Method and apparatus for forming wave-shaped conductor elements of an electrical winding

Abstract

The present invention relates to a method for forming a wave-shaped conductor element (2) for electrical windings starting from a wire (3). The method according to the invention comprises a series of operating steps for feeding the wire (3) onto a forming unit (4) according to corresponding movement rules and operating sequences, in order to ensure that the wave-shaped conductor element (2) is laid only on the operating face (9) of the forming unit (4) by means of corresponding wire feeders (25) of the wire (3).

Description

Technical Field

[0001] This invention relates to a method and apparatus for forming a waveform-type conductor element. Such a waveform conductor element, once inserted into the ferromagnetic core of an electrical machine, is suitable for providing electrical windings. Background Technology

[0002] The ferromagnetic cores currently under discussion are primarily of the slotted type, allowing for easy radial insertion of conductor elements that form the corresponding electrical windings. The slots can be open towards the outside or inside of the ferromagnetic core. The wave-shaped conductor elements are then electrically connected to other wave-shaped conductor elements arranged on the ferromagnetic core, thereby forming the electrical windings of rotating electromechanical equipment, such as stators and rotors. Rotating electromechanical equipment includes motors (powered by AC and DC), generators, AC generators, and electromagnetic brakes.

[0003] The waveform conductor element, upon insertion into a ferromagnetic core, has multiple adjacent linear portions extending parallel to each other, at least three if necessary, and multiple bridge-like portions inserted between them to connect the adjacent linear portions to each other. The bridge-like portions are alternately arranged on one end and the other end of the linear portions. The linear portions are inserted into slots in the ferromagnetic core (e.g., stator core), while the bridge-like portions protrude from corresponding end sides of the core. The cross-section of the conductor forming the conductor element can be circular, square, or rectangular. The dimensions of the conductor element's cross-section typically depend on the width of the cross-section of the slot in the core of the ferromagnetic core (e.g., stator core).

[0004] An open-slot rotary motor is a machine in which the slots housing the ferromagnetic core (which may be located in the stator or in the rotor) are open so as to allow the linear portion of the conductor element to be directly inserted radially into the slot, unlike a closed-slot motor in which the conductor element (e.g., the type called hairpin or the type called I-pin) needs to be introduced longitudinally into each slot.

[0005] The ability to insert conductor elements into open slots means that they can be pre-processed to form the winding portion to be set (e.g., composed of a specific shape structure of conductor elements having straight sections connected by corresponding bridging portions), so that the winding can be constructed more quickly while minimizing the welds required to join the portions of the conductor elements.

[0006] To accelerate the forming operation of conductor elements, it is known to use a device that enables the shank of the conductor element to be formed into a wave structure.

[0007] A method is known that involves winding the shank of a conductor element around a plate (of a given size) in a specific distribution pattern, i.e., alternately laying the linear portion of the waveform element on two opposing surfaces of the plate, so that it needs to be axially pulled out after the distribution is completed.

[0008] The process described above is very fast, but it cannot precisely control the orientation of the shank of the conductor element (if it has a polygonal cross-section, it may be necessary to maintain a specific distribution of its transverse surface). Furthermore, the winding needs to be axially slid out, which introduces specific and non-negligible dimensional constraints, particularly a larger overall volume.

[0009] Alternatively, it is known to lay the shank of the conductor element onto a fixed forming unit. Once the shank has been laid onto such a forming unit, a matching movable clamp arranged on the forming unit is simultaneously actuated to deform the shank and obtain the desired waveform profile of the conductor element. By employing this solution, the clamp (or other specialized equipment) can also perform lateral withdrawal (essentially along a direction perpendicular or partially inclined relative to the laying surface), which allows for a reduction in the overall volume of equipment suitable for producing semi-finished products consisting of shanks with waveform profiles. Using this technique, the orientation of the wires can also be controlled with precise accuracy, and thus the correct placement of the corresponding surfaces is maintained during the laying of the shank (in cases where a semi-finished product with a polygonal cross-section of the shank is required). In contrast, in this solution, the time required to produce the semi-finished product is considerably longer, and therefore also impacts the final cost of processing and the semi-finished product itself. Summary of the Invention

[0010] The object of the present invention is to overcome the above-mentioned disadvantages by providing a method for forming a waveform conductor element having a shape and orientation corresponding to a theoretical standard within a given tolerance.

[0011] Within this scope, the object of the present invention is to provide a method for forming a waveform conductor element for an electrical winding of a rotary slotted electromechanical device, which ensures a higher productivity than that achievable by laying the shank of the conductor element on a fixed forming unit.

[0012] Another object of the present invention is to provide an apparatus for forming a waveform conductor element for an electrical winding, which occupies less space overall than conventional apparatuses that wrap the shank of the conductor element around a forming unit.

[0013] Another object of the present invention is to provide an apparatus for forming waveform conductor elements of electrical windings, which operates with a higher precision than conventional apparatus that winds the shank of the conductor element around the forming unit.

[0014] Another object of the present invention is to provide an apparatus for forming waveform conductor elements of electrical windings, which ensures a lower cost compared to the prior art, which requires the use of a suitable clamp to lay the shank of the conductor element on a fixed forming unit.

[0015] Another object of the present invention is to provide an apparatus for forming a waveform conductor element for an electrical winding, which is capable of fully automated forming operations to produce a basic waveform shape of the shank of the conductor element.

[0016] Another object of the present invention is to provide a method and apparatus for forming a low-cost, easy-to-implement and safe-to-use electrical winding waveform conductor element.

[0017] This objective and these goals are achieved by the method of forming a waveform conductor element for an electrical winding according to claim 1.

[0018] This objective and these goals are also achieved by the apparatus for forming a waveform conductor element for an electrical winding according to claim 8. Attached Figure Description

[0019] Other features and advantages of the invention will become more apparent from the following detailed description of preferred, but not exclusive, embodiments of the method and apparatus for forming electrical windings, which are illustrated in the accompanying drawings as non-limiting examples, wherein:

[0020] Figure 1 A schematic perspective view of an apparatus for forming a waveform conductor element of an electrical winding according to the present invention, in a first operating position during the application of the method according to the present invention;

[0021] Figure 2 yes Figure 1 A schematic perspective view of the device in a second operating position during application of the method according to the invention;

[0022] Figure 3 yes Figure 1 A schematic perspective view of the device in a third operating position during application of the method according to the invention;

[0023] Figure 4 yes Figure 1 A schematic perspective view of the device in a fourth operating position during application of the method according to the invention;

[0024] Figure 5 yes Figure 1 A schematic perspective view of the device in a fifth operating position during application of the method according to the invention;

[0025] Figure 6 yes Figure 1 A schematic perspective view of the device in a sixth operating position during application of the method according to the invention;

