Apparatus for forming induction windings on salient poles of electric machine and associated operating method

Abstract

A device (1) for forming an induction winding (C) wound on salient poles (P) of an electric machine, comprising: at least one support group (2) for temporarily accommodating said ferromagnetic cores (R) of said electric machine in a configuration in which at least one radial salient pole (P) faces and approaches at least one assembly (3), said assembly (3) rotating relative to an axis (X) parallel to the radial direction of the respective salient pole (P); an assembly (3) provided with at least one wire feeder (4) of at least one conductor (W); and at least one structure (5, 6) for guiding and transporting the conductor (W), which structure can be at least partially inserted into the at least one groove (S) for surrounding the respective salient pole (P).

Description

Technical Field

[0001] This invention relates to an apparatus for forming an induction winding on the salient pole of an electric motor, particularly suitable for providing windings on the rotor of an electric motor (of any type, and therefore also suitable for automotive use) and / or a generator (especially a DC generator or AC generator). The invention also relates to a method for implementing the aforementioned induction winding. Background Technology

[0002] A salient pole is part of a ferromagnetic core, which typically protrudes in the radial direction and is composed of laminations (laminated to reduce eddy current losses).

[0003] The induction winding consists of one or more conductors (typically metal wires coated with a dielectric material) arranged to form multiple coils around a corresponding magnetic core (a salient pole in this example).

[0004] Automating the induction winding on the salient pole is particularly complex and requires a rotating assembly responsible for feeding the conductor wire: the rotating assembly is usually labeled by the term flyer.

[0005] However, this component does not allow for optimal distribution of conductor coils, which may overlap arbitrarily, thus affecting the proper functioning of the windings.

[0006] The use of conductor delivery structures designed to precisely define the position of each conductor coil laid out by a rotating assembly (flyer) is well-known.

[0007] Application number WO2021205279 (claiming priority to Italian Patent 102020000007288) in the name of the same applicant shows a device for implementing (or providing) this type of winding, which is provided with a particularly efficient transmission structure.

[0008] However, the structure described in the aforementioned patent documents has some key problems.

[0009] First, whenever the format of the salient poles on which the windings are to be implemented needs to be changed, the entire transmission structure must be replaced.

[0010] This means that production downtime needs to be provided for the time required for operators to perform the conveyor structure replacement operation each time the form is changed.

[0011] Secondly, a delivery structure needs to be designed for each type of salient pole form on which the windings are implemented: this leads to a significant increase in procurement costs, and requires a dedicated area for their storage when they are not in use (resulting in logistical problems and costs).

[0012] According to application number WO2021205279, the conveyor structure needs to be replaced each time the form is changed, which requires the presence of trained personnel for these activities, resulting in increased equipment-related costs attributable to the company. Summary of the Invention

[0013] The object of the present invention is to solve the above-mentioned problems by providing a device for forming an induction winding on a salient pole of an electric motor, wherein the device does not require replacement of the conveying structure when the form of the salient pole on which the winding is implemented changes.

[0014] Within the scope of this objective, the object of the present invention is to provide an apparatus for forming an induction winding on the salient pole of an electric motor at a lower operating cost than that anticipated with solutions employing existing technologies in the art.

[0015] Another object of the present invention is to provide an apparatus for forming an induction winding on the salient pole of an electric motor without requiring a storage area for replacement parts to ensure proper operation.

[0016] Another object of the present invention is to provide an apparatus for forming an induction winding on the salient pole of an electric motor, wherein the apparatus does not require supervision and intervention of a professional operator during form change operations.

[0017] Another object of the present invention is to design a method for forming an induction winding on the salient pole of an electric motor, which is applicable to operation on different types of rotors of electric motors with a wide range of variable dimensions.

[0018] Another object of the present invention is to design a method for forming an induction winding on the salient pole of an electric motor, which provides a short downtime during form change operations, which in any case is shorter than the downtime currently provided in the prior art.

[0019] Another object of the present invention is to provide an apparatus and method for forming an induction winding on the salient pole of an electric motor, which is low in cost, relatively simple to implement, and reliable in application.

[0020] This objective and these objectives are achieved by the apparatus for forming an induction winding on the salient pole of an electric motor as described in claim 1.

