A process and apparatus for arranging a shaped wire guide

Abstract

The invention relates to a process for arranging M shaped wire elements (100) around a containment element (1300) to obtain a shaped wire elements annular assembly, wherein M is greater than 1, comprising the steps of: a) providing M shaped wire elements (100); b) placing a first shaped wire element of the M shaped wire elements (100) in such a way that a first distance (PL1) between the first shaped wire element (100) and the containment element (1300) is maintained at least in part; c) placing a second to an Nth shaped wire element of the M shaped wire elements (100) around the containment element (1300) in sequence, wherein N is greater than 2, wherein an (N+1)th to an Mth shaped wire element of the M shaped wire elements (100) overlaps with the first shaped wire element (100) of the assembly (200) of shaped wire elements (100); d) changing the first distance (PL1) between at least a portion of the first shaped wire element (100) and the containment element (1300) to a second distance (PL2), wherein the second distance (PL2) is greater than the first distance (PL1); and e) placing the (N+1)th to the Mth shaped wire element (100, 130) around the containment element (1300) in sequence to complete the shaped wire elements annular assembly. The invention also relates to a process for manufacturing a hairpin structure electrical machine stator, to an arrangement for arranging M shaped wire elements to obtain an assembly, to the use of such an arrangement, and to a production plant for manufacturing a hairpin stator.

Description

Technical Field

[0001] This invention relates to a process for preparing an assembly of multiple shaped lead wires, preferably to a process for preparing an assembly of multiple shaped lead wires having a hairpin shape, more preferably to a process for manufacturing a motor stator with a hairpin structure, to an assembly, preferably to a motor stator with a hairpin structure obtainable by the process, to the use of such an assembly of multiple shaped lead wires in a motor, preferably to the use of such a stator with a hairpin structure in a motor, to a motor including a stator and rotor with a hairpin structure, and to an apparatus including a moving part driven by such a motor. Background Technology

[0002] Hairpin-type motor stators are now commonly found in drive motors, especially in the automotive industry. Using this manufacturing technique, a profile (usually rectangular) is first bent into a U-shape, also known as a conductor clip or "hairpin." Then, the legs of this hairpin are arranged in a circle and inserted into slots in the laminated stator core. In the next step, on the rear side of the stator, the free ends of the legs are concentrically twisted around the stator axis at a certain angle. All free ends on a certain diameter (i.e., one layer of winding) are alternately twisted clockwise and counterclockwise. This process is also called "twisting." The free ends adjacent to each other due to the twisting are welded together, and depending on the winding scheme, so-called interconnecting bridges are placed on the winding ends and welded to the free ends to connect the conductor clips into a single winding. The free ends are then arbitrarily insulated, and the entire stator is impregnated. This technique allows for a high degree of automation and achieves a high copper fill factor, i.e., a high ratio of conductor coverage area to slot area. Due to its rectangular cross-section and fewer turns, the hairpin stator has a fill factor of approximately 73%, which is significantly higher than that of conventional winding methods (45-50%, depending on insulation thickness). Therefore, the hairpin stator is particularly suitable for the manufacture of motors in the automotive industry, especially for drive units.

[0003] When arranging the legs of the hairpin into the slots of the stator core, the hairpins must be positioned very close to each other to achieve a high fill density in the hairpins and therefore the stator windings. Furthermore, the arrangement generates a force that pulls the assembled pins or hairpins towards the center of the receiving device. As a result, the space for assembling the last few hairpins is very limited, making the arrangement of the hairpins difficult.

[0004] US2020212771A1 describes a pre-assembled nest for forming an annular crown from multiple U-shaped conductive hairpins. The pre-assembled nest includes a receiving member with multiple grooves for receiving the legs of the U-shaped hairpins. The grooves are configured in size and geometry such that, in each case, a first leg of the hairpin can rotate within a groove, thereby achieving unconstrained positioning of a second leg of the hairpin in another groove. However, manufacturing and using dedicated pre-assembled nests increases production costs and requires significant changes to the arrangement process. Summary of the Invention

[0005] The present invention aims to overcome the shortcomings of the prior art in manufacturing shaped lead wires, especially shaped lead wires with a hairpin shape.

[0006] One object of the present invention is to provide an arrangement process or apparatus for arranging shaped wires in a cost-effective manner.

[0007] Another object of the present invention is to provide an arrangement process or apparatus for arranging shaped wires that requires minimal structural modifications compared to known hairpin arrangement processes or apparatuses.

[0008] The independent claims contribute to at least partially solving at least one, and preferably more than one, of the above-described objectives. The dependent claims provide preferred embodiments that contribute to at least partially solving at least one of the stated objectives.

[0009] The process for arranging shaped wire members according to the first embodiment of the first aspect of this application contributes to solving at least one object of the present invention. A process for arranging M shaped wire members around a receiving element to obtain a ring assembly of shaped wire members, wherein M is greater than 1, includes the following steps: - Provides M shaped lead wire components; - The first of the M shaped lead wires is placed in such a manner that a first distance (PL1) between the first shaped lead wire (at least a portion) and the receiving element is maintained; - The second to the Nth of the M shaped wires are placed sequentially around the receiving element, where N is greater than 2, and the (N+1)th to the Mth shaped wires overlap with the first shaped wire in the assembly; - Change the first distance (PL1) between at least a portion of the first formed lead wire and the receiving element to a second distance (PL2), wherein the second distance (PL2) is greater than the first distance (PL1); and - The (N+1)th to the Mth shaped lead wires are placed sequentially around the receiving element to complete the assembly.

[0010] In a second embodiment of the process according to the first aspect of the present invention (wherein, the second embodiment preferably depends on the first embodiment of the process according to the first aspect of the present invention), the process further includes the following steps: Reduce at least a portion of the first shaped lead wire from the second distance PL2 to the third distance PL3 of the receiving element.

[0011] In a third embodiment of the process according to the first aspect of the present invention, which preferably depends on a first or second embodiment of the process according to the first aspect of the present invention, the step of placing the first shaped lead wire includes: - A placeholder element is provided at the receiving element, wherein the thickness of the placeholder element is equal to a first distance PL1; - A first shaped lead wire is placed around a receiving element, with a placeholder element in between, such that at least a portion of the first shaped lead wire is moved away from the receiving element by a first distance PL1.

[0012] In a fourth embodiment of the process according to the first aspect of the invention (wherein, the fourth embodiment preferably depends on a third embodiment of the process according to the first aspect of the invention), the occupant element includes a plug-like tool.

[0013] In a fifth embodiment of the process according to the first aspect of the invention, which preferably depends on any one of the first to fourth embodiments of the process according to the first aspect of the invention, the step of changing the first distance PL1 to the second distance PL2 includes: moving the first shaped lead wire away from the receiving element to increase the first distance PL1 between the first shaped lead wire and the receiving element to the second distance.

[0014] In a sixth embodiment of the process according to the first aspect of the invention, which preferably relies on a fifth embodiment of the process according to the first aspect of the invention, the step of removing the first shaped lead wire from the receiving element includes: pulling the first shaped lead wire away from the receiving element by means of a pulling element.

[0015] In a seventh embodiment of the process according to the first aspect of the invention (wherein, the seventh embodiment preferably depends on a sixth embodiment of the process according to the first aspect of the invention), the pulling element includes a hook-shaped tool.

