intermittent and alternates with the insertion motion of the clamp 401.

[0345] Figure 77 It shows relative to Figure 76 The configuration shown is a successive configuration over time. The spindle 601 and the star-shaped component 100 are relative to their previous positions ( Figure 76 The upper clamp 401 plate 409 is lowered, thereby lowering the pop-out element 407, and the linear portion 4a of the coil is inserted into the corresponding stator slot 106.

[0346] Figure 78 It shows relative to Figure 77The configuration shown is a successive configuration over time. The spindle 601 and the star-shaped component 100 are relative to their previous positions ( Figure 76 Remain still. Figure 76 The clamping system 400 moves away from the spindle 601, and the upper clamp 401 and lower clamp 402 open and are ready to take the new coil from the winding tool 20. The operating system 610 brings the new sector 110 of the yoke 101” above the stator slot 106 that accommodates the linear portion 4a of the coil 4.

[0347] Figure 79 It shows relative to Figure 78 The configuration shown is a successive configuration over time. The spindle 601 and the star-shaped component 100 are relative to their previous positions ( Figure 77 The system 610 keeps the new sector 110 of the yoke 101” resting on the stator slot 106 that accommodates the linear portion 4a of the coil 4, and pushes the fork element 611 to engage with the lever 612 of the spindle 601 to confine the sector 110 on the star element 100.

[0348] Figure 80 It shows relative to Figure 79 The configuration shown is a successive configuration over time. The spindle 601 and the star-shaped component 100 are relative to their previous positions ( Figure 79 Remain stationary. The operating system 610 releases the new sector 110 of the yoke 101” and moves away to take another sector 110 of the same yoke 101”. Now, the coil 4 is correctly inserted into the star member 100: the linear portions 4a and 4b are confined in the corresponding stator slots 106 by the two sectors 110 of the yoke 101” and by the four fork-shaped elements 611 of the corresponding levers 612.

[0349] Figure 81 It shows relative to Figure 80 The configuration shown is a successive configuration over time. The spindle 601 and the star member 100 rotate (counterclockwise) by an angle sufficient to provide the clamping system 400 with additional stator slots 106 to be filled by the linear portion 4b of the new coil 4, after which the spindle 601 and the star member 100 stop again and remain stationary.

[0350] At this point, repeat the steps described in the previous attached figures to complete the winding of the star-shaped piece 100.

[0351] Figure 82 It shows relative to Figure 81 The configuration shown is a successive configuration over time, in which two coils 4 are positioned on star 100 and the four sectors 110 of yoke 101” are anchored to spindle 601 by lever 612.

[0352] Figure 83It shows relative to Figure 82 The configuration shown is a successive configuration over time, in which three coils 4 are positioned on star 100 and the six sectors 110 of yoke 101” are anchored to spindle 601 by lever 612.

[0353] Figure 84 It shows relative to Figure 83 The configuration shown is a successive configuration over time, in which four coils 4 are positioned on star 100 and eight sectors 110 of yoke 101” are anchored to spindle 601 by lever 612.

[0354] The insertion of each new coil is performed according to the electrical layout, thus matching the assembly steps of stator S2; the angular deviation between the linear portions 4a and 4b of all coils is corrected electrically.

[0355] Figure 86 It shows relative to Figure 85 The configuration shown is a successive configuration over time, in which five coils 4 are positioned on star 100 and ten sectors 110 of yoke 101” are anchored to spindle 601.

[0356] Figure 87 The stator S2 with all windings completed is shown. The example in this figure uses eighteen sectors 110 with nine coils 4 and a yoke 101”, each coil having three linear sections 4a and three linear sections 4b. Clearly, each sector 110 has a 20° angle cut off at its center. All sectors 110 are anchored to the spindle 601 via fork-shaped elements 611, and the yoke 101” is now assembled. The stator S2 can now be pulled out of the spindle 601.

[0357] Figure 88 The removal process has begun. The spindle 601 and stator S2 are stationary. The gripper system 700 is operated such that the gripper 701 moves closer to grip the stator S2.

[0358] Figure 89 A gripper 701 closed on the yoke 101” of stator S2 is shown, with the main shaft 601 in a stationary state.