[0021] This objective and these objectives are also achieved by means of the method for forming an induction winding on the salient pole of the motor as described in claim 10. Attached Figure Description

[0022] Further features and advantages of the invention will become more apparent from the description of preferred, but not exclusive, embodiments of the apparatus and method for induction winding on the salient poles of an electric motor, shown by way of non-limiting example in the accompanying drawings, wherein:

[0023] Figure 1 This is a schematic isometric view of a possible embodiment of a device for forming an induction winding on a salient pole of an electric motor according to the present invention;

[0024] Figure 2 It is based on Figure 1 A schematic isometric view of the conveying structure of the equipment in the first configuration;

[0025] Figure 3 yes Figure 2 A schematic isometric view of the conveyor structure in the second configuration;

[0026] Figure 4 yes Figure 2 A schematic front view of the conveyor structure in the first configuration;

[0027] Figure 5 yes Figure 2 A schematic front view of the conveyor structure in the second configuration;

[0028] Figure 6 yes Figure 1 A schematic side view of a partial cross-section of the equipment;

[0029] Figure 7 yes Figure 1 A schematic front view of a partial cross-section of the device, wherein the conductor feeder is shown according to different assumed operating positions during its operation;

[0030] Figure 8 This is a schematic isometric view of another embodiment of the apparatus for forming an induction winding on the salient pole of an electric motor according to the present invention;

[0031] Figure 9 yes Figure 8 A schematic isometric view of the conveying structure of the equipment in the first configuration;

[0032] Figure 10 yes Figure 8 A schematic isometric view of the conveyor structure in the second configuration;

[0033] Figure 11 yes Figure 10 A schematic front view of the conveyor structure in the first configuration;

[0034] Figure 12 yes Figure 10 A schematic front view of the conveyor structure in the second configuration;

[0035] Figure 13 yes Figure 8 A schematic side view of a partial cross-section of the device;

[0036] Figure 14 yes Figure 8 A schematic front view of a partial cross-section of the device, wherein the conductor feeder is shown according to different assumed operating positions during its operation. Detailed Implementation

[0037] Referring to the accompanying drawings, the means for making the induction winding C is generally specified by reference numeral 1.

[0038] The induction winding consists of at least one conductor W wound around the salient pole P of the ferromagnetic core R of the motor; more precisely, the ferromagnetic core R may be, for example, the rotor R of a motor or generator.

[0039] In the following text, any ferromagnetic core on which the induction winding C will be formed will be represented by the reference letter R (therefore, this reference is not limited to the rotor of a rotating electric machine). The core R will have a longitudinal axis Y: if the core R is a rotor used to realize the rotation of the motor, then the axis Y will coincide with the axis of rotation of the rotor.

[0040] The salient poles P extend parallel to the axis of rotation Y of the magnetic core R (when the magnetic core R is a rotor type), protrude radially and are spaced apart from each other, forming a separating groove S between each adjacent salient pole P (the conductor W can pass through the groove so as to wind in such a way that a predefined coil is formed on the corresponding surface of the salient pole P).

[0041] The device 1 according to the invention includes a rotating assembly 3 equipped with (or provided with) a wire feeder 4, which is assigned for the controlled supply of at least one conductor W; the device 1 also includes: at least one support assembly 2 for temporarily supporting a ferromagnetic core R; and at least one guiding and conveying structure 5, 6 for guiding and conveying the at least one conductor W, the structure 5, 6 being sized (or size) to be at least partially insertable into at least one of a plurality of slots S surrounding a corresponding salient pole P.

[0042] Structures 5 and 6 can be advantageously mounted on support group 2: rotating component 3 can be conveniently rotated relative to support group 2 about (or around) the rotation axis X.

[0043] The guiding and conveying structures 5 and 6 will advantageously include a pair of longitudinal (preferably laminar) elements 7 and 8 and at least a pair of transverse elements 11 and 12, which are symmetrically opposite each other and inserted between the longitudinal elements 7 and 8. The guiding and conveying structures 5 and 6 will be configured to translate along a trajectory having at least one component dx parallel to the axis of rotation X of component 3 between a first configuration and a second configuration. In the first configuration, the pairs of longitudinal and transverse elements 7, 8 and 11, 12 are spaced apart from the slot S, and in the second configuration, they surround pole P (preferably by entering the slot S at least partially transverse to pole P) to guide and convey at least one conductor W provided by at least one wire feeder 4, determining (or generating) an orderly and regular arrangement (distribution, placement, subdivision) of the coil of conductor W on at least one corresponding pole P. Notably, preferably, a control device will be configured to translate structures 5 and 6 toward / away from pole P.

[0044] The lateral elements 11 and 12 constituting the aforementioned pair of lateral elements can be operated (or configured) to move along (or between) a direction dy (i.e., between reciprocating approach and removal positions) that is parallel to the axis Y of the ferromagnetic core R, thereby allowing adjustment of their distance so that the lateral elements 11 and 12 can be positioned (relative to each other) at a distance Pa close to the axial extension Pa of the (corresponding) pole P in the direction of the axis Y of the magnetic core R. The axial extension Pa corresponds to the height of the lamination group constituting the magnetic core R.