[0026] Figure 7 yes Figure 1A schematic perspective view of the device in a seventh operating position during application of the method according to the invention;

[0027] Figure 8 yes Figure 1 A schematic perspective view of the device in the first part of operation during the application of the method according to the invention;

[0028] Figure 9 yes Figure 1 A schematic perspective view of the device in the second part of operation during the application of the method according to the invention;

[0029] Figure 10 yes Figure 1 A schematic perspective view of the first component of the device;

[0030] Figure 11 yes Figure 10 A top view of the components;

[0031] Figure 12 yes Figure 1 A schematic perspective view of the second component of the device;

[0032] Figure 13 yes Figure 12 A top view of the components;

[0033] Figure 14 yes Figure 1 A schematic perspective view of the forming elements of the equipment;

[0034] Figure 15 It is in active configuration. Figure 14 A top view of the forming element, which includes a portion of the forming wire;

[0035] Figure 16 This is a schematic perspective view of a machine according to the present invention, which includes a device for forming a waveform conductor element for electrical windings.

[0036] Referring to the accompanying drawings, reference numeral 1 generally indicates an apparatus for forming a waveform conductor element 2 suitable for applying the method according to the invention. Detailed Implementation

[0037] It should be noted that the method and apparatus 1 according to the invention are specifically indicated for providing a waveform conductor element 2, which can be used as part of an electrical winding in a rotary slotted electromechanical device, but it should be noted from this point that such a conductor element 2 can also be used in other different applications.

[0038] Referring to one of the possible embodiments and uses of the method and apparatus 1 according to the invention, it should be noted that the manufactured electrical conductor element 2 can be adapted to form part of an electrical winding for rotating slotted electromechanical equipment (i.e., motors and / or generators and / or electromagnetic brakes, wherein the slots are formed by continuous grooves disposed on the surface of an electromagnetic core, wherein an electrical winding can be inserted after substantially radial movement or movement having a radial component relative to the core).

[0039] As previously stated, each waveform conductor element 2 can also be used in other applications, which in any case remain within the protection scope defined by this invention.

[0040] Therefore, the method according to the invention is suitable for manufacturing a waveform conductor element 2 of an electrical winding made from a conductor 3.

[0041] This method involves a series of steps performed sequentially.

[0042] In the first step i), it is necessary to provide a forming unit 4 rotatable about the longitudinal rotation axis 5: such forming unit 4 must include an operating surface 9 supporting a plurality of forming elements 11, 14, 15, 16, 17, 18, wherein each forming element 11, 14, 15, 16, 17, 18 sequentially includes a corresponding abutment base 11d, 14d, 15d, 16d, 17d, 18d, a corresponding first abutment element 11e, 14e, 15e, 16e, 17e, 18e, and a corresponding second abutment element 11f, 14f, 15f, 16f, 17f, 18f.

[0043] In the subsequent second step ii), the end of the wire 3 needs to be locked to the forming unit 4 by means of the locking element 9a. The locking element 9a is integral with the operating surface 9 of the forming unit 4 and includes a seat 12 in which the end of the wire 3 can be locked.

[0044] In the subsequent third step iii), it is necessary to lay the wire 3 along the first straight section 10, starting from the end locked by the locking element 9a, in a direction transverse to the longitudinal axis 5.

[0045] Then the fourth step (iv) can be performed, which requires activating the first forming element 11 among the plurality of forming elements 11, 14, 15, 16, 17, 18 to constrain the wire 3 at the end of the first straight portion 10.

[0046] The subsequent fifth step (v) involves rotating the forming unit 4 180° relative to the longitudinal axis 5 to obtain a first tip bend 23a of the wire 3, which is at least partially arranged on the first forming element 11.

[0047] In the sixth step vi), the wire 3 is laid along a direction having a component parallel to the longitudinal axis 5 by pulling the first top bend 23a onto the first forming element 11.

[0048] The traction tip bend 23a defines the formation of the arc portion of the conductor 3 corresponding to the bridge-shaped portion of the conductor element 2, which connects two consecutive linear portions (i.e., portions 10 and 13 in this discussion): the arc portion starts from the first portion 10 and extends to the starting portion 22 of the arc portion, which terminates at the tip bend 23 (23a at the forming element 11); after the tip bend 23, there is the end portion 24 of the arc portion.

[0049] Basically, the starting portion 22 is formed after the top bend 23 (23a in this case) is pulled; on the other hand, the ending portion 24 is arranged accordingly after subsequent operations. Initially, the wire 3 is pulled onto the forming elements 11, 14, 15, 16, 17, 18, causing the top bend 23 (23a in the relevant case) to shift until it reaches its final position, thereby forming the starting portion 22. Then, before the wire 3, which is already outside the forming elements 11, 14, 15, 16, 17, 18, is laid in the subsequent seventh step vii) described below, it is further pulled longitudinally a distance that is substantially equal to the starting portion 22. For this purpose, once the wire has left the forming elements 11, 14, 15, 16, 17, 18, the second abutting shoulder elements 29, 28 are activated to force the wire 3 to be laid on a parallel plane.

[0050] When the wire 3 is locked between the corresponding forming elements 11, 14, 15, 16, 17, 18 (especially the first abutting elements 11e, 14e, 15e, 16e, 17e, 18e) and the first abutting shoulder elements 28, 29, the formation of the starting portion 22 (displacement of the top bend portion 23) is performed, and then, without the forming elements 11, 14, 15, 16, 17, 18, the wire 3 is pulled, forcing it between the first abutting shoulder element and the second abutting shoulder element 28, 29 of the wire feeder 25, thereby forming the end portion 24.

[0051] In subsequent step seven vii), the wire 3 needs to be laid along the second straight section 13, starting from the first forming element 11, in a direction parallel to and opposite to the first straight section 10, and in a direction transverse to the longitudinal axis 5. The second straight section 13 starts from the front part opposite to the portion that connects to the top bend 23 of the end section 24.

[0052] Step 8 (viii) includes activating the second forming element 14 of the plurality of forming elements 11, 14, 15, 16, 17, 18 to constrain the wire 3 at the end of the second straight segment 13.

[0053] In the ninth step (ix), the forming unit 4 needs to be rotated -180° relative to the longitudinal axis 5 (i.e., in the opposite direction relative to the previous rotation step) in order to obtain the second top bend 23b of the wire 3 arranged at least partially on the second forming element 14.

[0054] Step 10 (x) involves laying the wire 3 along a direction having a component parallel to the longitudinal axis 5 by pulling the second top bend 23b onto the second forming element 14.