[0016] In an eighth embodiment of the process according to the first aspect of the invention (which preferably depends on any one of the third to seventh embodiments of the process according to the first aspect of the invention), the step of reducing the second distance PL2 to the third distance PL3 includes: removing the occupant element and / or the pulling element.

[0017] In a ninth embodiment of the process according to the first aspect of the invention (wherein, the ninth embodiment preferably depends on any one of the second to eighth embodiments of the process according to the first aspect of the invention), the third distance PL3 is equal to zero.

[0018] In a tenth embodiment of the process according to the first aspect of the invention (which preferably depends on any one of the first to ninth embodiments of the process according to the first aspect of the invention), the first distance PL1 is greater than the width W of the formed conductor.

[0019] A method for manufacturing a hairpin stator according to a second aspect of the present invention contributes to solving at least one objective of the present invention. The process includes the following steps: - Provide wires, - Wherein, the conductor has a conductor surface and a conductor cross-section; - Wherein, at least 50% of the surface of the conductor is coated with an electrical insulating layer; - The conductors are separated to obtain longitudinal conductor components. - Wherein, the longitudinal guide member includes a first end and a second end; - The longitudinal conductor is shaped into a shaped conductor, the shaped conductor including a first leg having a first end, a second leg having a second end, and a bridging portion connecting the first leg and the second leg; - A plurality of such shaped wires are arranged relative to each other to obtain an assembly of shaped wires, wherein the arrangement is accomplished in such a way that the legs of each of the plurality of shaped wires are oriented substantially in the same direction, wherein the arrangement is accomplished in any of the first to tenth embodiments of the first aspect of the invention. - The assembly is introduced into a stator comprising multiple slots, each slot having a first slot end and a second slot end. This introduction is accomplished by inserting the legs of the shaped conductor into the first slot end of each slot of the stator, wherein the end of each leg protrudes from the stator at the second slot end of the slot, and then these ends are twisted to achieve a specific spatial arrangement of these ends; and - Provide electrical contact between the first or second end of a given shaped conductor and the first or second end of another shaped conductor.

[0020] The arranging device according to a first embodiment of the third aspect of the present invention contributes to solving at least one object of the present invention. The arranging device is used to arrange M shaped wire members to obtain an assembly, wherein M is greater than 1, and the arranging device includes: - A placeholder element adapted and arranged to maintain a first distance PL1 between the first (at least a portion) of the M forming guides introduced from the receiving element into the arrangement and the receiving element; and - A pulling element adapted and arranged to pull the first shaped lead wire away from the receiving element to increase a first distance PL1 between at least a portion of the first shaped lead wire and the receiving element to a second distance PL2.

[0021] In a second embodiment of the arrangement device according to a third aspect of the invention (wherein, the second embodiment preferably depends on a first embodiment of the arrangement device according to a third aspect of the invention), the occupant element comprises: - An extension, particularly in the form of a plug, is adapted and arranged to be positioned between the first shaped lead introduced into the arranging device and the receiving element, wherein the thickness of the extension is equal to a first distance PL1; and - A fixing part, connected to an extension part, which is adapted and arranged for attachment to a receiving element.

[0022] In a third embodiment of the arranging device according to a third aspect of the present invention (wherein, the third embodiment preferably depends on a first or second embodiment of the arranging device according to a third aspect of the present invention), the pulling element comprises: - The curved portion, particularly in a hook shape, is adapted and arranged to hook the first shaped lead wire introduced into the arranging device; and - A handle portion connected to the bending portion is adapted and arranged to move away from the receiving element to increase the first distance PL1 between at least a portion of the first shaped lead introduced into the arrangement device and the receiving element to a second distance PL2.

[0023] In a fourth embodiment of the arranging device according to a third aspect of the invention, which preferably depends on any one of the first to third embodiments of the arranging device according to a third aspect of the invention, the pulling element is adapted and arranged to: pull the first shaped wire introduced into the arranging device away from the receiving element after the second to Nth of the M shaped wires introduced into the arranging device are placed sequentially around the receiving element, wherein N is greater than 2, and wherein the (N+1)th to Mth of the M shaped wires introduced into the arranging device overlap with the first shaped wire in the assembly.

[0024] In a fifth embodiment of the arranging device according to the third aspect of the invention (this embodiment preferably depends on a fourth embodiment of the arranging device according to the third aspect of the invention), after the first distance PL1 between at least a portion of the first forming wire introduced into the arranging device and the receiving element is increased to a second distance PL2 by the pulling element, the (N+1)th to the Mth of the M forming wires introduced into the arranging device are placed around the receiving element in sequence.

[0025] In a sixth embodiment of the arranging device according to a third aspect of the invention (wherein, this embodiment preferably depends on any one of the first to fifth embodiments of the arranging device according to a third aspect of the invention), the arranging device further includes: a removal element adapted and arranged to remove a occupant element and / or a pulling element to reduce a second distance PL2 between at least a portion of the first shaped lead introduced into the arranging device and the receiving element to a third distance PL3.

[0026] In a seventh embodiment of the arrangement device according to the third aspect of the invention (which preferably depends on a sixth embodiment of the arrangement device according to the third aspect of the invention), the third distance PL3 is equal to zero.

[0027] In an eighth embodiment of the arranging device according to the third aspect of the invention (which preferably depends on any one of the first to seventh embodiments of the arranging device according to the third aspect of the invention), the first distance PL1 is greater than the width W of the shaped conductor introduced into the arranging device.

[0028] In a ninth embodiment of the arranging device according to a third aspect of the invention (this embodiment preferably depends on any one of the first to eighth embodiments of the arranging device according to a third aspect of the invention), the arranging device further includes: the receiving element, which is adapted and arranged to receive M shaped wires introduced into the arranging device to obtain the assembly.

[0029] In a tenth embodiment of the arrangement device according to a third aspect of the invention (this embodiment preferably depends on any one of the first to ninth embodiments of the arrangement device according to a third aspect of the invention), the arrangement device further includes: the placement element, which is adapted and arranged such that M shaped conductors to be introduced into the arrangement device are placed around the receiving element.

[0030] The manufacturing apparatus for producing hairpin stators according to a fourth aspect of the present invention contributes to solving at least one objective of the present invention. The manufacturing apparatus includes: - An arrangement device according to any one of the first to tenth embodiments of the third aspect of the present invention; and - A processing apparatus adapted and arranged for processing the obtained shaped lead wire assembly to produce a hairpin stator.

[0031] The use of the arranging device according to any one of the first to tenth embodiments of the third aspect of the present invention in the process for producing shaped wire component assemblies according to any one of the first to tenth embodiments of the first aspect of the present invention contributes to achieving at least one object of the present invention.

[0032] In this invention, a spacer element is positioned between the first forming lead member and the receiving element, thereby enabling the pulling element to pull the first forming lead member outward, thus increasing the basket-forming space to facilitate the arrangement of the remaining forming lead members. This invention is compatible with existing basket-forming methods and apparatuses, and is therefore cost-effective. The spacer element is particularly advantageous in arranging the second and subsequent rings of hairpins. Attached Figure Description

[0033] The accompanying drawings are for illustrative purposes only and should not be construed as limiting the invention. Furthermore, the drawings are not to scale.