[0045] Furthermore, it is explained that a pair of transverse elements 11, 12 and guide and conveyor structures 5, 6 move by means of corresponding linear actuators 11a, 12e.

[0046] The corresponding linear actuators 11a and 12e can be selected from electromechanical actuators, hydraulic actuators, pneumatic actuators, and electromagnetic actuators. The linear actuators 11a and 12e are commanded by controllers 11a' and 12e' to adjust the relative distance between the transverse elements 11 and 12 in the longitudinal direction dy parallel to the rotation axis Y of the rotor R, thereby adapting to the axial extension Pa of the corresponding reference salient pole P.

[0047] Preferably, the linear actuators 11a and 12e are associated with the corresponding motors assigned to them for activation.

[0048] Advantageously, the actuation devices for the moving guide structures 5, 6 and the linear actuators 11a, 12e will be controlled by a control and command unit, which will allow for the automatic operation of device 1. It is noted here that the control and command unit is of the type such as a programmable automation machine (computer) or a programmable logic controller (PLC).

[0049] Specifically, in one possible embodiment of the invention, the control unit will be able to command the linear actuators 11a, 12e to adapt to the dimensions of the axial extension Pa of the salient pole P, so that the lateral elements 11, 12 are arranged relative to each other at a distance close to the footprint of the axial extension of the salient pole P. Similarly, the control unit will also command the assigned manipulation device to move toward / away from the salient pole P according to predefined logic based on the product to be implemented (the winding C on pole P).

[0050] The transverse elements 11, 12 include surfaces 13, 14 which are opposite to those facing the salient pole P and are arranged parallel to the longitudinal thickness P1 of the pole P. The opposite surfaces 13, 14 are configured to engage with the longitudinal elements 7, 8 to form an outer profile which is assigned and configured to guide and deliver at least one conductor W provided by at least one wire feeder 4.

[0051] Furthermore, the element 8 is configured to translate according to a trajectory by means of at least one corresponding control device, the trajectory having a motion component in the direction dz, which is transverse to the mutual approaching / separated rotation axes X near the respective end edges 10 of the salient pole P, so as to adjust their positions (and thus indirectly adjust their distance) as a function of the longitudinal thickness Pl of the salient pole P.

[0052] It is important to point out that the X-axis and Y-axis are perpendicular to each other and lie in the same plane: relative to this plane, an additional Z-axis orthogonal to the plane in which the X-axis and Y-axis are arranged can be identified, which will be useful in the following text for defining the movement of device 1 and its components.

[0053] As mentioned earlier, in order to correctly identify device 1 and its spatial geometry, a Cartesian coordinate system has been introduced, consisting of the X-axis (rotation of component 3), the Y-axis (core R), and the Z-axis (perpendicular to the plane containing the X-axis and Y-axis). Thus, for these three axes, directions dx (displacement or movement direction along the X-axis), dy (displacement or movement direction along the Y-axis), and dz (displacement or movement direction along the Z-axis) are defined.

[0054] At least one corresponding manipulator for moving the longitudinal element 8 is configured for translating each element 8 between a first configuration and a second configuration. In the first configuration, the element 8 is not inserted laterally into the slot S of a particular pole P, not even partially, and the end edges 10 are at maximum mutual distance. In the second configuration, the element 8 is inserted laterally into the slot S of the pole P, wherein the corresponding end edge 10 faces and is close to the ferromagnetic core R near the portion of the pole P closest to the Y-axis. In this second configuration, the elements 8 are at minimum distance from each other, and their respective end edges 10 face and are close to the surface of the salient pole P of the coil to accommodate the conductor W.

[0055] In practice, in order to arrange / distribute the coils of conductor W in an orderly manner on the salient pole P, each element 8 needs to be able to translate (advance / retreat along the X-axis direction dx toward the Y-axis): in this way, their end edges 10 will gradually align with the portions of pole P that are at different radial distances from the Y-axis, thereby allowing conductor W to be arranged on the desired radially extended portion, thus preventing the possibility that new coils may randomly overlap with previous coils (all coils will be arranged according to the desired structural distribution, using element 8 for guiding and positioning each coil).

[0056] In addition, it should be noted that each horizontal element 12 is composed of a corresponding pair of blocks 12a, 12b.

[0057] Each block 12a, 12b will be effectively coupled to a corresponding element 8 as part of a pair of longitudinal elements 8, and will protrude from the corresponding element 8 in a cantilever manner.