[0055] In this case, the traction tip bend 23b also defines the formation of the arc portion of the conductor 3 corresponding to the bridge-shaped portion of the conductor element 2, which connects two consecutive linear portions (i.e., the linear portion of the second portion 13 to the subsequent linear portion): the arc portion starts from the second portion 13 and leads to the corresponding starting portion 22, which terminates at the tip bend 23b at the forming element 14; after the tip bend 23b, there is an end portion 24 that leads to the subsequent straight segment in which the conductor 3 is arranged.

[0056] The method according to the invention includes an eleventh step xi): repeating steps iii) to x) a given number of times on other corresponding forming elements 15, 16, 17, 18 among a plurality of forming elements 11, 14, 15, 16, 17, 18 until a conductor element 2 consisting of a portion of the basic waveform conductor 3 is obtained.

[0057] The twelfth and final step (xii) involves removing the waveform conductor element 2 and extracting it from the forming unit 4. The wire 3 may be supplied after being pre-cut at an upstream station. Alternatively, the wire 3 may be cut after the waveform conductor element 2 has been fully formed in the forming unit 4.

[0058] In the method according to the invention, advantageously, the waveform conductor element 2 is laid only on the operating surface 9 of the forming unit 4 by the wire feeder 25.

[0059] It should be noted that the forming unit 4 may include two opposing operating surfaces 9, and the corresponding wire feeder 25 will cooperate with each of these surfaces to allow the simultaneous fabrication of two waveform conductor elements 2.

[0060] It should be noted that the activation step of forming elements 11, 14, 15, 16, 17, 18 can certainly include the corresponding rotation of such forming elements 11, 14, 15, 16, 17, 18 about the corresponding rotation axes 11a, 14a, 15a, 16a, 17a, 18a perpendicular to the operating surface 9: such rotation is performed by forming elements 11, 14, 15, 16, 17, 18 from the disengaged position to the engaged position.

[0061] The disengagement and engagement positions of the forming elements 11, 14, 15, 16, 17, and 18 can be spaced by an angle of a given width, preferably 90°, which corresponds to the rotation amplitude around the respective axes 11a, 14a, 15a, 16a, 17a, and 18a.

[0062] The rotation of each forming element 11, 14, 15, 16, 17, 18 about its corresponding rotation axis 11a, 14a, 15a, 16a, 17a, 18a can be achieved by a pneumatic drive system, but other embodiments are not excluded.

[0063] At the engagement position, the wire 3 is placed above the surfaces of the abutment bases 11d, 14d, 15d, 16d, 17d, and 18d of the corresponding forming elements 11, 14, 15, 16, 17, and 18 through the protrusions 11g, 14g, 15g, 16g, 17d, and 18g of the first abutment elements 11e, 14e, 15, 16, 17, and 18.

[0064] Basically, as in the appendix Figure 15 As can be seen, the protruding portions 11g, 14g, 15g, 16g, 17g, and 18g extend beyond the end portion 24 and a portion of the first portion 10, locking them onto the surfaces of the abutting bases 11d, 14d, 15d, 16d, 17d, and 18d.

[0065] Such first abutting elements 11e, 14e, 15e, 16e, 17e, 18e may advantageously include sidewalls 11b, 14b, 15b, 16b, 17b, 18b, which are adapted to be placed along the side of the guide wire 3 at the engagement position of the respective forming elements 11, 14, 15, 16, 17, 18.

[0066] Each of the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f can move between a retracted position and a withdrawn position. In the withdrawn position, each of the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f protrudes relative to the abutment bases 11d, 14d, 15d, 16d, 17d, and 18d to constrain the wire 3 in the engagement position.

[0067] According to possible embodiments (shown by non-limiting example in the accompanying drawings), each of the second abutment elements 11f, 14f, 15f, 16f, 17f, 18f is movable between a retracted position and a withdrawn position. In the retracted position, each of the second abutment elements 11f, 14f, 15f, 16f, 17f, 18f is fully accommodated within its respective abutment base 11d, 14d, 15d, 16d, 17d, 18d. In the withdrawn position, the second abutment elements 11f, 14f, 15f, 16f, 17f, 18f are movable between a retracted position and a withdrawn position. Each of f, 16f, 17f, and 18f protrudes from, at least partially from, such abutment bases 11d, 14d, 15d, 16d, 17d, and 18d, and abuts against the side of the wire 3 at the engagement position occupied by the corresponding forming elements 11, 14, 15, 16, 17, and 18; thus, each of the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f constitutes an abutment shoulder against which the wire 3 can abut to maintain the correct geometric orientation.

[0068] According to this embodiment, in contrast, the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f can move between a retracted position and a withdrawn position. In the retracted position, the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f are completely accommodated within the corresponding abutment bases 11d, 14d, 15d, 16d, 17d, and 18d. In the withdrawn position, the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f protrude from the corresponding abutment bases 11d, 14d, 15d, 16d, 17d, and 18d. In this withdrawn and protruding position, they protrude outward from the corresponding abutment bases 11d, 14d, 15d, 16d, 17d, and 18d to abut against the side of the wire 3 in the engagement position, thus serving as an abutment surface for the wire 3.

[0069] The second abutting elements 11f, 14f, 15f, 16f, 17f, and 18f can only be in the corresponding withdrawn and protruding position after the corresponding forming elements 11, 14, 15, 16, 17, and 18 have reached the mentioned engagement position.

[0070] The sides of the second abutting elements 11f, 14f, 15f, 16f, 17f, and 18f on which the wire 3 is arranged (serving as the abutting surface of the wire 3) are opposite to the sides of the wire 3 arranged to abut against the sidewalls 11b, 14b, 15b, 16b, 17b, and 18b. In this way, the wire 3 can be locked between the walls 11b, 14b, 15b, 16b, 17b, and 18b, the second abutting elements 11f, 14f, 15f, 16f, 17f, and 18f, the abutting bases 11d, 14d, 15d, 16d, 17d, and 18d, and the protrusions 11g, 14g, 15g, 16g, 17g, and 18g (thereby ensuring that no undesirable plastic deformation occurs during subsequent laying and / or forming operations).

[0071] Once the corresponding forming elements 11, 14, 15, 16, 17, 18 have reached the engagement position, the forming unit 4 preferably uses a pneumatic drive to advantageously drive the extension of the second abutment elements 11f, 14f, 15f, 16f, 17f, 18f. As an example, it should be noted that each forming element 11, 14, 15, 16, 17, 18 can conveniently include a small hole below the second abutment elements 11f, 14f, 15f, 16f, 17f, 18f to allow the passage of compressed airflow from the forming unit 4 (which is in turn connected to the pneumatic drive circuit), which lifts the second elements 11f, 14f, 15f, 16f, 17f, 18f and pulls them out by causing them to protrude.