[0359] At this time, as Figure 90 As shown, the fork-shaped element 611, which had previously been confined to the spindle 601 by sector 110, is removed. This removal is achieved by applying a thrust in the axial direction to lever 612 via a suitable device (not shown) to counteract the force. Figure 63 The thrust of the spring 613' shown.

[0360] Figure 91The final step of pulling the stator S2 out of the spindle 601 is shown, at which point the spindle 60 is ready to start a new cycle to manufacture the new stator S2. The yoke 101” remains closed in the gripper 701 until the yoke 101” is wrapped by a suitable device (e.g., a metal strip); then the gripper 701 opens to release the stator S2.

[0361] Figure 92 This is a schematic diagram (a cross-sectional view of the stator) showing the layout of a star-shaped yoke stator wound according to known technology. Its structural layout is similar to... Figure 30 The stator structure of the electric motor M is shown in the figure. It can be noted that the windings 107' inserted into the stator slots 106' are not ordered: the wires 14 are arranged randomly. Figure 92 The table details the technical characteristics of the winding, such as: the diameter of conductor 14 is 9.9 mm, the number of parallel lines arranged, the number and area of ​​loops, the thickness of the insulating paper, and the area of ​​stator slot 106' is 117.340 mm². 2 .

[0362] This configuration (one of the most popular configurations currently) achieves a fill factor of approximately 39% (bare wire / groove).

[0363] Figure 93 It includes five possible layout views of the wound star-shaped yoke stator S1 according to the present invention (shown in cross-sectional views of the stator slots), and also includes a table of technical requirements for the windings of each layout.

[0364] and Figure 92 The construction differences of the known technologies shown are readily apparent: the method and apparatus according to the invention allow the formation of a winding 107 in which the conductors (dominant conductors) 14 and possibly smaller diameter conductors (complementary conductors) 14' are arranged in an orderly manner according to a desired layout and become immutable through the carburizing and pressing treatment of the coil 4 described earlier.

[0365] The table specifies the diameter and other parameters of conductors 14 and 14' for each of the five layouts. (Based on reference...) Figures 1-29 The description states that conductors 14 and 14' are pressed and carburized. A thickness of 0.2 mm is considered for the insulating paper positioned between winding 107 and stator slot 106.

[0366] By reading the last row at the bottom of the table, it can be noticed that for all layouts, the fill factor is always higher than 64%, and almost reaches 71% in the third winding layout, in which eight to seven wires 14 are provided for each layer, with a wire diameter of 0.9mm, for a total of eight loops, and two complementary wires 14' with a diameter of 0.45mm.

[0367] The example shown considers a rectangular stator slot 106. The dimensions of each stator slot 106 for different layouts are described.

[0368] Figure 94 This is a cross-sectional view of a hypothetical star-shaped yoke stator. Stator slot 106' (left side) is filled in a conventional manner compared to the same stator slot 106 (right side) filled using the method according to the invention. Slots 106' and 106 are identical and defined by the same star-shaped element and the same yoke. Although hypothetical, this image clearly shows the difference in the arrangement of conductor 14 between known schemes and the present invention, and clearly demonstrates that stators S1 and S2 manufactured according to the claimed method are practically identifiable and distinguishable from stators manufactured according to known technology. The area (cross-section) is equal to 117.34 mm². 2 The tank contains the following contents:

[0369] - In slot 106' on the left, there are eight loops of winding formed by nine parallel copper wires 14 with a diameter of 0.9 mm (the outer diameter of the resin-coated wire is 0.987 mm), with a total of seventy-two wires in each slot 106'. This configuration achieves a fill factor of approximately 39%.

[0370] - In slot 106 on the right, there are eight loops of winding formed by seven to eight parallel copper wires 14 with a diameter of 0.9 mm (the outer diameter of the resin-coated wire is 0.987 mm), with a total of one hundred and twenty wires in each slot 106. A fill factor of approximately 68.6% is achieved in this configuration.