[0058] In detail, the blocks 12a and 12b of a pair of blocks 12a and 12b can be advantageously configured to be arranged such that they are at least partially superimposed to form a guiding and conveying support for at least one conductor W provided by at least one wire feeder 4, so as to surround the pole P with the conductor W, which provides the induction winding C.

[0059] Therefore, the longitudinal element 8 and the blocks 12a and 12b can be conveniently actuated synchronously with each other so that the blocks 12a and 12b translate at the same degree (the translation can optionally be automated by employing a control and command unit, which will be responsible for: actuating the control device according to the motion components arranged in the directions dx and dz so that each element 8 moves toward and away from the ferromagnetic core R; and actuating the linear actuator 12e, which is responsible for the axial movement of the blocks 12a and 12b in the axial direction dy).

[0060] However, it cannot be ruled out that these movements may be asynchronous depending on the specific implementation requirements.

[0061] Therefore, it has been shown that the guiding and conveying structures 5, 6 include a pair of transverse sheet elements 9, 10 associated with actuation devices configured to translate along a trajectory having at least one radial component parallel to the respective salient pole P, to approach and / or be spaced apart relative to pole P between a first configuration and a second configuration. In the first configuration, the elements 7, 8 are completely external in the radial direction relative to the spatial occupancy profile of the ferromagnetic core R including pole P, and in the second configuration, they define the respective pole P, with their end edges 9, 10 facing and close to the ferromagnetic core R near the base of pole P.

[0062] Structures 5 and 6 also include at least one pair of symmetrical and opposite transverse elements 11 and 12, which are inserted between elements 7 and 8 and coupled to the same elements 7 and 8.

[0063] The transverse elements 11 and 12 can move in the same direction, adjusting their positions by moving closer to each other and / or spaced apart (thus indirectly adjusting their distance).

[0064] At least one salient pole P on which the induction winding C is to be implemented (or formed) can be advantageously housed in a cavity defined by elements 7, 8 and by corresponding transverse elements 11, 12, which will be arranged at a mutual distance greater than and close to the length of the corresponding pole of interest P.

[0065] The outlines of elements 7 and 8 and surfaces 13 and 14 opposite to the surfaces of the transverse elements 11 and 12 facing the salient pole P are advantageously configured to guide and transport at least one conductor W provided by at least one wire feeder 4, thereby resulting in the coils of conductor W being arranged in an orderly and regular manner on at least one corresponding pole P.

[0066] Referring to an embodiment that is undoubtedly of practical significance, it is illustrated herein that at least one linear actuator (configured to command the automatic approach and / or automatic separation of the lateral elements 11, 12) may be advantageously inserted between elements 7, 8 and the corresponding lateral elements 11 and 12.

[0067] The actuation device for actuating element 8 is configured to translate element 8 according to a trajectory having motion components in directions of approaching / separating each other, so as to adjust their positions (and thus indirectly adjust their distance) as a function of the width of the respective salient poles P.

[0068] The distance between each element 8 should be greater than and close to the width of the corresponding pole P, so as to surround it with a predefined mechanical clearance.

[0069] At least one component selected between the actuators assigned to the movement of structures 5 and 6 (approaching and separating from the base of the salient pole P) and the actuators assigned to the movement of elements 7 and 8 (approaching and separating from each other) may be usefully of a type selected from hydraulic cylinders, pneumatic cylinders, screw and nut assemblies, rack and pinion assemblies, electric belts or chains, linear motors, pushrod cranks, cam pushrods, and combinations thereof.

[0070] The actuator of element 8 is configured to translate element 8 according to a trajectory defined between a first configuration and a second configuration. In the first configuration, the spatial occupancy profile of element 8 relative to the ferromagnetic core R including magnetic pole P is completely external in the radial direction and they are at maximum distance from each other. In the second configuration, they surround the respective magnetic pole P and their end edges 10 face and approach the ferromagnetic core R near the base of magnetic pole P and are at minimum distance from each other. In this second configuration, the respective end edges 10 of element 8 face and approach the surface extending in the radial direction of magnetic pole P, which is used to accommodate the coil of conductor W.

[0071] Referring to the embodiment described above, each lateral element 12 is defined to be effectively composed of a pair of blocks 12a, 12b, each block being provided with corresponding protruding attachments 12c, 12d.

[0072] Each block 12a, 12b is coupled to the corresponding longitudinal element 8, and optionally a corresponding actuator is inserted in the middle.

[0073] In the installation configuration, the protruding attachments 12c, 12d will be efficiently at least partially overlapped to form a continuous surface configured to guide and deliver at least one conductor W provided by at least one wire feeder 4, regardless of the mutual distance between the elements 8.