[0072] Referring to alternative embodiments (no illustrative figures are provided due to their intuitive form and features), it should be noted that the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f may also be constituted by a suitable clamping device that retracts from and retracts into a recess in the forming unit 4, the recess being open on the operating surface 9.

[0073] These clamping devices can be made of contoured clamps, thus suitable for clamping and holding the wire 3 without damaging it, and can be fully retracted into the recess in the forming unit 4 (in which case it will not cause any obstruction to the movement of the wire feeder 25), and pulled out only when necessary to clamp the wire 3 and ensure the stability of its arrangement.

[0074] It is possible that the recesses are substantially aligned with the peripheries of the forming elements 11, 14, 15, 16, 17, 18, so that the withdrawal of the clamping device can also ensure that the forming elements 11, 14, 15, 16, 17, 18 are locked in one of the corresponding configurations (i.e., active configuration and passive configuration) (or possibly both), thereby increasing the overall rigidity of the device 1 and thus ensuring higher precision in forming the conductor element 2.

[0075] It should be noted that the top bend 23 (e.g., the bend 23a formed at the forming element 11 or the bend 23b formed at the forming element 14) is obtained on the first abutting element 11e, 14e, 15e, 16e, 17e, 18e of the respective forming elements 11, 14, 15, 16, 17, 18.

[0076] Basically, without the first abutting elements 11e, 14e, 15e, 16e, 17e, 18e on the corresponding forming elements 11, 14, 15, 16, 17, 18, it is impossible to make the top bend 23 with the wire 3 by operating only on the operating surface 9 of the forming unit 4, and therefore it is impossible to make it into a waveform conductor element 2.

[0077] Referring to embodiments that undoubtedly have practical and application value, the wire feeder 25 and the forming unit 4 can move toward and away from each other.

[0078] Specifically, at least one component selected from wire feeder 25 and forming unit 4 can move in the direction of longitudinal axis 5.

[0079] The wire feeder 25 and the forming unit 4 interact with each other during the laying and rotating steps to plastically deform the wire 3 into the basic waveform shape of the electrical conductor element 2.

[0080] Specifically, the forming unit 4 can be translated along the direction of the longitudinal axis 5 so that the corresponding part of the operating surface 9 is aligned with the wire feeder 25; accordingly, the wire feeder 25 can move forward and backward toward and away from the longitudinal axis 5 in a direction transverse to the axis 5, respectively, in order to change its configuration outside the contour of the forming unit 4 to its configuration across the contour, facing and approaching the operating surface 9.

[0081] The wire feeder 25 can be advantageously mounted on a movable arm 25a, which can translate toward and away from the forming unit 4; the movable arm 25a is mounted such that it can slide on the guide rod 25b for up and down movement.

[0082] The wire feeder 25 may advantageously include at least a first abutting shoulder element 28 and a second abutting shoulder element 29, which are arranged opposite to each other, with the wire 3 (which extends through the corresponding channel 30) arranged opposite to each other between them.

[0083] Each abutment shoulder element 28, 29 can move independently between a retracted position and an extended position. In the retracted position, each abutment shoulder element is housed inside the wire feeder 25. In the extended position, each abutment shoulder element protrudes at least partially from the wire feeder 25 to define the wire 3 during the corresponding steps of longitudinal laying on the respective forming elements 11, 14, 15, 16, 17, 18.

[0084] The protection provided by this invention also extends to the apparatus 1 for manufacturing the waveform conductor element 2 of the electrical winding starting from the conductor 3.

[0085] The device 1 according to the invention includes a wire feeder 25 for feeding wires 3, for example, from a supply device, and a forming unit 4 mounted such that it can rotate about a longitudinal axis 5 and includes at least one operating surface 9.

[0086] The device 1 according to the invention may also include means for supplying the wire 3, which is not shown in the figures because it is conventional and typically includes a spool wound with the wire 3, a conveying device, and optionally an accumulation buffer.

[0087] In one embodiment, the forming unit 4 may be mounted on a carriage movable along a longitudinal axis 5, the relative movement of the forming unit 4 along the longitudinal axis 5 causing traction of the top bend 23. In another embodiment, the wire feeder 25 may be mounted on a carriage 4a, which may move parallel to the longitudinal axis 5 of the forming unit 4.

[0088] On the operating surface 9 of the forming unit 4, there is a locking element 9a suitable for locking the end of the wire 3.

[0089] In addition, a plurality of forming elements 11, 14, 15, 16, 17, 18 are provided on the operating surface 9 of the forming unit 4: each of the plurality of forming elements 11, 14, 15, 16, 17, 18 is adapted to interact with the wire 3 conveyed by the wire feeder 25 to produce a conductor element 2 having a preset waveform shape.

[0090] According to the present invention, each forming element 11, 14, 15, 16, 17, 18 includes a portion of the wire 3 abutting against a corresponding abutting base 11d, 14d, 15d, 16d, 17d, 18d, a corresponding first abutting element 11e, 14e, 15e, 16e, 17e, 18e, and a corresponding second abutting element 11f, 14f, 15f, 16f, 17f, 18f.

[0091] The device 1 according to the invention further includes at least one control and management unit 31, which is at least connected to the wire feeder 25, the forming unit 4 and the plurality of forming elements 11, 14, 15, 16, 17, 18, and can be programmed to execute the following instructions:

[0092] - Actuate the wire feeder 25 to lay the wire 3 along the first straight portion 10 from its end, which is locked by the locking element 9a, in a direction transverse to the longitudinal axis 5.

[0093] - Activate the first forming element 11 (belonging to multiple forming elements 11, 14, 15, 16, 17, 18) to constrain the wire 3 at the end of the first straight section 10;

[0094] - Rotate the forming unit 4 180° relative to the longitudinal axis 5 to obtain a first tip bend 23a of the wire 3 that is at least partially housed on the first forming element 11;

[0095] - By pulling the first top bend 23a onto the first forming element 11, the wire 3 is laid along a direction having a component parallel to the longitudinal axis 5;

[0096] - A wire 3 is laid from the first forming element 11 along the second straight section 13 in a direction parallel to and opposite to the first straight section 10 and in a direction transverse to the longitudinal axis 5.

[0097] - Activate the second forming element 14 (belonging to multiple forming elements 11, 14, 15, 16, 17, 18) to constrain the wire 3 at the end of the second straight section 13;

[0098] - Rotate the forming unit 4 relative to the longitudinal axis 5 by -180° (i.e., in the opposite direction to the previous rotation step) to obtain a second tip bend 23b of the wire 3 that is at least partially housed on the second forming element 14;

[0099] - By pulling the second top bend 23b onto the second forming element 14, the wire 3 is laid along a direction having a component parallel to the longitudinal axis 5;

[0100] - Repeat the previous steps a given number of times in other corresponding forming elements 15, 16, 17, 18 (belonging to multiple forming elements 11, 14, 15, 16, 17, 18) until a conductor element 2 consisting of a portion of substantially wave-shaped wire 3 is obtained;

[0101] Remove the waveform conductor element 2 and extract it from the forming unit 4. The wire 3 can be pre-cut and supplied from the upstream station. Alternatively, the wire 3 can be cut after the waveform conductor element 2 has been fully formed in the forming unit 4.