[0034] Figure 1 A shaped lead wire 100 with a hairpin shape is shown, which can be referred to process step c (according to the present invention).

[0035] Figure 2 This illustrates a basket-shaped assembly composed of shaped wires 100, obtainable by a process according to the invention for manufacturing components, each shaped wire 100 having a hairpin shape, the assembly being placed as... Figure 3 The previous state of the laminated stator core 300 in slot 303.

[0036] Figure 3 A side view of a laminated stator core 300 is shown, into which a shaped conductor 100 or one or more components of such a shaped conductor 100, which is available according to the process of the present invention, may be introduced to form a stator 400 with a hairpin structure.

[0037] Figure 4 A top view of this laminated stator core 300 is shown.

[0038] Figure 5 The diagram shows the connection end of a shaped wire 100 obtained by the process according to the invention after bending in opposite directions.

[0039] Figure 6 A stator 400 with a hairpin structure is shown, which can be manufactured by a process according to the invention for preparing components.

[0040] Figure 7An arrangement device 1400 (according to an embodiment of the invention) is shown, which includes a placeholder element 1450 and a pulling element 1480.

[0041] Figure 8 The application of the arranging device 1400 in a process for arranging the first turn of a plurality of shaped wires 100 is shown (according to an example of the invention).

[0042] Figure 9 The application of the arranging device 1400 in a process for arranging a second loop of a plurality of shaped wires 100 is shown (according to an example of the invention). Detailed Implementation

[0043] This disclosure will be more readily understood by referring to the following detailed description, which is incorporated herein by reference in conjunction with the accompanying drawings and embodiments, which form part of this disclosure. It should be understood that this disclosure is not limited to the specific apparatuses, methods, applications, conditions, or parameters described and / or illustrated herein, and the terminology used herein is for illustrative purposes only and is not intended to limit the scope of this disclosure. Furthermore, as used herein, the singular forms “a,” “an,” and “the” include “at least one” and multiples. Additionally, when the plural form is referred to in the specification (including the appended claims), it includes the singular forms “a,” “an,” “an,” and “the,” and also includes “at least one.” Moreover, when a specific numerical value is referred to in the specification (including the appended claims), it includes at least that specific numerical value, unless the context clearly specifies otherwise.

[0044] As used herein, the term "multiple" means more than one. When describing a range of values, another instance includes starting from and / or ending at the specified value. Similarly, when a value is expressed as an approximation using the preposition "about," it should be understood that the specified value constitutes another instance. All ranges include endpoints and are combinable.

[0045] The terms “basically,” “approximately,” and their derivatives, as well as words with similar meanings, when used to describe size, shape, spatial relationship, distance, direction, and other similar parameters, include the parameter and a range of 10% higher and lower than the parameter, including 5% higher and lower than 5%, including 3% higher and lower than 3%, including 1% higher and lower than 1%.

[0046] Figure 1A shaped conductor 100 with a hairpin shape is shown, which can be referred to in process step c (according to the invention). The hairpin is preferably a copper hairpin, its outer surface including an insulating layer (shown in black). The hairpin includes two generally parallel legs 101 and 103, the first leg 101 having a first end 102 and the second leg 103 having a second end 104, wherein the insulating layer is preferably removed at the first end 102 and the second end 104 (shown in gray). The conductor used to form the hairpin preferably has a rectangular cross-sectional shape, for example, a width of 3.24 mm and a thickness of 2.84 mm. However, the actual dimensions of the rectangular cross-sectional shape depend, for example, on the size of the stator into which the hairpin is to be introduced, and / or the density of the shaped conductor assembly to be introduced into the stator slot. The thickness of the insulating layer coated on at least a portion of the conductor surface can, for example, range from 0.01 mm to 0.1 mm, preferably from 0.03 to 0.07 mm. Preferably, the hairpin portion 105 (the two legs 101 and 103 are connected to each other through the bridging portion, such as...) Figure 1 (As shown by the dashed circle in the middle) It is three-dimensionally curved such that when the outer edges of the cross-sectional areas of the two legs 101 and 103 of a particular shaped conductor 100 are aligned in the same way, the two legs are not in the same plane.

[0047] Figure 2 A basket-shaped assembly of a hairpin-shaped shaped conductor 100, obtainable by a process according to the invention for manufacturing components, is shown, wherein the shaped conductor 100 is arranged in the form of a circle or ring, wherein two such circles 202 and 203 are formed concentrically. This shaped conductor assembly can be placed into a slot 303 of a laminated stator core 300, such as... Figure 3 As shown, a stator 400 is used to form a hairpin structure. At the end of the process for fabricating the component, when the ends 102 and 104 of the hairpin are interconnected in a clearly defined manner, each circle or loop 202, 203 forms a conductive winding. As... Figure 2 As shown, the shaped lead wires 100 are arranged relative to each other such that the first end 102 and the second end 104 of each shaped lead wire are oriented in substantially the same direction. In this case, it is also preferable that the first end 102 and the other end 104 of all these shaped lead wires 100 lie substantially within the same plane 201 (indicated by the dashed circle at the bottom of the assembly). On opposite sides of the assembly, the section 105 of the hairpin that connects the two legs 101 and 103 of a given hairpin to each other may also lie substantially within the same plane.

[0048] Figure 3 A side view of a laminated cylindrical stator core 300 is shown, along with a shaped conductor 100 or an assembly 200 of such a shaped conductor 100 (e.g., according to the process of the present invention). Figure 2(As shown) can be introduced into the stator core to form a stator of hairpin structure 400. The cylindrical stator core 300 includes an outer peripheral surface 301 and an outer peripheral surface 302, with a plurality of slots 303 formed between the outer peripheral surface 302 and the outer peripheral surface 301. The outer peripheral surface 302 defines an inner cylindrical space 306 extending axially within the stator 300 (e.g., ...). Figure 4 As shown in the figure, the first leg 101 and the second leg 103 of the forming conductor 100 are introduced into the slot 303 of the cylindrical stator core 300. Figure 3 The cylindrical stator core 300 shown is formed by a large number of stacked electrical laminations 304, each of which closes to form a ring. The cylindrical stator core 300 includes individual stator core teeth 305, each formed by a large number of stacked electrical laminations 304. The stator core teeth 305 are components of the stator core 300 and are designed as circumferentially spaced, radially inwardly oriented, toothed stator body portions, wherein the free space between two adjacent teeth 305 forms a slot 303 into which a shaped conductor 100 can be introduced as described above.

[0049] Figure 4 A top view of a laminated stator core 300 is shown, which is similar to... Figure 3 The stator core shown is an example. Figure 4 As shown, based on the width of the slot 303, each slot 303 can accommodate a certain number n of the legs 101 and 103 of the formed wire component 100. Figure 4 (where n is 6).