[0074] Advantageously, at least one corresponding linear actuator can be inserted between each element 8 and the blocks 12a, 12b coupled thereto. The linear actuator is configured to command the blocks 12a, 12b to automatically approach and / or automatically space from each other, adjusting their distance such that it is greater than and close to the length of the corresponding salient pole P (to ensure that the structure 6 can surround the salient pole P with a predefined mechanical clearance).

[0075] Furthermore, it is worth noting that the actuators inserted between each element 8 and the blocks 12a, 12b are synchronized to ensure that the blocks 12a, 12b of the same width translate simultaneously, maintaining the continuity of a continuous surface formed by at least partially overlapping protruding attachments 12c, 12d of the blocks 12a, 12b, configured to guide and transport at least one conductor W.

[0076] The present invention also relates to a method for forming an induction winding C wound on a salient pole P of a ferromagnetic core R of an electric motor, wherein the salient pole P extends parallel to the Y-axis, which, in the case of a rotating electric motor, corresponds to the axis of rotation of the magnetic core R.

[0077] This method consists of a series of consecutive steps.

[0078] During the first step I (i.e., in the following configuration, where), the ferromagnetic core R of the motor needs to be arranged such that at least one radial salient pole P faces (and is close to) at least one rotating assembly 3 for distributing conductor W. Here, such assembly 3 will be rotatable about its own axis of rotation X.

[0079] The subsequent step II provides the insertion of corresponding guiding and transporting structures 5, 6 for conductor W between at least one pole P and the corresponding rotating component 3 (i.e., configured to form guiding and transporting structures).

[0080] Step III provides the dimensions of the seat for adjusting the guiding and conveying structures 5 and 6, which is designed to temporarily accommodate at least a portion of the salient pole P.

[0081] The bases of structures 5 and 6 must actually have a size slightly larger than the space occupied by the salient pole P in order to accommodate it with a predetermined width of mechanical clearance. In practice, step III requires guiding and conveying structures 5 and 6 to surround the salient pole P.

[0082] Step IV defines that after one end of conductor W is secured to a surface on which at least one salient pole P is formed to which winding C is implemented, conductor W is conveyed (or delivered) via at least one rotating wire feeding assembly 3 such that, during rotation of assembly 3, the wire W abuts against at least one surface of guide and conveying structures 5, 6 before being arranged as a coil on the corresponding surface of pole P. In practice, step IV requires that at least one conductor W be conveyed by means of wire feeder 4 during rotation of rotating assembly 3 to allow the conductor W to slide on guide and conveying structures 5, 6.

[0083] Then it must continue—during the fifth step V, the guiding and conveying structures 5, 6 are translated in a direction dx parallel to the X-axis of assembly 3, specifically by aligning the corresponding end edges 9, 10 with the areas where each coil of conductor C, gradually provided by rotating assembly 3, is to be laid out. In practice, the fifth step V requires translating the guiding and conveying structures 5, 6 along the direction dx to obtain an ordered and regular coil of conductor W wound around the surrounding salient pole P.

[0084] The method according to the invention specifically provides a third adjustment step III to truly adjust the mutual distance between a pair of transverse elements 11, 12 of structures 5, 6.

[0085] Lateral elements 11 and 12 are inserted between a pair of longitudinal elements 7 and 8; the mutual distance between the lateral elements 11 and 12 is conveniently adjusted along the direction dy, parallel to the rotation axis Y of the ferromagnetic core R, to accommodate the axial extension Pa of the salient pole P. The adjustment step requires the translation of the pair of lateral elements 11 and 12 along the longitudinal direction dy, parallel to the rotation axis Y of the rotor R, by means of corresponding linear actuators 11a and 12e. Each linear actuator 11a and 12e is controlled by a corresponding controller 11a' and 12e' associated with it.

[0086] It should be noted that the guiding and conveying structure 6 may advantageously include a pair of facing longitudinal (preferably sheet-like) elements 8 and a pair of transverse elements 12, the transverse elements 12 being inserted between the longitudinal elements 8 and arranged symmetrically between the centerline of each of the elements 8 and their end edges 16.

[0087] In this case, the third adjustment step III will provide translation of the longitudinal elements 8 in the direction of mutual approach / separation, so as to adjust the width of the base of the guide and conveyor structure 6 as a function of the width of the longitudinal thickness Pl of the salient pole P on which the structure 6 will operate.