[0102] In device 1, the waveform conductor element 2 is laid only on the operating surface 9 of the forming unit 4 via the wire feeder 25.

[0103] The latter aspect is particularly important because it allows the waveform conductor element 2 to be removed from the operating surface 9 using only a clamping device that can perform movement toward / away from the operating surface 9 of the forming unit 4, i.e., it has a simpler structure than the structure in the prior art.

[0104] Each of the forming elements 11, 14, 15, 16, 17, 18 is rotatably mounted on the operating surface 9 about a corresponding axis of rotation 11a, 14a, 15a, 16a, 17a, 18a, between a disengaged position and an engaged position. The disengaged and engaged positions of the forming elements 11, 14, 15, 16, 17, 18 can be spaced apart by an angle of a given width, preferably 90°, which corresponds to the rotational amplitude about the corresponding axis 11a, 14a, 15a, 16a, 17a, 18a.

[0105] The forming elements 11, 14, 15, 16, 17, and 18 in the joining position are arranged alternately in two opposing rows parallel to the longitudinal axis 5, as shown in the non-limiting example in the figure.

[0106] At the engagement position, the wire 3 is positioned above the surfaces of the abutment bases 11d, 14d, 15d, 16d, 17d, and 18d via the protrusions 11g, 14g, 15g, 16g, 17g, and 18g of the first abutment elements 11e, 14e, 15e, 16e, 17e, and 18e. As previously indicated, in the attached... Figure 15 As can be seen, the protruding portions 11g, 14g, 15g, 16g, 17g, and 18g extend beyond the end portion 24 and a portion of the first portion 10, locking them onto the surfaces of the abutting bases 11d, 14d, 15d, 16d, 17d, and 18d.

[0107] It should also be emphasized that when the corresponding forming elements 11, 14, 15, 16, 17, 18 are in the corresponding engagement positions, each first abutting element 11e, 14e, 15e, 16e, 17e, 18e includes sidewalls 11b, 14b, 15b, 16b, 17b, 18b positioned along the side of the guide wire 3.

[0108] Each of the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f can move between a retracted position and a withdrawn position. In the withdrawn position, each of the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f protrudes relative to the abutment bases 11d, 14d, 15d, 16d, 17d, and 18d to constrain the wire 3 in the engagement position.

[0109] According to possible embodiments (shown by non-limiting example in the accompanying drawings), each of the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f can move between a retracted position and a withdrawn position. In the retracted position, the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f are fully accommodated within their respective abutment bases 11d, 14d, 15d, 16d, 17d, and 18d. In the withdrawn position, the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f are... 15f, 16f, 17f, and 18f protrude from the abutment bases 11d, 14d, 15d, 16d, 17d, and 18d, at least partially protruding from the bases, and abut against the side of the wire 3 at the engagement position occupied by the corresponding forming elements 11, 14, 15, 16, 17, and 18; thus, each of the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f constitutes an abutment shoulder against which the wire 3 can abut to maintain the correct geometric orientation.

[0110] Referring to alternative embodiments (no illustrative figures are provided due to their intuitive form and features), it should be noted that the second abutment elements 11f, 14f, 15f, 16f, 17f, and 18f may also be constituted by a suitable clamping device that retracts from and retracts into a recess in the forming unit 4, the recess being open on the operating surface 9.

[0111] These clamping devices can be made of contoured clamps, thus suitable for clamping and holding the wire 3 without damaging it, and can be fully retracted into the recess in the forming unit 4 (in which case it will not cause any obstruction to the movement of the wire feeder 25), and pulled out only when necessary to clamp the wire 3 and ensure the stability of its arrangement.

[0112] It is possible that the recesses are substantially aligned with the peripheries of the forming elements 11, 14, 15, 16, 17, 18, so that the withdrawal of the clamping device can also ensure that the forming elements 11, 14, 15, 16, 17, 18 are locked in one of the corresponding configurations (i.e., active configuration and passive configuration) (or possibly both), thereby increasing the overall rigidity of the device 1 and thus ensuring higher precision in forming the conductor element 2.

[0113] The first abutting elements 11e, 14e, 15e, 16e, 17e, and 18e of the corresponding forming elements 11, 14, 15, 16, 17, and 18e have a shape structure suitable for generating the top bend 23.

[0114] The wire feeder 25 and the forming unit 4 include corresponding actuators, which are controlled by the control and management unit 31 and adapted to move toward and away from each other.

[0115] At least one of such actuators has a travel of its movable element in a direction having at least one component along the longitudinal axis 5. The wire feeder 25 and the forming unit 4 interact with each other during the laying and rotation steps to plastically deform the wire 3 into the basic waveform shape of the electrical conductor element 2.

[0116] According to a preferred embodiment, the actuator of the forming unit 4 enables it to travel forward and backward along the direction of the longitudinal axis 5, while the actuator of the wire feeder 25 has a travel direction perpendicular to the longitudinal axis 5, which allows the wire feeder 5 to be moved toward and away from the operating surface 9 (so that the wire feeder 5 partially overlaps with the surface 9, or so that the wire feeder 5 is outside the outline of the forming unit 4 that defines the surface 9).

[0117] The wire feeder 25 advantageously includes at least a first abutting shoulder element and a second abutting shoulder element 28, 29, which are arranged opposite each other and define a channel 30 for feeding the conductor 3.

[0118] Each abutment shoulder element 28, 29 is movable independently between a retracted position and an extended position. In the retracted position, each abutment shoulder element 28, 29 is housed inside the wire feeder 25. In the extended position, each abutment shoulder element 28, 29 protrudes at least partially from the wire feeder 25 to define and transfer the wire 3 during the longitudinal laying of the wire 3 on the respective forming elements 11, 14, 15, 16, 17, 18.

[0119] Each electrical conductor element 2, which is part of the conductor 3 and is formed by applying the method (e.g., using device 1), can also undergo further forming operations (if these operations are indicated as inserting them into the opening slot of the electrical machinery to which they are used).

[0120] According to the preferred embodiment, the forming unit 4 is substantially rectangular (although the possibility of adopting a different shape structure that extends approximately in one longitudinal direction and is parallel to the reference axis 5 is not excluded).