[0050] Figure 5 The connecting ends 102 and 104 of the formed conductors in an assembly obtainable by the process according to the invention are shown, the connecting ends having been bent in opposite directions. To form the hairpin structure of the stator 400, the first end 102 and the second end 104 of each formed conductor 100 introduced into the slots 303 of the cylindrical stator core 300 are bent in such a manner that an S-shaped end is obtained, wherein the first end 102 of a given formed conductor 100 (hairpin) is bent in one direction and the other end 104 is twisted in the opposite direction, such that the first end 102 of one formed conductor 100 is adjacent to the second end 104 of another formed conductor 100. The ends 102 and 104, thus so close together, are then joined to each other, for example, by laser welding. If this process is performed for all the formed conductors 100 in a given loop 202, 203 of the circularly arranged formed conductors 100, a conductive winding is obtained in the cylindrical stator core 300.

[0051] Figure 6A stator 400 with a hairpin structure is shown, which can be manufactured by a process for preparing components according to the invention. The stator 400 includes a stator core 300 into which assemblies 200 of shaped conductors 100 (preferably hairpin-shaped assemblies 200 of shaped conductors 100) have been introduced, and wherein the ends 102 and 104 of each hairpin have been twisted and connected as described above. The stator 400 also includes a connecting portion 401 to achieve electrical contact between the various windings of the stator 400.

[0052] Figure 7 An arrangement apparatus 1400 according to an embodiment of the present invention is shown for arranging a plurality of shaped wire members 100 to obtain an assembly of wire members 100. In one embodiment, the shaped wire members to be arranged are two-dimensional line segments, wherein the bridging portion 105 is substantially in the same plane as the first leg 101 and the second leg 103. In a preferred embodiment, the shaped wire members to be arranged are three-dimensional line segments, wherein the bridging portion 105 protrudes from the plane of the first leg 101 and the second leg 103, such as... Figure 1 As shown. In another preferred embodiment, the three-dimensional shaped conductor 100 has an offset bend in the bridging portion 105. The offset bend is particularly Z-shaped, such as... Figure 8 and Figure 9 As shown. Due to the bias bend in the bridging portion 105, in the assembly 200 of the formed conductor 100, a portion of the bridging portion 105 is closer to the receiving element 1300 than another portion of the bridging portion 105.

[0053] In this embodiment, M shaped lead wires 100 are arranged around a receiving element 1300, where M is greater than 1. The receiving element 1300 may be part of a pre-assembled element. In one example, the receiving element 1300 is cylindrical, having a bottom surface and a body. The M shaped lead wires are arranged in one or more loops around the receiving element 1300, such as... Figure 8 and Figure 9 As shown. In this invention, the (N+1)th to the last formed wire member 100 of the M formed wire members 100 overlaps with the first formed wire member 100 of the assembly 200. Here, N is greater than 2.

[0054] like Figure 7As shown, the arranging device 1400 includes a placeholder element 1450 and a pulling element 1480. The placeholder element 1450 includes an extension 1451 (particularly in the form of a plug) and a fixing portion 1455 connected to the extension 1451. When arranging the first coil of the formed wire 100 in the arranging assembly 200, the extension 1451 may be disposed between the first formed wire 100 introduced into the arranging device 1400 and the receiving element 1300. When arranging subsequent coils or more of the formed wire, the extension 1451 may be disposed between the first formed wire 100 and the circumference of the previous coil of the assembled formed wire. In this case, the previous coil or more of the assembled formed wire can be considered as part of the receiving element 1300.

[0055] The extension 1451 has a thickness equal to the first distance PL1, such as Figure 7 As shown. In one example, the first distance PL1 is greater than the width W of the formed conductor, as... Figure 8 As shown. Therefore, the occupant element 1450 can maintain a first distance PL1 between the first shaped lead wire 100 and the receiving element 1300. Figure 8 As shown, when the shaped lead wires 100 are arranged, the fixing portion 1455 can rest on or be attached to the receiving element 1300 to support the extension portion 1451. In one example, the width of the extension portion 1451 can be smaller than the extension dimension of the bridging portion 105. In one example, as... Figure 8 As shown, the occupant element 1450 can be configured to be a portion of the bridging portion 105 of the first shaped lead wire 100, but smaller than another portion of the bridging portion 105. Figure 8 The portion on the right in the example is closer to the receiving element 1300. Figure 8 (The left portion in the example) is adjacent. Therefore, at least a portion of the first shaped lead 100 is away from the receiving element 1300 by a first distance PL1.

[0056] The pulling element 1480 is used to pull the first shaped lead wire 100 away from the receiving element 1300, thereby increasing a first distance PL1 between at least a portion of the first shaped lead wire 100 and the receiving element 1300 to a second distance PL2. In one embodiment, the pulling element 1480 includes a bend 1481 and a handle 1485 connected to the bend 1481. The bend 1481 is particularly hook-shaped and capable of hooking the first shaped lead wire 100. The handle 1485 can be driven to move away from the receiving element 1300.

[0057] In one embodiment, the arranging device 1400 further includes a removal element (not shown) for removing the occupant element 1450 and / or the pulling element 1480 after the shaped lead arrangement is completed. As a result, the distance between at least a portion of the first shaped lead and the receiving element 1300 decreases from a second distance PL2 to a third distance PL3. The third distance PL3 may be equal to zero.

[0058] Figure 8 The application of the arranging device 1400 in the process of arranging the first turn of a plurality of shaped wires 100 is shown. Figure 9 The arrangement of the second ring of molded wire members is shown. During the arrangement process, before arranging the first ring of molded wire members, a placeholder element 1450 is positioned at the receiving element 1300 as follows: a fixing portion 1455 rests on or is attached to the base surface of the receiving element 1300, while an extension portion 1451 extends along the body of the receiving element 1300. It should be noted that when arranging the second and subsequent rings of molded wire members, the placeholder element 1450 is positioned at the circumference of the ring preceding the assembled molded wire member, such as... Figure 9 As shown. In this case, the housing element 1300 can be considered as including a previously assembled one or more turns of shaped conductor.

[0059] Then, the first shaped lead wire is placed such that the extension 1451 is located between the first shaped lead wire and the receiving element 1300. That is, the first shaped lead wire is placed such that at least a portion of the first shaped lead wire is maintained at a first distance PL1 between it and the receiving element 1300.

[0060] Next, the second to the Nth of the M shaped conductors are sequentially placed around the receiving element 1300. To achieve a high fill density in the shaped conductors and thus the stator windings, the conductors must be positioned very close to each other, and some shaped conductors overlap with adjacent segments. In an embodiment of the invention, it is assumed that the (N+1)th to the Mth of the M shaped conductors 100 overlap with the first shaped conductor 100 in the assembly 200.

[0061] Then, the pulling element 1480 pulls the first forming lead away from the receiving element 1300. As a result, the distance between at least a portion of the first forming lead and the receiving element 1300 increases from a first distance PL1 to a second distance PL2. This arrangement generates a force that pulls the placed forming lead toward the center of the receiving element. Consequently, the space for assembling the last few hairpins is very limited, making the arrangement of the forming lead difficult. By using the pulling element 1480, the basket space is increased to facilitate the arrangement of the remaining forming lead. Furthermore, the placeholder element 1450 leaves some space between the first forming lead and the receiving element 1300, which also helps to pull the first forming lead by the pulling element 1480. The present invention is particularly advantageous in arranging the second and subsequent hairpin loops due to the placement of the placeholder element. Without the placeholder element, it would be difficult to hook the first forming lead in the second or subsequent loops.