[0088] Each of the pair of transverse elements 12 will sequentially include a pair of corresponding blocks 12a, 12b, each of which will be coupled to a corresponding element 8 in the pair of longitudinal elements 8 and extend from it in a cantilever manner. In this case, the third step III for adjustment will also include adjusting the mutual distance between the pair of blocks 12a, 12b in a direction dz perpendicular to the mutual approach / separation direction dy of the transverse elements 12.

[0089] Two possible embodiments are illustrated with the aid of the accompanying drawings.

[0090] In the appendix Figures 1 to 7 The first embodiment shown by way of non-limiting example is particularly suitable for forming an induction winding C on the salient pole P of a rotor R (or other similar ferromagnetic core) when the number of poles is less than or equal to 4.

[0091] In this case, structure 5 will be provided with a pair of sheet-like elements 7 placed at a fixed distance from each other and parallel to each other, so as to accommodate a salient pole P with a width smaller than the distance between the elements 7.

[0092] However, the possibility of using an embodiment in which the sheet elements 7 can be arranged at an adjustable distance from each other cannot be ruled out: in this case, it would be necessary to provide transverse elements 11 of the extendable / retractable type to completely occupy the space between the sheet elements 7 so that the base formed by the structure 5 is always closed and complete.

[0093] In any case, the two transverse elements 11 will be able to slide along the sheet element 7, adjusting their relative distance (while maintaining mirror symmetry with respect to the transverse centerline of each sheet element 7).

[0094] By adjusting the position of the transverse element 11, the length of the base defined by the structure 5 can be changed to best accommodate the size of the salient pole P on which it will be operated, thereby facilitating the provision of a regular and orderly induction winding C.

[0095] The position of each lateral element 11 can be adjusted by manual or automatic actuators, but the latter is the primary option.

[0096] The edges 9 of each sheet element 7 and the surface 13 opposite to the convex pole P surface of the transverse element 11 are advantageously configured to guide and transport at least one conductor W provided by at least one wire feeder 4, resulting in the orderly and regular deposition of coils of conductor W on at least one corresponding pole P.

[0097] In the appendix Figures 8 to 14 The second embodiment shown by way of non-limiting example is particularly suitable for providing an induction winding C on a salient pole P of a rotor R (or other similar ferromagnetic core) with a number of poles greater than 4.

[0098] In this case, structure 6 will provide a pair of sheet elements 8 placed in an adjustable manner, smoothly mounted in a slot S surrounding the corresponding salient pole P so as to accommodate the salient pole P.

[0099] The two lateral elements 12 will be able to slide along the sheet element 8, adjusting their relative distance (while maintaining mirror symmetry with respect to the lateral centerline of each sheet element 8).

[0100] Each lateral element 12 will consist of a pair of mutually facing blocks 12a and 12b (each of which will be able to slide along the corresponding sheet element 8).

[0101] Each block will be provided with protruding attachments 12c, 12d: the protruding attachments 12c and 12d of the opposite blocks 12a and 12b are adjacent and staggered, such that the same protruding attachments 12c, 12d ensure the continuity of the surfaces 14 of the respective transverse elements 12 (formed by them) at any distance between the respective sheet elements 8 (within the intended design operating interval to change the width of the base of structure 6). The continuity of surface 14 will be crucial because the conductor W is actually partially guided by surface 14 during its arrangement in the form of a coil on the corresponding surface of the salient pole P.

[0102] By adjusting the spacing between the transverse elements 12, the length of the base defined by the structure 6 can be changed to best accommodate the size of the salient pole P on which it must operate, thereby facilitating the provision of a regular and orderly induction winding C.

[0103] The position of the lateral element 12 can be adjusted by means of a manual or automatic actuator, but the latter is the primary option.

[0104] The edge 10 of the longitudinal element 8 and the surface 14 (formed by the corresponding edges of attachments 12c and 12d) opposite to the surface of the transverse element 12 facing the salient pole P will be advantageously configured to guide and deliver at least one conductor W provided by at least one wire feeder 4, resulting in the orderly and regular deposition of coils of conductor W on at least one corresponding pole P.

[0105] Advantageously, the present invention solves the above-mentioned problems by providing a device 1 for forming an induction winding C on a salient pole P of a motor. This device does not require replacement of the conveying structures 5 and 6 when the form of the salient pole P on which the winding is to be implemented changes, because the structures 5 and 6 define a base whose width can be adjusted according to specific usage requirements.

[0106] Conveniently, the device 1 according to the invention ensures lower operating costs than would be expected by employing solutions based on the prior art.

[0107] Advantageously, the device 1 according to the invention does not require a storage area for replacing parts to ensure proper operation services.