[0121] In such an embodiment, it should be noted that the forming unit 4 is arranged such that its long side 6 (more precisely, its longer edge, corresponding to one of the longer parallel sides of the rectangle constituting its shape) is along a direction parallel to the longitudinal axis 5, and its short side 7 (more precisely, its longer edge) is along a direction transverse to the longitudinal axis 5.

[0122] Furthermore, the forming unit 4 is located on the reference plane 8: the operating surface 9 of the forming unit 4 is parallel to the reference plane 8.

[0123] It should also be noted that forming elements 11, 14, 15, 16, 17, and 18 protrude from the operating surface 9 in a direction perpendicular to the reference plane 8.

[0124] Regarding the steps of the rotational forming unit 4, it should be noted that if we assume that the rotation applied to the forming unit 4 during step v) corresponds to 180° (or -180°), then the next rotation applied to the forming unit 4 during step ix) corresponds to -180° (or 180°).

[0125] It should be noted that steps iv) and vii) of laying the wire 3 longitudinally onto the forming elements 11 and 14 (and also onto the forming elements 16, 17, and 18 when these steps are repeated) are performed along a given path in the longitudinal direction 20 (in Figure 10 (as shown in the figure) has at least one component in the lateral direction 21 (e.g. Figure 10 The conductor 3 has at least one component (as shown). Such components 20 and 21 are contained on the reference plane 8 (or in any case, they lie on the plane 8 or on a plane parallel to it). In the starting portion 22, the conductor 3 has a component 21 in the direction away from the axis 5 until the top bend 23; in the ending portion 24, the conductor 3 has a component 21 in the direction of movement toward the axis 5 until the second portion 13.

[0126] Each forming element 11, 14, 15, 16, 17, 18 may, during steps iii) and vii) of the laying of the straight section in which it participates, be in a standby position away from the conductor 3 (e.g., for forming elements 15, 16, 17, 18, as shown in the attached figure). Figures 1 to 6 (as shown) and engagement locations (e.g., for formed elements 11 and 14, as attached) Figures 1 to 6 As shown, for the forming element 15, as Figure 7 and 8 Rotating between (as shown), in the engagement position, at least one wing of the forming element abuts against a portion of the surface of the wire 3.

[0127] The motion rules for laying the wire 3 are defined by the interaction between the motion rules of the wire feeder 25 and the motion rules of the forming unit 4, both of which are determined by the corresponding actuators controlled and managed by the control and management unit 31.

[0128] Each forming element 11, 14, 15, 16, 17, 18 may optionally include retaining elements 11c, 14c, 15c, 16c, 17c, 18c, which are adapted to lock the end portion 24 after the “bent” region consisting of the starting portion 22, the top bend 23 and the end portion 24 has been formed, so as to further ensure that the region is locked, thereby preventing unwanted plastic deformation.

[0129] Referring to embodiments with undeniable practical and application value, the forming elements 11, 14, 15, 16, 17, and 18 protruding from the operating surface 9 of the forming unit 4 are multiple elements arranged side-by-side and adjacent to each other along the longitudinal direction (parallel to axis 5): these forming elements 11, 14, 15, 16, 17, and 18 constitute an abutment reference for properly laying the conductor 3 in a shape structure that defines a substantially wave-shaped portion formed by the forming portion of the conductor element 2.

[0130] Retaining elements 11c, 14c, 15c, 16c, 17c, and 18c can be easily moved between a first passive configuration and a second active configuration. In the first passive configuration, they are completely outside the corresponding forming elements 11, 14, 15, 16, 17, and 18, and do not extend beyond any part of them (e.g., in...). Figure 1 In the first passive configuration, the retaining elements 14c, 15c, 16c, 17c, and 18c are in the second active configuration, at least one end of which protrudes above a portion of the corresponding forming elements 11, 14, 15, 16, 17, and 18 and beyond a portion of the wire 3 (particularly the end portion 24).

[0131] Optionally, retaining elements 11c, 14c, 15c, 16c, 17c, and 18c present on the forming unit 4 are configured to constrain the guide wire 3 along the corresponding forming elements 11, 14, 15, 16, 17, and 18, thereby preventing their displacement and plastic deformation.

[0132] Optional retaining elements 11c, 14c, 15c, 16c, 17c, and 18c can rotate about corresponding rotation axes on the operating surface 9: in this case, rotation can also be achieved by corresponding actuators (e.g., pneumatic, electric, or hydraulic).

[0133] It is important to note that each abutment shoulder element 28, 29 is configured to impose a movement restriction (and thus generate a force) on the conductor 3 during its laying in portions 22 and 24 (before and after the top bend 23). Due to the constraint of the conductor 3 between the abutment shoulder elements 28, 29 (or due to the constraint defined by only one of them), the conductor 3 will not undergo undesirable plastic deformation due to the mechanical stress generated by the subsequent associated bending and torsional operations.

[0134] The wire feeder 25 has two opposing abutment shoulder elements 28, 29 on its sides (which define the end opening of the channel 30 inside the conductor wire feeder 25, in which the conductor 3 slides): each abutment shoulder element 28, 29 can be in an extended position (in which it protrudes from the end face of the wire feeder 25) or a retracted position (in which it does not protrude from the end face of the wire feeder 25).

[0135] When both abutting shoulder elements 28 and 29 are retracted, the conductor 3 delivered by conductor feeder 25 can pass freely, so that channel 30 serves as a guide (for the straight and transverse laying step) and as a fulcrum for the top bend 23 of the waveform conductor element 2, which is performed on the corresponding forming elements 11, 14, 15, 16, 17, and 18 (during the 180° rotation step).

[0136] On the other hand, when the abutting shoulder elements 28 and 29 are in the withdrawn position (protruding), or when both are in the withdrawn position, that is, during the step of laying the wire 3 longitudinally (along sections 22 and 24), the wire 3 is subjected to torsional force in the Z-shaped section (obtained by first withdrawing the first abutting shoulder element 28 and then withdrawing the second abutting shoulder element 29), and in the subsequent S-shaped section (obtained by first withdrawing the second abutting shoulder element 29 and then withdrawing the first abutting shoulder element 28).

[0137] It should be emphasized again that, according to the present invention, there may be an embodiment in which the forming unit 4 has an operating surface 9 on two mutually opposing surfaces.

[0138] In this case, device 1 includes two separate wire feeders 25, which lay corresponding wires 3 (e.g., from corresponding and separate supply devices) on these mutually opposing operating surfaces 9 substantially simultaneously.

[0139] This embodiment enables productivity that is essentially twice that of the previously described version with a single operating face 9.

[0140] The device 1 according to the invention can be provided such that, in order to form the waveform conductor element 2, it may also include a removal tool 32 for removing the waveform conductor element 2 once it has been fully formed.