[0062] Then, the (N+1)th to the Mth forming wires are sequentially placed around the receiving element 1300 to complete the assembly. When all M forming wires are arranged, the occupant element 1450 and / or the pulling element 1480 are removed. As a result, the distance between at least a portion of the first forming wire and the receiving element 1300 is reduced from the second distance PL2 to the third distance PL3, or reduced to zero.

[0063] A process for preparing a shaped lead wire assembly 200 according to the present invention is also provided.

[0064] Process step a.

[0065] In step a of the process for preparing a plurality of shaped conductor assemblies according to the present invention, a conductor is provided, the conductor having a conductor surface, wherein at least 50%, preferably at least 75%, more preferably at least 95% of the conductor surface is coated with an electrically insulating layer. The conductor surface coated with the electrically insulating layer is the peripheral surface of the conductor, the peripheral surface surrounding the conductor in a direction parallel to the longitudinal axis of the conductor.

[0066] Preferably, the conductor can have any cross-sectional shape, such as circular, elliptical, or rectangular, with a rectangular cross-section being particularly preferred. In the case of such a rectangular shape, the lengths of the sides A and B of the rectangular cross-sectional area A×B are preferably in the range of 1 to 10 mm, more preferably in the range of 1.5 to 8 mm, and even more preferably in the range of 2 to 6 mm. Furthermore, the lengths of the sides A and B defining the rectangular cross-sectional shape of the conductor can differ from each other by at least 0.25 mm, at least 0.5 mm, or at least 1 mm.

[0067] The electrical insulation layer covering at least a portion of the conductor surface can be based on any material, such as varnish, paper, polymer, glass fiber, mica, and combinations thereof. In one specific example, the electrical insulation layer can be a polyamide-imide film. Furthermore, the method used to coat the conductor assembly can be any method, as long as it is a method commonly used for insulating coating, such as impregnation, electrodeposition coating, oxidation film formation, or electroplating. Conductors coated with this electrical insulation layer are suitable for use in process step a. It is commercially available from Hitachi Cable America, Inc., located in White Plains, New York.

[0068] In process step a, the conductor is provided, preferably by a continuous process in which the conductor wound on a spool is continuously unwound from the spool by a feed element and subsequently straightened in multiple stages to reduce residual curvature and residual stress. The process of providing the conductor may also include an additional step in which, after the straightening process, the electrical insulation layer of the conductor is preferably partially stripped (removed) at regular intervals. Both laser-based and mechanical processes are used here to at least partially remove the electrical insulation layer.

[0069] Process step b.

[0070] In process step b of the assembly for preparing a plurality of shaped conductors according to the invention, the conductors provided in process step a are separated to obtain a plurality of longitudinal conductor segments, wherein each of the plurality of longitudinal conductor segments includes a first end and a second end. Preferably, the separation is performed within a stripped area of ​​the conductor, preferably substantially at the center of the stripped area, so that the resulting longitudinal conductor is stripped at its first and second ends by a certain length—this length depends on the length of the conductor area stripped in process step a.

[0071] The length of each of the plurality of longitudinal conductor segments obtained in process step b depends on the shape of the shaped conductor to be formed in process step c, preferably on the shape of the hairpin. For example, the conductor can be separated by a simple cutting process using a cam-driven punch and die assembly that forms a notch of defined depth across the conductor surface at the middle of the stripped section, thereby separating the conductor at that point. Alternatively, the conductor can also be separated by a process selected from shearing, cutting with a tool, biting, tearing, or a combination of two or more of these methods.

[0072] Process step b may additionally include a process step in which the ends of the lead wires are sharpened or chamfered to facilitate the arrangement of the shaped lead wires (preferably hairpins) in the slots of the stator, as described below.

[0073] Process step c.

[0074] In step c of the process according to the invention for preparing an assembly composed of a plurality of shaped conductors, longitudinal conductors are shaped to obtain shaped conductor segments, the shaped conductors including a first leg having a first end, a second leg having a second end, and a bridging portion connecting the first leg and the second leg, preferably forming a hairpin. Preferably, the shaping is performed in such a manner that a shaped conductor is obtained in which the first leg and the second leg point substantially in the same direction and are substantially parallel to each other. In one embodiment of the process according to the invention, the shaped conductor is characterized by a two-dimensional structure, i.e., the two legs of a given shaped conductor extend in one plane. In another embodiment of the process according to the invention, the shaped conductor is characterized by a three-dimensional structure, i.e., the two legs of a given shaped conductor extend in two parallel planes offset from each other, this embodiment being particularly preferred. To obtain such a three-dimensional shape, the bridging portion connecting the first leg and the second leg has a twisted "U" shape. Figure 1 An example of this 3D structure hair clip is shown in the image.

[0075] The forming of longitudinal conductors can be achieved by any method that a person skilled in the art would consider suitable for forming conductors such as copper wires. Preferred forming methods include computer numerical control (CNC) bending, rotary bending, press bending, free bending, and combinations of at least two of these methods. CNC bending allows for 2D and 3D bending of the conductor. The conductor is directly bent into the desired final profile using one or more bending tools. When using rotary bending, the conductor is positioned on a stop system in which an upper beam clamps the conductor onto a lower beam. These bending fixtures impart the desired 2D geometry to the conductor. The desired 3D geometry can be obtained by combining the rotary bending process with a die bending process or a free bending process. When using press bending, a 2D-bent hairpin is positioned on a die. Subsequently, the 3D shape is imparted to the hairpin by the downward movement of the press bending machine. When using free bending, one leg of the 2D-bent hairpin is placed between the upper and lower jaw plates. The gripper then grasps the free hairpin leg and pulls the hairpin apart to obtain the desired 3D shape.

[0076] It should be noted that in the process according to the invention, process step c does not necessarily have to be performed after process step b, but may also be performed before process step b. In this case, a shaped wire component is first prepared at the free end of the wire provided in process step a. Subsequently, the shaped wire component is separated from the wire to obtain the shaped wire component used in process step d. This shaped wire component will then be used to prepare the assembly of the shaped wire component.

[0077] Process step d.

[0078] In process step d (i.e., the process for preparing an assembly of multiple shaped lead wires), the shaped lead wires obtained in process step c are arranged relative to each other such that the first end and the second end of each of these shaped lead wires are oriented substantially in the same direction. In this case, it is also preferred that the first end and the second end of each of these shaped lead wires are substantially in the same plane. The total number of shaped lead wires arranged in process step d depends on the required size of the assembly and can be, for example, in the range of 25 to 3000, in the range of 50 to 2000, or in the range of 100 to 1000.

[0079] Preferably, the formed conductors are arranged in one or more loops, wherein, in the case of more than one loop, these loops can be arranged concentrically. In this case, it is particularly preferred that multiple formed conductors are arranged within a cylindrical stator core, preferably within a cylindrical stator core, the stator core including an outer peripheral surface, an inner peripheral surface, and multiple slots formed between the inner and outer peripheral surfaces, the inner peripheral surface defining an internal space, preferably an internal cylindrical space, extending axially within the stator core, wherein the formed conductors are placed in the slots of the stator core. The longitudinal axis of the legs of the formed conductors, preferably the longitudinal axis of the legs of the hairpin, extends parallel to the internal space of the stator core along its axial direction. Depending on the width of the slot, each slot can accommodate n legs of formed conductors, preferably legs of formed conductors with a hairpin shape, where n is preferably an even number in the range of 2 to 12, more preferably an even number in the range of 4 to 10. Within a given slot, the slot positions of the legs of the formed conductor can be numbered from 1 (the slot position farthest from the stator's internal space) to x (the slot position closest to the stator's internal space). An example of a cylindrical stator core in which the formed conductor obtained in process step c can be placed is shown below. Figure 3 As shown.