[0371] In the left slot 106', the wires 14 are grouped, but in a disordered arrangement, not ordered; conversely, in the right slot 106, the wires 14 are grouped in an ordered arrangement, and this same arrangement is achieved and maintained in the linear portions 4a and 4b of the coil 4 used to manufacture the winding object of the present invention. The ordered arrangement of the wires 14 in the right slot 106 is equivalent to... Figure 93 The arrangement is visible in the diagram. The diameter of the conductor 14 is equal to the geometry of the stator slot. In the slot 106' on the left, the fill factor is approximately 39%, while in the slot 106' on the right, the fill factor is approximately 68.6%, which is significantly larger (greater than 20%).

[0372] This specification provides sufficient information to distinguish between a stator directly formed using the method of the present invention and a stator formed using known techniques. It is clear, in fact, that the fill factor is certainly larger, and particularly in the stators S1 and S2 according to the present invention, the arrangement of the conductors 14 in the slots 106 between the teeth 104 is ordered in a manner not found in the prior art. Specifically, by observation... Figures 93-94It can be noted that the conductors 14 are arranged in multiple loops, each loop consisting of a certain number of wires (6, 7, 8, etc.), and these conductors have an unchangeable ordered matrix layout. Therefore, stators S1 and S2 can be identified and distinguished from other known stators simply by observing the number and arrangement of the conductors in the slots between the stator teeth.

[0373] Figure 95 This is a graph showing the relationship between leakage current (vertical axis) in the stator winding and rotational speed (horizontal axis). The graph compares a motor made using a star-shaped yoke stator S' according to known technology and a motor made using a star-shaped yoke stator S1 according to the present invention (with other technical features being the same).

[0374] The comparisons were conducted under identical conditions: identical motor power / size, identical standard rotor, identical winding stack height, etc.

[0375] At 3400 rpm, considering the rated speed, a conventional motor is affected by a leakage current of 4270.205 W in the stator windings, while a motor with the stator S1 according to the invention is affected by a leakage current of 3016.136 W; this is a better value of about 29.7%.

[0376] At 10,000 revolutions per minute (RPM), considering the maximum speed (speed), a conventional motor is affected by a leakage current of 7155.682 W in the stator windings, while the motor with the stator S1 according to the invention is affected by a leakage current of 5716.293 W; this is a better value of about 20.1%.

[0377] Figure 96 This is a graph showing the relationship between the efficiency (vertical axis) and the rotational speed (horizontal axis) of an electric motor made with a star-shaped yoke stator according to known technology and an electric motor made with a star-shaped yoke stator according to the present invention, under the same conditions.

[0378] The comparisons were conducted under identical conditions: identical motor power / size, identical slot area, identical standard rotor, identical winding stack height, etc.

[0379] At 3250 rpm, taking into account the rated speed (speed), the conventional motor has an efficiency of 95.3%, while the motor with the stator S1 according to the invention has an efficiency of 96.4%; this is a better value of about 1.1%.

[0380] At 7000 rpm, a conventional motor has an efficiency of 94.2%, while the motor with the stator S1 according to the invention has an efficiency of 95.2%; this is a better value of about 1.1%.

[0381] At 10,000 revolutions per minute (RPM) (considering maximum speed), a conventional motor has an efficiency of 92.5%, while a motor with stator S1 has an efficiency of 93.9%; this is a better value of approximately 1.45%.

[0382] Figure 97 This is a graph showing the relationship between the output power (vertical axis) and the rotational speed (horizontal axis) of a motor made with a star-shaped yoke stator according to known technology and a motor made with a star-shaped yoke stator according to the present invention, under the same conditions.

[0383] The comparisons were conducted under identical conditions: identical motor power / size, identical slot area, identical standard rotor, identical winding stack height, etc.

[0384] It can be noted that, compared to motors using conventional winding insertion methods, the motor of the present invention, made with stator S1, can generate greater power. (Observation) Figure 97 As can be seen, the difference is already apparent at 1750 rpm, and becomes increasingly pronounced above 3400 rpm. The following comparison table provides a quantitative comparison:

[0385]

[0386] Therefore, ultimately, the apparatus and method according to the invention can manufacture stators, thereby enabling the manufacture of electric motors; given the dimensions and basic geometry, these motors significantly outperform those obtained using conventional winding techniques.