[0108] Advantageously, the device 1 according to the invention does not require the supervision and intervention of a skilled operator during form-changing operations.

[0109] Usefully, the method of forming an induction winding C on the salient pole P of a motor is applicable to operation on different types of rotors R of motors whose dimensions can vary over a wide range.

[0110] Positively, method 1 according to the invention provides for shorter downtime at the plant where the method is installed during form change operations, in any case, the downtime is shorter than that currently provided in the art.

[0111] Effectively, the device 1 and method according to the invention are relatively simple to provide in practice and low in cost: these features make the device 1 and method according to the invention a guaranteed innovation.

[0112] The present invention, thus conceived, is readily subject to numerous modifications and variations, all of which are within the scope of the inventive concept; all details may also be replaced with other technically equivalent elements.

[0113] In the exemplary embodiments shown, the features given in relation to a particular example may actually be interchanged with other different features present in other embodiments.

[0114] In practice, depending on the requirements and existing technology, the materials and dimensions used can be any material.

[0115] The disclosure of Italian patent application No. 102023000020895, which claims priority to this application, is incorporated herein by reference.

[0116] If any technical feature mentioned in a claim is followed by a reference numeral, the sole purpose of including such reference numerals is to improve the comprehensibility of the claim, and therefore such reference numerals do not limit the interpretation of each element identified by example of these reference numerals.

Claims

1. An apparatus for forming an induction winding (C) for a motor having salient poles, wherein, At least one conductor (W) is wound around a salient pole (P(W)) of a ferromagnetic core (R) of the motor, wherein the salient poles (P) extend parallel to the axis of rotation (Y) of the core (R), project radially, and are spaced apart from each other, defining slots (S) between successive salient poles (P). The device includes a rotating assembly (3) equipped with a wire feeder (4) for at least one conductor (W), a support assembly (2) for temporarily supporting the ferromagnetic core (R), and at least one guiding and conveying structure (5; 6) for the at least one conductor (W), the structure (5; 6) being sized to be at least partially insertable into one of the slots (S) around the corresponding salient pole (P), and being mounted on the support assembly (2), wherein the rotating assembly (3) is rotatable relative to the support assembly (2) about the axis of rotation (X), wherein the guiding and conveying structure (5; 6) is rotatable relative to the support assembly (2) about the axis of rotation (X), wherein the guiding and conveying structure (5; 6) is rotatable relative to the support assembly (2) about the axis of rotation (X). The feeding structure (5; 6) includes a pair of longitudinal elements (7; 8) and at least a pair of transverse elements (11; 12), which are inserted between the longitudinal elements (7; 8) and face each other. The guiding and conveying structure (5; 6) is configured to translate along a trajectory having at least one component (dx) of the axis of rotation (X) parallel to the rotating assembly (3) and is movable between a first configuration and a second configuration. In the first configuration, the pair of longitudinal (7; 8) and transverse (11; 12) elements are away from the ferromagnetic core (R), while in the second configuration, they are around one of the salient poles (P) to guide and convey the at least one conductor (W) supplied by the at least one wire feeder (4) to obtain an ordered and regular conductor (W) coil wound around the surrounding salient pole (P). The characteristic feature is that the transverse elements (11; 12) of the pair of transverse elements (11; 12) are configured to move between reciprocating approach and removal positions in the longitudinal direction (dy) of the rotation axis (Y) parallel to the ferromagnetic core (R) to adjust their distance, such that the pair of transverse elements (11; 12) can be positioned at a distance close to the axial extension (Pa) of the corresponding salient pole (P).

2. The device according to claim 1, characterized in that, The pair of lateral elements (11; 12) and the guiding and conveying structure (5; 6) are moved by corresponding linear actuators (11a, 12e).

3. The device according to claim 2, characterized in that, The linear actuators (11a; 12e) are of a type selected from electromechanical actuators, hydraulic actuators, pneumatic actuators, or electromagnetic actuators, and are characterized in that the linear actuators (11a; 12e) are commanded by a controller (11a'; 12e') to adjust the relative distances of the transverse elements (11; 12) in the longitudinal direction (dy) parallel to the axis of rotation (Y) of the rotor (R), thereby adapting to the axial extension (Pa) of the corresponding salient pole (P) to be wound.

4. The device according to at least one of the preceding claims, characterized in that, The lateral elements (11; 12) include corresponding inclined surfaces (13; 14) arranged parallel to the longitudinal extension (Pl) of the pole (P) and configured to interact with the longitudinal elements (7; 8) To form a shape that is configured to guide the at least one conductor (W) during winding around the salient pole (P).