[0141] The removal tool 32 includes at least one clamping element 33 for holding the waveform conductor element 2 to remove it from the operating surface 9 of the forming unit 4. In a preferred embodiment, such at least one clamping element 33 is composed of a plurality of grippers 34 that can move from a release position to a clamping position. The grippers 34 can be arranged such that they can move relative to each other within the removal tool 32, allowing them to handle various shapes and sizes of the waveform conductor element 2.

[0142] The removal tool 32 is mounted on a gantry robot 35, which is movable to ensure at least one change in the height of the removal tool 32 (by moving it up and down) and / or a change in the translation of the removal tool 32 (moving back and forth from the forming unit 4) in order to process the waveform conductor element 2 and switch it to the process that occurs downstream. The removal tool 32 can also move parallel to the axis of rotation 5.

[0143] Advantageously, the present invention solves the aforementioned problems by providing a method for forming a portion of an electrical winding for rotating slotted electrical machinery having high-precision standards. The winding portion is composed of conductor elements 2, which have a shape and orientation corresponding to theoretical standards within a given tolerance.

[0144] Conveniently, the method according to the invention ensures a higher productivity than that achievable by laying wires 3 on the fixed forming unit 4.

[0145] The advantage is that the equipment 1 used to manufacture the electrical winding portion of the rotary slotted electromechanical according to the invention provides a reduced space footprint, typically less than that of conventional equipment that requires winding wires around the forming unit 4.

[0146] Advantageously, the device 1 according to the invention operates with a higher precision than conventional devices that can be achieved by winding the wire 3 around the forming unit 4.

[0147] On the positive side, the device 1 according to the invention ensures a reduction in cost compared to the prior art, which requires the use of a suitable clamp to lay the wire 3 on the fixed forming unit 4.

[0148] Advantageously, the device 1 according to the invention enables the forming operation to be fully automated to produce the basic waveform shape of the conductor 3, thereby providing an extremely accurate and repeatable conductor element 2.

[0149] The positive aspect is that the method and apparatus 1 according to the invention for forming portions of electrical windings for rotary slotted electromechanical equipment are easy to implement and practically feasible at low cost; such characteristics make the method and apparatus 1 according to the invention a safe innovation in use.

[0150] Therefore, the conceived invention is readily subject to numerous modifications and variations, all of which are within the scope of the appended claims. Furthermore, all details may be replaced by other technically equivalent elements.

[0151] In the illustrated embodiments, the individual characteristics shown for a particular instance may be interchanged with other different characteristics present in other embodiments.

[0152] In practice, the materials and dimensions used can be any materials and dimensions as required and in accordance with existing technology.

[0153] The disclosure of Italian patent application No. 102024000007696, which claims priority to this application, is incorporated herein by reference.

[0154] Where any technical feature mentioned in a claim is followed by a reference numeral, such reference numerals are included only to increase the comprehensibility of the claim, and therefore, such reference numerals do not limit the interpretation of each element identified by way of example through such reference numerals.

Claims

1. A method for forming a waveform conductor element (2) of an electrical winding starting from a conductor (3), the method comprising the steps of: i) Provides a forming unit (4) rotatable about a longitudinal rotation axis (5), the forming unit (4) including an operating surface (9) supporting a plurality of forming elements (11, 14, 15, 16, 17, 18), wherein each forming element (11, 14, 15, 16, 17, 18) includes a corresponding abutment base (11d, 14d, 15d, 16d, 17d, 18d) and a corresponding first abutment element (11e, 14e, 15e, 16e, 17e, 18e). ii) Lock the first end of the wire (3) to the forming unit (4) by means of the locking element (9a); iii) Lay the first straight portion (10) of the conductor (3) from the first end of the lock along a first straight direction transverse to the longitudinal axis (5); iv) Move the first forming element (11) of the plurality of forming elements (11, 14, 15, 16, 17, 18) in a corresponding engagement position to constrain the wire (3) at the end of the first straight portion (10) away from the locked first end; v) Rotate the forming unit (4) 180° about the longitudinal axis (5) to obtain the first top bend (23a) of the wire (3) on the corresponding first abutting element (11e) of the first forming element (11). vi) By pulling the first top bend (23a) onto the first forming element (11), the wire (3) is laid along a direction having a component parallel to the longitudinal axis (5). vii) Starting from the first forming element (11), a second straight section (13) of the conductor (3) is laid transversely to the longitudinal axis (5) along a second straight direction opposite to the first straight direction. The second straight section (13) is substantially parallel to the first straight section (10). viii) Move the second forming element (14) of the plurality of forming elements (11, 14, 15, 16, 17, 18) in the corresponding engagement position to constrain the wire (3) at the end of the second straight portion (13); ix) Rotate the forming unit (4) in the opposite direction of the longitudinal axis (5) by -180°, i.e. in the opposite direction of the previous rotation, to obtain the second top bend (23b) of the wire (3) on the corresponding first abutment element (14e) of the second forming element (14). x) By pulling the second top bend (23b) onto the second forming element (14), the wire (3) is laid along a direction having a component parallel to the longitudinal axis (5). xi) Repeat the steps of laying, moving, and rotating the remaining forming elements (15, 16, 17, 18) among the plurality of forming elements (11, 14, 15, 16, 17, 18) until a waveform conductor element (2) consisting of the plastically deformed portion of the wire (3) is obtained; and xii) Remove the waveform conductor element (2) from the forming unit (4); The waveform conductor element (2) is laid only on the operating surface (9) of the forming unit (4).

2. The method according to claim 1, characterized in that, The step of moving the forming elements (11, 14, 15, 16, 17, 18) includes the corresponding rotation of the forming elements (11, 14, 15, 16, 17, 18) about their respective rotation axes (11a, 14a, 15a, 16a, 17a, 18a), which are preferably parallel to each other and perpendicular to the operating surface (9), between the disengaged position and the corresponding engaged position.

3. The method according to one or more of the preceding claims, characterized in that, Each first abutting element (11e, 14e, 15e, 16e, 17e, 18e) is placed above the corresponding abutting base (11d, 14d, 15d, 16d, 17d, 18d) of the forming element (11, 14, 15, 16, 17, 18d) and includes a corresponding protrusion (11g, 14g, 15g, 16g, 17g, 18g) protruding from the corresponding abutting base (11d, 14d, 15d, 16d, 17d, 18d). When the forming element (11, 14, 15, 16, 17, 18) rotates, the wire (3) engages the corresponding protrusion (11g, 14g, 15g, 16g, 17g, 18g) at the corresponding engagement position to form the top bend (23).