Claims

1. A method for manufacturing a dual-component stator (S1, S2), said dual-component stator having distributed windings, said dual-component stator being referred to as a star-yoke stator. The stator (S1, S2) includes: - The outer body (101', 101") is called the yoke, and - A main body (100), located inside the yoke (101', 101"), the main body (100) being referred to as a star-shaped component, the main body (100) having an inner cylindrical surface (102) and a plurality of radial stator teeth (104), the inner cylindrical surface (102) defining a receiving cavity for the rotor (R) of the motor, the plurality of radial stator teeth (104) extending from the cylindrical surface (102) toward the yoke (101', 101"), and stator slots (106) provided between the plurality of radial stator teeth (104), the stator slots (106) being used to receive windings (107) formed by conductors (14, 14'). The method includes: - Manufacture (A) a coil (4) formed by conductors (14, 14'), wherein one or more conductors (14, 14') are wound on a winding tool (20) to form at least one coil (4), the coil (4) including at least one linear portion (4a, 4b), the linear portion (4a, 4b) further including line segments of a plurality of individual conductors (14, 14'), and the linear portion being adapted to be inserted into one of the stator slots (106); - The star-shaped member (100) is supported (C) on the rotation axis (503, 603), wherein at least one first stator slot (106) is operable by the manipulator (400) of the coil (4); - The first linear portion (4b) of the coil (4) is inserted (D) into at least one first stator slot (106) by the manipulator (400), and the second linear portion (4a) of the coil (4) is constrained; - Rotate the star-shaped member (100) about the rotation axis (503, 603) by an angle (E), thereby deforming the coil (4) at the portion (4c) between the linear portions (4a, 4b) and making at least one second stator slot (106) available for operation by the manipulator (400); - The second linear portion (4a) of the coil (4) is inserted (F) into at least one second stator slot (106) by means of the manipulator (400); - Repeat steps (G) D, E and F until the winding of the star (100) is completed, thereby inserting the linear portions (4a, 4b) of the coil (4) into each stator slot (106); - Constrain the star-shaped member (100) (H) to the yoke (101', 101").

2. The method according to claim 1, wherein, During step E, the star-shaped member (100) rotates by an angle corresponding to the angle between the first stator slot (106) and the second stator slot (106), which may be adjacent or non-adjacent. During steps D and F, the star-shaped member (100) remains stationary, and steps E alternate with steps D and F.

3. The method according to claim 1 or 2, wherein, In step E, the star-shaped component (100) rotates about the rotation axis (503, 603) by an angle that corresponds to the electrical phase of the completed stator (S1, S2).

4. The method according to any one of the preceding claims, wherein, Includes a pressing and / or carburizing step (B) prior to step D, wherein the linear portions (4a, 4b) of the at least one coil (4) are subjected to pressing, hot carburizing, or pressing and hot carburizing in a desired order or simultaneously, in order to compact the respective conductor segment portions (14, 14').

5. The method according to claim 4, wherein, The pressing and / or carburizing step (B) includes the following steps: while the coil (4) is wound on the winding tool (20), pressing the linear portion (4a, 4b) of the coil (4) with one or more pressing elements (30), and heating the linear portion (4a, 4b) by one or more heating devices (31) integrated in or connected to the pressing element (30).

6. The method according to claim 4 or 5, wherein, In the pressing and / or carburizing step (B), the hot carburizing process is achieved by inserting one or more heating elements (31) between the linear portions (4a, 4b) of the coil, thereby heating the linear portions (4a, 4b) to a predetermined carburizing temperature while the coil (4) is wound on the winding tool (20).

7. The method according to any one of claims 4-6, wherein, In the pressing and / or carburizing step (B), while the coil (4) is wound on the winding tool (20), the linear portions (4a, 4b) are pressed by a pressing device (300) inserted between the linear portions (4a, 4b).

8. The method according to any one of the preceding claims, wherein, In the coil manufacturing step (A), a complementary wire (14') with a smaller cross-section relative to the wire (14) is added to one or more wires (14) such that the complementary wire (14') occupies the gap between the wires (14).