[0080] Preferably, in this stator core, the forming conductors (preferably hairpin-shaped forming conductors) form n / 2 turns, each turn extending circumferentially, wherein the first turn r1 is the turn closest to the inner cylindrical space, and the last turn rx is the turn farthest from the inner cylindrical space, wherein the forming conductors are arranged in these turns such that the first leg of a given forming conductor is placed at slot position y in one of a plurality of slots (where y can be, for example, position 1, position 3, position 5, etc.), and the second leg of the same forming conductor can be positioned at slot position y+1 in another slot (for example, if the first leg is placed in position 1 of the first slot, then the second leg is placed in position 2 of the other slot). The circumferential distance between two slots in the stator core depends, for example, on the distance between the first end and the second end of the given forming conductor. When the forming conductors (preferably hairpin-shaped forming conductors) are placed into the slots in this manner, a plurality of concentrically arranged forming conductor turns are obtained, the number of turns being n / 2. According to a specific embodiment of the process of the present invention, n is 4, 6, 8, or 10, thus there are 2, 3, 4, or 5 hairpin rings in the assembly. At the end of process step e (described below), each of these rings forms a conductive stator winding, which are arranged concentrically.

[0081] The stator core, preferably cylindrical, can be designed as a single piece or in multiple pieces, particularly in multiple segments. A single-piece stator core is characterized in that, viewed circumferentially, the entire stator core appears as a single unit. The stator core is preferably formed from a large number of electrically insulated laminations, which are layered and encapsulated into a laminated core. This structure keeps the eddy currents induced in the stator by the stator magnetic field at a low level. These laminations are typically made of electrical steel and are stacked and encapsulated to form a stack. The individual laminations are then held in the laminated core by bonding, welding, or screwing. A segmented stator core is characterized by being composed of individual stator segments. The stator core can be composed of individual stator teeth, each individual stator tooth formed by an electrical lamination. The stator teeth are components of the stator core, designed as circumferentially spaced, tooth-like, radially inwardly extending portions of the stator body, with the free space between two adjacent teeth forming the aforementioned slots.

[0082] In addition to these slots, the cylindrical stator core may also include separate cooling channels, which may be integrated into the laminated core of the stator (as disclosed in EP 3 157 138 A1) or integrated into the slots together with the conductive stator windings (as disclosed by Markus Schiefer: “Indirect winding cooling of a high-utilization permanent magnet excitation synchronous motor with toothed coil windings”, dissertation, Karlsruhe Institute of Technology (KIT), 2017).

[0083] Before the shaped conductors are introduced into the slots of the cylindrical stator core, these slots are preferably insulated. For this purpose, insulating paper is typically fed from a roll, then continuously folded and cut into the appropriate shapes. After the paper is cut and folded, the insulating paper is inserted into the slots of the stator, one slot at a time. In subsequent process steps, the insulating paper can be expanded using a forming die that moves to both sides of the stator and expands the slot insulation by applying heat.

[0084] Different methods can be used to introduce the shaped conductors (preferably hairpin-shaped shaped conductors) into such a cylindrical stator core. For example, the shaped conductors can be introduced into the slots of the stator one after another. However, according to a preferred embodiment of the process for preparing the assembly according to the invention, a plurality of shaped conductors (preferably a plurality of hairpin-shaped shaped conductors) are first assembled in such a way that the arrangement of the first and second ends of all the shaped conductors in the assembly corresponds to the arrangement of the slots of the cylindrical stator core, thereby forming a basket-like body comprising one or more turns (or crowns) of shaped conductors (preferably one or more turns of hairpins), and then the basket-like body (or each individual turn) is introduced into the slots of the cylindrical stator core. For example, a process for manufacturing such a hairpin "pre-assembled nest" is disclosed in US 11,652,392 B2. Figure 2 An example of such a basket is shown, which includes two concentric rings of hairpin-shaped shaped guide wires.

[0085] It should be noted that not all hairpin-shaped shaped conductors assembled in a cylindrical stator core must have exactly the same shape. Typically, two, three, or more different types of hairpins can be assembled in the stator, as disclosed in US2014 / 319953 A1.

[0086] When assembling the formed wires in the aforementioned basket configuration (preferably assembling hairpin-shaped formed wires), this can be done on a workpiece carrier or a conveying device. Preferred assembly strategies include techniques such as rotational or radial feed. Subsequently, all the formed wires assembled in such a basket can be aligned to the desired circuit in a single layer. Then, aided by an entry mask and abutment support for hairpin guidance and an assembly holder for hairpin insertion, all the formed wires in each layer can be assembled into the cylindrical stator core. After the formed wire or its assembly is introduced from one side of the stator core into a slot in the stator core, the ends of the formed wires protrude from the opposite side of the stator.

[0087] The process according to the present invention is characterized in that, in process step d, M shaped lead wires are arranged around the receiving element to obtain an annular assembly of the shaped lead wires, wherein M is greater than 1, and includes the following steps: - Provides M shaped lead wire components; - The first of the M shaped lead wires is placed in such a manner that a first distance (PL1) between the first shaped lead wire (at least a portion) and the receiving element is maintained; - The second to the Nth of the M shaped wires are placed sequentially around the receiving element, where N is greater than 2, wherein the (N+1)th to the Mth of the M shaped wires overlap with the first shaped wire in the assembly; - Change the first distance (PL1) between at least a portion of the first formed lead wire and the receiving element to a second distance (PL2), wherein the second distance (PL2) is greater than the first distance (PL1); and - The (N+1)th to the Mth shaped lead wires are placed sequentially around the receiving element to complete the assembly.

[0088] According to a preferred embodiment of the invention, the process further includes the step of reducing at least a portion of the first formed lead member from a second distance PL2 to a third distance PL3 from the receiving element. In one example, the reduction step includes removing the occupant element and / or the pulling element. In one example, the third distance PL3 is equal to zero. In one example, the first distance PL1 is greater than the width W of the formed lead member.

[0089] Preferably, the step of placing the first shaped lead wire includes: - A placeholder element is arranged at the receiving element, wherein the placeholder element has a thickness equal to the first distance PL1, wherein the placeholder element includes a plug-like tool; - A first shaped lead wire is placed around a receiving element, with a placeholder element in between, such that at least a portion of the first shaped lead wire is moved away from the receiving element by a first distance PL1.

[0090] In a preferred embodiment, the shaped guide wires to be arranged are three-dimensional line segments, wherein the bridging portion 105 protrudes from the plane of the first leg 101 and the second leg 103, as shown in the figure. Figure 1 As shown. In another preferred embodiment, the three-dimensional shaped conductor 100 has an offset bend in the bridging portion 105. The offset bend is particularly Z-shaped, such as... Figure 8 and Figure 9 As shown. Due to the bias bend in the bridging portion 105, in the assembly 200, a portion of the bridging portion 105 is closer to the receiving element 1300 than another portion of the bridging portion 105.