4. The method according to one or more of the preceding claims, characterized in that, Each first abutting element (11e, 14e, 15e, 16e, 17e, 18e) includes a sidewall (11b, 14b, 15b, 16b, 17b, 18b) that contacts the wire (3) in the engagement position.

5. The method according to one or more of the preceding claims, characterized in that, Each forming element (11, 14, 15, 16, 17, 18) includes a corresponding second abutment element (11f, 14f, 15f, 16f, 17f, 18f) movable between a retracted position and an advanced position, wherein the second abutment element (11f, 14f, 15f, 16f, 17f, 18f) protrudes from a corresponding abutment base (11d, 14d, 15d, 16d, 17d, 18d) to constrain the wire (3) in the engagement position.

6. The method according to one or more of the preceding claims, characterized in that, The conductor (3) is displaced relative to the forming unit (4) along the longitudinal axis (5) to pull the first top bend (23a) along a direction having a component parallel to the longitudinal axis (5) during the laying step of the conductor (3).

7. The method according to one or more of the preceding claims, characterized in that, The conductor (3) is provided by a wire feeder (25), which is movable up and down relative to the forming unit (4).

8. An apparatus (1) for forming a waveform conductor element (2) for an electrical winding from a conductor (3), the apparatus (1) comprising: -Wire feeder (25), configured to supply wire (3). - The forming unit (4) includes the operating surface (9). - A locking element (9a), which is mounted on the operating surface (9) and configured to lock the first end of the wire (3) supplied by the wire feeder (25). - A plurality of forming elements (11, 14, 15, 16, 17, 18) are mounted on the operating surface (9), each of the plurality of forming elements (11, 14, 15, 16, 17, 18) being configured to interact with the wire (3) supplied by the wire feeder (25), wherein each forming element (11, 14, 15, 16, 17, 18) includes a corresponding abutment base (11d, 14d, 15d, 16d, 17d, 18d) and a corresponding first abutment element (11e, 14e, 15e, 16e, 17e, 18e), and - Removal tool (32), which is configured to remove the waveform conductor element (2) from the forming unit (4). The forming unit (4) is characterized in that it is rotatably mounted about a longitudinal axis (5), and it further includes: - A controller (31), which is connected to the wire feeder (25), the forming unit (4), and the plurality of forming elements (11, 14, 15, 16, 17, 18), and is programmed to issue the following instructions: - Displace the wire feeder (25) to lay the first straight portion (10) of the wire (3) starting from the locked first end of the wire (3) along a first straight direction transverse to the longitudinal axis (5). - Move the first forming element (11) of the plurality of forming elements (11, 14, 15, 16, 17, 18) in a corresponding engagement position to constrain the wire (3) at the end of the first straight portion (10) away from the locked first end; - Rotate the forming unit (4) 180° about the longitudinal axis (5) to obtain the first top bend (23a) of the wire (3) on the corresponding first abutting element (1) of the first forming element (11). - By pulling the first top bend (23a) onto the first forming element (11), the wire feeder (25) and / or the forming unit (4) are displaced to lay the wire (3) along a direction having a component parallel to the longitudinal axis (5). - Displace the wire feeder (25) to lay a second straight portion (13) of the wire (3) from the first forming element (11) along a second straight direction opposite to the first straight direction, transverse to the longitudinal axis (5), the second straight portion (13) being substantially parallel to the first straight portion (10). - Move the second forming element (14) of the plurality of forming elements (11, 14, 15, 16, 17, 18) in the corresponding engagement position to constrain the wire (3) at the end of the second straight portion (13); - Rotate the forming unit (4) in the opposite direction about the longitudinal axis (5) by -180°, i.e. in the opposite direction to the previous rotation, to obtain the second top bend (23b) of the wire (3) on the corresponding first abutment element (14e) of the second forming element (14). - Displace the wire feeder (25) and / or the forming unit (4) to lay the wire (3) along a direction having a component parallel to the longitudinal axis (5), and pull the second top bend (23b) onto the second forming element (14); - Sequentially move the remaining forming elements (15, 16, 17, 18) of the plurality of forming elements (11, 14, 15, 16, 17, 18) into their respective engagement positions, thereby displacing the wire feeder (25) and / or the forming unit (4) and rotating the forming unit (4) until a waveform conductor element (2) consisting of the plastically deformed portion of the wire (3) is obtained. The waveform conductor element (2) is laid only on the operating surface (9) of the forming unit (4).

9. The device (1) according to the preceding claim, characterized in that, Each of the plurality of forming elements (11, 14, 15, 16, 17, 18) is rotatably mounted about a corresponding axis of rotation (11a, 14a, 15a, 16a, 17a, 18a), which is preferably parallel to each other and perpendicular to the operating surface (9), the rotation being between a disengaged position and the corresponding engaged position.

10. The device (1) according to claim 8 or 9, characterized in that, When in the respective engagement positions, the forming elements (11, 14, 15, 16, 17, 18) are alternately arranged on two opposite rows parallel to the longitudinal axis (5).

11. The device (1) according to one or more of claims 8, 9 and 10, characterized in that, Each first abutting element (11e, 14e, 15e, 16e, 17e, 18e) is placed above the corresponding abutting base (11d, 14d, 15d, 16d, 17d, 18d) of the forming element (11, 14, 15, 16, 17, 18d) and includes a corresponding protrusion (11g, 14g, 15g, 16g, 17g, 18g) protruding from the corresponding abutting base (11d, 14d, 15d, 16d, 17d, 18d), the corresponding protrusion (11g, 14g, 15g, 16g, 17g, 18g) being configured to be engaged by the wire (3) in the corresponding engagement position to form the top bend (23) when the forming element (11, 14, 15, 16, 17, 18) rotates.

12. The device (1) according to one or more of claims 8 to 11, characterized in that, Each first abutting element (11e, 14e, 15e, 16e, 17e, 18e) includes a sidewall (11b, 14b, 15b, 16b, 17b, 18b) configured to abut against the wire (3) in the engagement position.

13. The device (1) according to one or more of claims 8 to 12, characterized in that, Each forming element (11, 14, 15, 16, 17, 18) includes a corresponding second abutment element (11f, 14f, 15f, 16f, 17f, 18f) movable between a retracted position and a forward position, in which the second abutment element protrudes from the corresponding abutment base (11d, 14d, 15d, 16d, 17d, 18d) to constrain the wire (3) in the engagement position.

14. The device (1) according to one or more of claims 8 to 13, characterized in that, The wire feeder (25) is mounted on a movable arm that is movable toward and away from the forming unit (4), and the movable arm is slidably mounted on the column and moves up and down.

15. The device (1) according to one or more of claims 8 to 14, characterized in that, The wire feeder (25) is mounted on a slide (4a) that is movable along the longitudinal axis (5) of the forming unit (4).

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