9. The method according to any one of the preceding claims further comprises the step of insulating the conductor (14), wherein, Electrical insulation layer: - It may be applied, at least to the linear portions (4a, 4b) of the coil (4), after an optional pressing and / or carburizing step (B), or -Applied between the stator teeth (104) before step D of the linear portion (4a, 4b) of the inserted coil (4).

10. The method according to any one of the preceding claims, wherein, In the coil manufacturing step (A), a series of multiple coils (4) are manufactured on the same winding tool (20) such that the linear portions (4a, 4b) of the coils (4) are spaced apart from the linear portions (4a, 4b) of the subsequent coils (4) by a predetermined pitch distance.

11. The method of claim 10, wherein: - Before step E and during insertion step D, the first linear portions (4b) of a series of coils (4) are simultaneously inserted into the corresponding stator slots (106) of the star-shaped member (100). After step E, the second linear portion (4a) of a series of coils (4) is simultaneously inserted into the corresponding stator slot (106) of the star member (100), so that the corresponding windings (117) are distributed in multiple stator slots (106).

12. The method according to any one of the preceding claims, wherein, Between steps D and E, and between steps F and G, the following are provided: In step (D', F'), the stator slot (106) in which the corresponding linear portions (4a, 4b) of the coil (4) are temporarily closed by a closing device (510) of the stator slot (106), the closing device (510) being movable between a retracted position and a forward position, in which the stator slot (106) is opened in the radial direction and can be approached and touched by the manipulator (400), and in the forward position, the stator slot (106) is closed in the radial direction and prevents the linear portions (4a, 4b) of the coil (4) from dislodging.

13. The method according to any one of the preceding claims, wherein, During the insertion step D, the first linear portion (4b) of each coil (4) remains coplanar with the second linear portion (4a) of the manipulator (400).

14. The method according to any one of the preceding claims, wherein, Steps C and G are performed by supporting the star-shaped member (100) within the spindle (501) and cylindrical surface (508) of the winding device (500); wherein the cylindrical surface (508) has a longitudinal opening (509) that provides a passage in the radial direction to the first stator slot (106) of the star-shaped member (100), thereby keeping only the stator slot (106) where the linear portions (4a, 4b) of the coils (4) need to be inserted from time to time accessible from the outside, while the rest of the star-shaped member (100) is confined between the spindle (501) and the cylindrical surface (508).

15. The method according to claim 14, wherein, Steps D and F are performed by rotating the star (100) to bring the stator slot (106) intended to accommodate the linear portions (4b, 4a) of the coil (4) to the longitudinal opening (509) and keeping the star stationary during the insertion of the linear portions (4b, 4a).

16. The method according to any one of the preceding claims, wherein, The yoke (101') is made as a single piece, and step H is performed by inserting a star-shaped piece (100) with windings (107) into the yoke (101').

17. The method according to any one of claims 1-11, wherein, The yoke (101”) is made into a set of sectors (110), and step H is performed by using an operating system (610) for sequentially operating the sectors (110) of the yoke (101”) between steps E and F and between steps F and G to constrain the sectors (110) of the yoke (101”) to the star member (100) at the stator slot (106) of the linear portion (4b, 4a) of the inserted coil (4), thereby closing the stator slot (106) from the outside.

18. The method according to claim 17, wherein, Step H is performed by temporarily constraining the sector (110) of the yoke (101”) to the star (110) and the spindle (601) supporting the star (110) by a removable fastening element (611), and holding the completed yoke (101”) together by a gripper system (700).

19. A dual-component stator (S1, S2), the dual-component stator being referred to as a star-shaped yoke stator, the dual-component stator being obtained directly using the method according to any one of the preceding claims.

20. An electric motor comprising a dual-component stator (S1, S2), the dual-component stator being referred to as a star-shaped yoke stator, the dual-component stator being obtained directly by the method according to any one of the preceding claims.