[0091] When arranging the first ring of formed wire members 100 in the assembly, the placeholder element may be disposed between the first formed wire member 100 introduced into the arranging device 1400 and the receiving element 1300. When arranging subsequent rings or multiple rings of formed wire members, the placeholder element may be disposed between the first formed wire member 100 and the circumference of the previous ring of the assembled formed wire member, such as... Figure 9 As shown. In this case, the housing element 1300 can be considered as including a previously assembled one or more turns of shaped conductor.

[0092] According to a preferred embodiment of the present invention, the step of changing the first distance PL1 to the second distance PL2 includes: moving the first shaped lead wire away from the receiving element to increase the first distance PL1 between at least a portion of the first shaped lead wire and the receiving element to the second distance. Preferably, the above step is accomplished by pulling the first shaped lead wire away from the receiving element using a pulling element. In one example, the pulling element includes a hook-shaped tool.

[0093] By using the pull element 1480, the basket space is increased to facilitate the arrangement of the remaining forming wires. Furthermore, the placeholder element 1450 leaves some space between the first forming wire and the receiving element 1300, which also facilitates the pulling of the first forming wire by the pull element 1480. The present invention is particularly advantageous in arranging the second and subsequent turns of the hairpin due to the placement of the placeholder element. Without the placeholder element, it would be difficult to hook the first forming wire in the second or subsequent turns.

[0094] Process step e.

[0095] In step e of the process according to the invention for preparing an assembly of multiple shaped conductors, electrical contact is provided between a first or second end of a given shaped conductor and a first or second end of another shaped conductor. Preferably, these contacts are formed for all shaped conductors located within a given loop of shaped conductors, thereby forming one or more conductive windings.

[0096] After the shaped conductors are assembled, preferably after these shaped conductors are assembled in the cylindrical stator core in the manner described above, the ends of the shaped conductors are electrically connected according to the desired winding scheme to form a conductive winding. For this purpose, electrical contact is provided between the first or second end of a given shaped conductor and the first or second end of another shaped conductor.

[0097] Prior to forming these contacts, the process may include a step of radially separating the ends of the shaped wires (= necking process) to allow for better axial access of the torsion tool in the subsequent torsion step. In this necking process, the ends of the shaped wires can be radially shaped by a forming tool to create sufficient distance between them.

[0098] After the separation, the first and second ends of each formed conductor in the assembly, preferably the first and second ends of each formed conductor with a hairpin shape, are twisted according to the requirements of the desired winding scheme, such that the first or second end of one formed conductor is in close contact with the first or second end of another formed conductor (=twisting process). To achieve this contact, the first leg of a given formed conductor is bent toward the direction of the first or second leg of the formed conductor to be connected to that given formed conductor, and vice versa. When the ends of the formed conductors are bent in this manner, an S-shaped structure at the ends is preferably obtained. In this context, it is particularly preferred that the formed conductors be bent in this manner after they are arranged in the cylindrical stator core, such that the two connecting ends of different hairpins represent adjacent connecting ends (see...). Figure 5 For the purposes of this invention, adjacent connection ends are understood to be the two connection ends that are closest to each other, and may even be adjacent to each other, i.e., they may be in mechanical contact with each other, as disclosed in, for example, DE 10 2017 201 533 A1 or DE 2019219 683 A1.

[0099] After the shaped conductor is bent as described above, the corresponding adjacent connection ends are electrically connected to each other, for example, by brazing, welding, or, as can also be envisioned, by mechanical plugging. Particularly preferred is to melt the surface of the copper ends by absorbing laser power, and then join them together during subsequent cooling (laser welding). If the adjacent connection ends are already electrically connected to each other, a corrosion-resistant insulating layer can then be provided for them according to the invention, wherein the corrosion-resistant insulating layer covers only the connection ends.

[0100] To achieve phase switching and winding connection, the process for fabricating an assembly of multiple shaped conductors preferably includes, as a further process step, connecting switching elements or components to the windings. This process is typically also performed via laser welding. Examples of interconnecting elements are contact rings, jumpers, and terminals. The process for providing such connections is disclosed in DE 10 2018 009206 A1.

[0101] According to the present invention, a component, preferably a hairpin-type motor stator, which contributes to solving at least one inventive objective, is also included, which can be obtained by the process.

[0102] Also contributing to solving at least one objective according to the invention is an electric motor comprising a stator of a hairpin structure obtainable by a process for preparing a hairpin structure motor stator, and a rotor located in an internal cylindrical space within the stator.

[0103] The motor according to the invention may further include a motor housing. The motor housing surrounds the motor. In particular, the stator is housed within the motor housing and fixed relative to the motor housing in an anti-rotational manner. The motor housing may also house control and power electronics. The motor housing may also be part of a cooling system for the motor, and is designed such that cooling fluid is supplied to the motor via the motor housing, particularly to the stator and cooling channels present in the stator, and / or heat is dissipated to the outside via the housing surface. Furthermore, the motor housing protects the motor and any electronic components that may be present from external influences. The motor housing may be formed, in particular, from a metallic material. Advantageously, the motor housing may be formed from a cast metallic material, such as gray cast iron or cast steel. In principle, it is also conceivable that the motor housing may be formed entirely or partially from plastic.

[0104] Contributing to the resolution of at least one object of the invention is a device comprising a moving part driven by such an electric motor. This motor is particularly intended for use in the powertrain of hybrid or fully electric vehicles. Specifically, the motor can be designed to achieve vehicle speeds exceeding 50 km / h, preferably exceeding 80 km / h, and especially exceeding 100 km / h. The motor particularly preferably has a power output greater than 30 kW, preferably greater than 50 kW, and especially greater than 70 kW. Furthermore, it is preferred that the motor provides a rotational speed greater than 5,000 rpm, particularly preferably greater than 10,000 rpm, and very particularly preferably greater than 12,500 rpm.

[0105] The motor can be mounted in an electrically operable final drive system. The electric final drive system of a motor vehicle includes a motor and a transmission, which form a structural unit. Specifically, it can be specified that the motor and transmission are arranged in a common drive system housing. Alternatively, the motor can have its own motor housing, and the transmission its own transmission housing; in this case, the structural unit can be implemented by fixing the transmission relative to the motor. This structural unit is sometimes also referred to as the E-axis.

[0106] In this application, a motor vehicle refers to a land vehicle that is powered by mechanical means and is not restricted by railway tracks. For example, a motor vehicle may be selected from categories such as passenger cars (cars), trucks (vans), mopeds, light motor vehicles, motorcycles, buses (COM), or tractors.

[0107] Reference List 100. Molded lead wire, preferably a shaped lead wire with a hairpin shape. 101 The first leg of the forming wire component 100 102 The first end of the formed wire component 100 103 The second leg of the forming wire component 100 104 The second end of the formed wire component 100 105 A bridging portion of the formed conductor 100, through which legs 101 and 103 are connected. 200 Assembly of formed wire component 100 201 The plane on which the ends 102, 104 of the first leg 101 and the second leg 103 of each formed guide wire 100 lie. 202 Assembled and formed first turn of wire component 100 203 The second turn of the assembled wire component 100 300 cylindrical stator core 301 Peripheral surface 302 inner peripheral surface 303 slot 304 Electrical laminate 305 teeth 400 hairpin-type stator 401 Connection Part 1300 housing element 1400 Arrangement Device 1450 Placeholder Component 1480 tension element 1451 Extension 1455 Fixing Part 1480 Bend 1485 handle part.