5. The device according to one or more of the preceding claims, characterized in that, The longitudinal element (8) is configured to translate by means of a corresponding motion device on a trajectory having a component in a transverse direction (dz) that is substantially perpendicular to the longitudinal direction (dy) in order to adjust the distance between the longitudinal elements (8) according to the size of the corresponding salient pole (P).

6. The device according to claim 5, characterized in that, The corresponding moving device is configured to translate the corresponding longitudinal element (8) between the first configuration and the second configuration, wherein in the first configuration, the longitudinal element (8) is removed from the slot (S), and in the second configuration, the longitudinal element (8) is at least partially inserted into the slot (S) on the side of one of the salient poles (P), and wherein the corresponding end edge (10) of the longitudinal element (8) faces and is close to the salient pole (P).

7. The device according to any one of the preceding claims, characterized in that, Each transverse element (12) includes a pair of blocks (12a, 12b), each block (12a, 12b) being fixed to and protruding from the corresponding longitudinal element (9) of the pair of longitudinal elements (8).

8. The device according to the preceding claims, characterized in that, The blocks (12a, 12b) of the pair of blocks are arranged to overlap at least partially in order to define a guide for the at least one conductor (W) provided by the at least one wire feeder (4) during winding around the salient pole (P).

9. The device according to the preceding claims, characterized in that, The longitudinal element (8) and the blocks (12a, 12b) can operate synchronously so that the blocks (12a, 12b) translate to the same degree.

10. The device according to any one of the preceding claims, characterized in that, The longitudinal element (8) is of the sheet type.

11. A method for forming an induction winding (C) wound on a salient pole (P) of a ferromagnetic core (R) of an electric motor, wherein the salient pole (P) extends parallel to the axis of rotation (Y) of the ferromagnetic core (R), the method comprising: - Arrange (I) the ferromagnetic core (R) of the motor such that one of its salient poles (P) faces the rotating assembly (3), wherein the rotating assembly (4) is rotatable about a rotation axis (X) that is substantially perpendicular to the rotation axis (Y) of the core (R); - A guide and conveyor structure (5; 6) is inserted between the salient pole (P) and the rotating assembly (3) to guide at least one conductor (W) to wind around the salient pole (P), wherein the guide and conveyor structure (5; 6) includes a pair of longitudinal elements (7; 8) and at least a pair of transverse elements (11; 12) inserted between the longitudinal elements (7; 8) and facing each other. -The salient pole (P) of (III) is surrounded by the guide and conveying structures (5; 6); - During the rotation of the rotating assembly (3), at least one conductor (W) is conveyed (IV) by means of a wire feeder (4), thereby allowing the conductor (W) to slide on the guiding and conveying structure (5; 6); - The guiding and conveying structure (5, 6) is translated (V) along a direction (dx) parallel to the rotation axis (X) of the rotating assembly (3) to obtain an ordered and regular conductor (W) coil wound around the surrounding salient pole (P); the method is as follows The feature is that it further includes an adjustment step, wherein the transverse elements (11; 12) of the pair of transverse elements (11; 12) move between reciprocating approach and removal positions in a longitudinal direction (dy) parallel to the axis of rotation (Y) of the ferromagnetic core (R) to adjust their distance until the pair of opposing elements (11; 12) are positioned at a distance close to the axial extension (Pa) of the corresponding salient pole (P).

12. The method according to the preceding claims, characterized in that, The adjustment step involves translating the pair of transverse elements (11; 12) in a longitudinal direction (dy) parallel to the axis of rotation (Y) of the rotor (R) by means of linear actuators (11a; 12e), and is characterized in that the linear actuators (11a; 12e) are commanded by the controller (11a'; 12e') associated with them.

13. The method according to claim 11 or 12, characterized in that, The adjustment step includes translating the longitudinal element (8) on a trajectory having a component in a lateral direction (dz) substantially perpendicular to the longitudinal direction (dy) to adjust the distance between the longitudinal elements (8) according to the size of the respective salient pole (P).

14. The method according to claim 13, characterized in that, Each of the pair of transverse elements (13) comprises a pair of blocks (12a, 12b), each block (12a, 12b) being fixed to and protruding from a corresponding longitudinal element (8) of the pair of longitudinal elements (8), and characterized in that the adjustment step further comprises adjusting the mutual distance of the pair of blocks (12b) in the transverse direction (dz) perpendicular to the longitudinal direction (dy).

15. The method according to any one of claims 11-14, characterized in that, The direction (dx) parallel to the rotation axis (X) of the rotating assembly (3) is perpendicular to the longitudinal direction (dy) parallel to the rotation axis (Y) of the core (R).

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