21. An apparatus (500, 600) for manufacturing star-shaped yoke stators (S1, S2), The stator (S1, S2) includes: - The outer body (101', 101") is called the yoke, and - A body (100), located inside the yoke (101', 101"), the body (100) being referred to as a star-shaped component, the body (100) having an inner cylindrical surface (102) and a plurality of radial stator teeth (104), the inner cylindrical surface (102) defining a receiving cavity for the rotor (R) of the motor, the plurality of radial stator teeth (104) extending from the cylindrical surface (102) toward the yoke (101', 101"), and stator slots (106) existing between the radial stator teeth (104), the stator slots (106) being for receiving windings (107) of conductors (14), The device (500, 600) includes: - At least one winding tool (20) configured to perform step A, wherein one or more wires (14, 14') are wound around the winding tool (20) to form a coil (4) comprising at least one linear portion (4a, 4b), the linear portion (4a, 4b) further comprising segment portions of a plurality of individual wires (14, 14'), and the linear portion (4a, 4b) is adapted to be inserted into one of the stator slots (106); - Spindles (501, 601), said spindles (501, 601) are rotatable about rotation axes (503, 603) and can be locked in multiple angular positions, said spindles (501, 601) are configured as follows: - Support the star-shaped member (100) such that at least one first stator slot (106) of the star-shaped member (100) can be approached and touched by the manipulator (400) of the coil (4), and - Rotate the star-shaped member (100) by an angle (E) corresponding to an angle that allows at least one second stator slot (106) to be approached and touched by the manipulator (400) of the coil (4), and may deform the coil (4) at a portion (4c) between the linear portions (4a, 4b) during step E. - A manipulator (400) for the coil (4), the manipulator (400) being configured to perform step D by inserting a first linear portion (4b) of the coil (4) into a corresponding stator slot (106) and constraining a second linear portion (4a) of the same coil (4), and to perform step F by inserting the second linear portion (4a) of the coil (4) into a corresponding stator slot (106). -The main shaft is capable of intermittent rotation, alternating with the operation of the manipulator (400) for inserting the linear portions (4a, 4b) of the coil (4).

22. The apparatus (500, 600) according to claim 21, wherein, The winding tool (20) includes a support frame (21) that supports a series of corner elements (23), wherein each corner element (23) in the series is arranged approximately along the edge of an ideal parallelepiped, and wherein each series of corner elements (23) is spaced apart from each other to define a corresponding series of winding chambers (24) to accommodate the wires (14) forming the coil (4).

23. The apparatus (500, 600) according to claim 21 or 22, comprising a wire guiding device (150), said wire guiding device (150) including an axial guide (151), wherein a plurality of wire guiding tubes (152) are slidable along said axial guide (151) in a controlled manner and independently of each other, wherein, Each wire guide tube (152) passes through and guides a layer formed by one or more wires (14, 14'), which is used to form a ring.

24. The apparatus (500, 600) according to any one of the preceding claims, comprising a pressing device (300) for pressing the linear portions (4a, 4b) of the coil (4), comprising a plate (301) having a series of inclined planes (303) adapted to contact the linear portions (4a, 4b) to be pressed.

25. The apparatus (500, 600) according to any one of the preceding claims includes a heating device (30') for performing hot carburizing treatment of the linear portions (4a, 4b) of the coil (4), comprising one or more heating elements (31), the heating elements (31) preferably being induction type, the heating elements (31) being shaped and arranged to be insertable between the linear portions (4a, 4b) of the coil (4).

26. The apparatus (500, 600) according to any one of the preceding claims, wherein, The manipulator (400) of the coil (4) includes a first clamp (401) or upper clamp and a second clamp (402) or lower clamp, wherein the lower clamp (402) is configured to remove a first linear portion (4b) of the coil (4) from the winding tool (20) to constrain the first linear portion (4b) and spring it into a first stator slot (106), and wherein the upper clamp (401) is configured to remove a second linear portion (4a) of the coil (4) from the winding tool (20) to constrain the second linear portion (4a) and spring it into a second stator slot (106).

27. The apparatus (500) as claimed in claim 26, wherein, The upper gripper (401) and the lower gripper (402) are movable relative to each other between the following positions: -Initially coplanar position, the coil (4) does not deform at the initial coplanar position, and - Multiple staggered positions, at which the clamps (401, 402) are in different planes and / or at different heights, to allow the linear portion (4b, 4a) of the coil (4) to be inserted into the stator slot (106) at different angular positions of the star (100) of the assembled stator (S1) each time.