Claims

1. A process for arranging M shaped lead wires (100) around a receiving element (1300) to obtain a shaped lead wire ring assembly, wherein M is greater than 1, comprising the following steps: a) Provide M shaped wire components (100); b) The first of the M shaped wires (100) is placed in such a manner that a first distance (PL1) (at least a portion) between the first shaped wire (100) and the receiving element (1300) is maintained; c) The second to the Nth of the M shaped wires (100) are placed sequentially around the receiving element (1300), where N is greater than 2, wherein the (N+1)th to the Mth of the M shaped wires (100) overlap with the first shaped wire (100) in the assembly (200) of the shaped wires (100); d) Changing a first distance (PL1) between at least a portion of the first shaped lead wire (100) and the receiving element (1300) to a second distance (PL2), wherein the second distance (PL2) is greater than the first distance (PL1); and e) The (N+1)th shaped lead wire (100) to the Mth shaped lead wire (100, 130) are placed around the receiving element (1300) in sequence to complete the shaped lead wire ring assembly.

2. The process according to claim 1 further includes the following steps: f) Reduce at least a portion of the first shaped lead wire (100) from the second distance (PL2) to the receiving element (1300) to a third distance (PL3).

3. The process according to claim 1 or 2, wherein, Step b) includes: b1) A placeholder element (1450) is provided at the receiving element (1300), wherein the thickness of the placeholder element (1450) is equal to a first distance (PL1). b2) The first shaped lead wire (100) is placed around the receiving element (1300) with a placeholder element (1450) in between, such that at least a portion of the first shaped lead wire (100) is away from the receiving element (1300) by a first distance (PL1).

4. The process according to any one of claims 1 to 3, wherein, Step d) includes: d1) The first shaped lead wire (100) is moved away from the receiving element (1300) to increase the first distance (PL1) between the first shaped lead wire (100) and the receiving element (1300) to a second distance (PL2).

5. The process according to claim 4, wherein, Step d1) includes: d11) The first shaped lead wire (100) is pulled away from the receiving element (1300) by means of the pulling element (1480).

6. The process according to any one of claims 3 to 5, wherein, Step f) includes: f1) Remove the placeholder element (1450) and / or the pulling element (1480).

7. A process for manufacturing a hairpin stator, the process comprising the following steps: i) Provide wire (501), -The conductor (501) has a conductor surface and a conductor cross-section; - wherein at least 50% of the surface of the conductor is coated with an electrical insulating layer; ii) The conductor (501) is separated to obtain a longitudinal conductor member. -The longitudinal guide member includes a first end (102) and a second end (104). iii) The longitudinal conductor is shaped into a shaped conductor (100), the shaped conductor (100) including a first leg (101) having a first end (102), a second leg (103) having a second end (104), and a bridging portion (105) connecting the first leg (101) and the second leg (103). iv) Arranging a plurality of such shaped wires (100, 130) relative to each other to obtain an assembly, wherein the arrangement is accomplished in such a way that the legs (101, 103) of each of the plurality of shaped wires (100) are oriented substantially in the same direction, wherein the arrangement is accomplished according to any one of claims 1 to 6; v) An assembly (200) of a shaped conductor (100) is introduced into a stator (300) comprising a plurality of slots (303), each slot (303) having a first slot end (303a) and a second slot end (303b), introduced by means of legs (102, 104) of the shaped conductor (100) being introduced into the first slot end (303a) of each slot (303) of the stator (300), wherein the ends (102, 104) of each leg (101, 103) protrude from the stator (300) at the second slot end (303b) of the slot (303), and then these ends (102, 104) are twisted to achieve a specific spatial arrangement of these ends (102, 104), and vi) Provide electrical contact between a first end (102) or a second end (104) of a given shaped conductor (100) and a first end (102) or a second end (104) of another shaped conductor (100).

8. An arrangement device (1400) for arranging M shaped wire members (100) to obtain a shaped wire member ring assembly, wherein M is greater than 1, the arrangement device comprising: - A placeholder element (1450) adapted and arranged to maintain a first distance (PL1) between at least a portion of the first shaped wire of the M shaped wires (100) introduced from the receiving element (1300) into the arranging device (1400) and the receiving element (1300); and - A pulling element (1480) is adapted and arranged to pull the first shaped lead wire (100) away from the receiving element (1300) to increase the first distance (PL1) between at least a portion of the first shaped lead wire (100) and the receiving element (1300) to a second distance (PL2).

9. The arrangement device (1400) according to claim 8, wherein, The placeholder element (1450) includes: - An extension (1451), particularly in the form of a plug, is adapted and arranged to be positioned between a first shaped lead wire (100) introduced into the arranging device (1400) and a receiving element (1300), wherein the thickness of the extension (1451) is equal to a first distance (PL1); and - A fixing part (1455) is connected to an extension part (1451), which is adapted and arranged for attachment to a receiving element (1300).

10. The arrangement device (1400) according to claim 8 or 9, wherein, The tension element (1480) includes: - The curved portion (1481), particularly in a hook shape, is adapted and arranged to hook the first shaped lead wire (100) introduced into the arranging device (1400); and - A handle portion (1485) connected to the bending portion (1481) is adapted and arranged to move away from the receiving element (1300) to increase the first distance (PL1) between at least a portion of the first shaped lead wire (100) introduced into the arranging device (1400) and the receiving element (1300) to a second distance (PL2).

11. The arrangement device (1400) according to any one of claims 8 to 10, wherein, The pulling element (1480) is adapted and arranged such that after the second to the Nth of the M shaped wires (100) introduced into the arranging device (1400) are successively placed around the receiving element (1300), the first shaped wire (100) introduced into the arranging device (1400) is pulled away from the receiving element (1300), where N is greater than 2, wherein the (N+1)th to the Mth of the M shaped wires (100) introduced into the arranging device (1400) overlap with the first shaped wire (100) in the assembly (200) of the shaped wire (100).

12. The arrangement device (1400) according to claim 11, wherein, After the pulling element (1480) increases the first distance (PL1) between at least a portion of the first forming wire (100) and the receiving element (1300) to a second distance (PL2), the (N+1)th to the Mth forming wires (100) introduced into the arranging device (1400) are successively placed around the receiving element (1300).

13. The arranging device (1400) according to any one of claims 8 to 12, further comprising: -Removal element, which is adapted and arranged for removing the occupant element (1450) and / or the pull element (1480) to reduce the second distance (PL2) between at least a portion of the first shaped lead wire (100) introduced into the arranging device (1400) and the receiving element (1300) to a third distance (PL3).

14. The arrangement device (1400) according to any one of claims 8 to 13, wherein, The first distance (PL1) is greater than the width (W) of the shaped lead wire (100) introduced into the arranging device (1400).

15. Use of the arranging device (1400) according to any one of claims 8 to 14 in a process for preparing an assembly (200) of a shaped conductor (100) according to any one of claims 1 to 6.

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