28. The apparatus (500, 600) according to claim 26 or 27, wherein, The grippers (401, 402) are provided with a pop-out element (407) operable to pop out the linear portion (4a, 4b) of the coil (4) from the grippers (401, 402) so that the linear portion (4a, 4b) can be inserted into the stator slot (106).

29. The device (500) according to any one of the preceding claims, comprising a support structure (502) and a carriage (505), wherein the main shaft (501) is constrained to the support structure (502), and the carriage (505) is movable relative to the main shaft (501) and / or the support structure (502) between the following positions: - In the first position, the carriage (505) does not obstruct the main shaft (501), and the star-shaped member (100) supported on the main shaft (501) is not restricted by the carriage (505). - Second position, in which the carriage (505) extends around the main shaft (501) and surrounds the star-shaped member (100) supported on the main shaft (501).

30. The apparatus (500) according to claim 29, wherein, The carriage (505) has an inner cylindrical surface (508) that is complementary to the star-shaped member (100) supported on the main shaft (501) and opens outward at a longitudinal opening (509) through which the manipulator (400) of the coil (4) is inserted to accommodate the linear portions (4a, 4b) of the coil (4) in the corresponding stator slots (106) of the star-shaped member (100).

31. The apparatus (500) according to claim 30, further comprising a closing device (510) configured to temporarily and upon command close the longitudinal opening (509).

32. The apparatus (500) as claimed in claim 31, wherein, The closing device (510) is a sliding or drawer-type device mounted on the carriage (505) and is provided with a panel (511) that is movable between the following positions: - In the retracted position, the panel (511) does not obstruct the longitudinal opening (509), thereby allowing the manipulator (400) to be inserted through the longitudinal opening (509) into the stator slot (106) of the star-shaped member (100) supported on the main shaft (501), and - Forward position, in which the panel (511) blocks the longitudinal opening (509) to prevent the linear portions (4a, 4b) of the coil (4) from dislodging from the stator slot (106).

33. The apparatus (600) according to any one of claims 21-28, comprising a system (610) for operating a sector (110) of a yoke (101”), the system (610) being provided with at least one gripper (620) having jaws (621, 622) movable to grip / release the sector (110) of the yoke (101”), wherein, The clamp is movable to a position for releasing the sector (110), where the sector (110) is anchored to the star (100) and closes one or more stator slots (106) of linear portions (4a, 4b) provided with coils (4).

34. The apparatus (600) of claim 33, comprising one or more fastening elements (611) transportable by an operating system (610) with each sector (110) of the yoke (101”) and configured to constrain the sectors (110) of the yoke (101”) to the spindle (601) during stator (S2) assembly, the fastening elements (611) being removable after assembly.

35. The apparatus (600) according to claim 34, wherein, The fastening element (611) is forked, engaging the two longitudinal ends of the sector (110) of the yoke (101”), and is capable of being inserted into a corresponding recess (605) on the main shaft (601) to span the linear portion (4a, 4b) of the coil (4) inserted into the stator slot (106) of the star (100).

36. The apparatus (600) according to claim 35, wherein, The fork-shaped element (611) engages the sector (110) of the corresponding yoke (101”) and has at least one tooth (611”) that can be inserted into a recess (605) of the spindle (601), wherein the spindle (601) includes at least one lever (612), and the tooth (611”) snaps into the corresponding lever (612), and wherein the lever is movable to release the tooth (611”) and allow the corresponding fork-shaped element (611) to be released.

37. The apparatus (600) according to claim 36, wherein, The recesses (605) for inserting the fork-shaped elements (611) are arranged circumferentially on the spindle (601) at a pitch proportional to or corresponding to the pitch between the sectors (110) of the yoke (101”), and the spindle includes at least one lever (612) for each recess (605), the lever (612) oscillating about a pin (613) which is counteracted by a spring (613'), and is provided with teeth (612') for engaging the teeth (611”) of the corresponding fork-shaped elements (611).

38. The apparatus (600) according to claim 37, wherein, The main shaft (601) is cylindrical, the lever (612) is arranged radially on the main shaft (601), and the pin (613') is arranged tangentially, i.e. orthogonally to the corresponding lever (612).

Images