Apparatus for the manufacture of laminations obtained by the conjunction of a plurality of shaped metal elements

Abstract

An apparatus (800) for the manufacture of a lamination (100) for the manufacture of a stator (200) or of a rotor (300) of a rotating electric machine (400) or of a laminated ferromagnetic core (500) of a static electric machine, said lamination (100) comprising a plurality of shaped metal elements (1) that can be coupled to each other by interference at the conjugable shaped sides (2, 3) of the shaped metal elements (1).

Description

[0001] APPARATUS FOR THE MANUFACTURE OF LAMINATIONS OBTAINED BY THE CONJUNCTION OF A PLURALITY OF SHAPED METAL ELEMENTS.

[0002] DESCRIPTION

[0003] The invention concerns an apparatus for the manufacture of a lamination through the conjunction of shaped metal elements.

[0004] It is known that rotating electric machines, used both as motors for the production of movement of mechanical parts and as electrical energy generators, are substantially made up of a fixed hollow part, called a stator, inside which a cylindrical part, called a rotor, rotates which is keyed on the rotation shaft of the stator.

[0005] It is also known that static electric machines, in particular the transformers, comprise a laminated ferromagnetic core of the column or shell type.

[0006] In order to manufacture the stator and the rotor of a rotating electric machine or the laminated ferromagnetic core of a static electric machine, particular elements of metallic material, which are only a few tenths of a millimetre thick, called laminations L in technical jargon, an example of which is shown in fig. 1 of the prior art, are stacked on top of each other.

[0007] In order to achieve the stable stacking of the laminations L for the manufacture of the stator, rotor or laminated ferromagnetic core, the laminations L themselves are secured to each other by means of particular connection techniques such as, for example, die-casting, nailing, welding process or other equivalent processes.

[0008] It is also known that, in most cases, these laminations L are obtained from foils of metallic material M, which are subjected to a stamping process carried out by means of particular pressing devices.

[0009] In particular, the most well-known and used techniques for the manufacture of the laminations L include a so-called stepwise or phasewise stamping.

[0010] In fact, with these techniques, laminations L are obtained which are made as a single body with a shape corresponding to the shape of the stator, rotor or laminated ferromagnetic core to be obtained.

[0011] However, as extensively described in the Italian Patent application no. VI2008A000159, filed by the same Applicant of the present application, these techniques used to obtain the aforesaid laminations L disadvantageously have the disadvantage of a high waste of metallic material.

[0012] In fact, as can be observed in fig. 2 of the prior art where a process for manufacturing a stator in steps is represented, the angular ends E and the central part C of each square Q of the metal foil M, on which the same laminations L are obtained, are not exploited and consequently become unused material scraps, possibly recoverable by melting.

[0013] For this reason, the aforesaid Patent application no. VI2008A000159 aims to reduce the scraps made during the stamping of the laminations L, by proposing to obtain on the same portions of material, previously considered as scraps, shaped metal elements that, joined together, allow to obtain laminations usable to manufacture the stator and the rotor of the so-called “exciter” in jargon.

[0014] Exciter means the excitation device, provided with a rotor and with a stator, which is used to power the electromagnets arranged on the main rotor of an alternator.

[0015] In particular, the technique proposed by the aforesaid Patent application provides for joining the various shaped metal elements together by welding.

[0016] Disadvantageously, as mentioned above, the laminations thus obtained are adapted to be used only for the manufacture of the stator and / or rotor of an exciter, and not also for the manufacture of the main stator and rotor of a rotating electric machine or the laminated ferromagnetic core of a static electric machine. This is because the welding technique used to conjoin the various shaped metal elements results in a non-negligible loss of magnetic flux in the junction area, which can be as much as 50% compared to a lamination made as a single body.

[0017] Thus, disadvantageously, the use of the laminations thus obtained for the manufacture of main stators and rotors of rotating electric machines or for the manufacture of laminated ferromagnetic cores of static electric machines would entail a high loss of performance of the machines themselves, thus making the aforesaid laminations clearly inadequate for this purpose.

[0018] The present invention is intended to overcome the claimed drawbacks.

[0019] In particular, the invention aims to manufacture shaped metal elements that, when conjoined together, allow laminations to be obtained with a yield only a few percentage points lower than the laminations made as a single body.

[0020] For this reason, it is an object of the present invention to manufacture shaped metal elements that allow to obtain laminations usable to manufacture the stator and / or the main rotor of a rotating electric machine and the laminated ferromagnetic core of a static electric machine.

[0021] Another object of the present invention is to obtain the shaped metal elements from portions of metal foil previously considered as scrap material.

[0022] Consequently, the object of the invention is the manufacture of shaped metal elements that allow a reduction in costs for the manufacture of the rotors, stators and laminated ferromagnetic cores respectively of rotating electric machines and of static electric machines.

[0023] The above objects are achieved by a shaped metal element having the features according to the main claim.

[0024] In particular, the shaped metal element of the invention is characterized in that it provides at least two sides with a conjugable shaped profile in such a way that such sides can be coupled by interference with the relative conjugable shaped profile sides of shaped metal elements placed adjacent to the shaped metal element itself.

[0025] Advantageously, this solution makes it possible to minimize the loss of magnetic flux in the junction area and therefore to slightly vary the efficiency with respect to the laminations obtained as a single body.

[0026] Further characteristics of the shaped metal elements are described in the dependent claims.

[0027] Also forming part of the invention are the lamination manufactured by the conjunction of a plurality of the aforesaid shaped metal elements, the rotor, the stator and the laminated ferromagnetic core obtained by stacking a plurality of the aforesaid laminations and finally the rotating electric machine and the static electric machine respectively comprising at least the aforesaid rotor or at least the aforesaid stator and the aforesaid laminated ferromagnetic core.

[0028] Finally, the method and two types of apparatus for the manufacture of the lamination by means of the aforesaid shaped metal elements are also part of the invention.

[0029] Said objects and advantages will be better highlighted during the description of a preferred embodiment of the invention which is given, by way of nonlimiting example, with reference to the attached drawings, wherein:

[0030] - fig. 1 represents a lamination of the prior art obtained as a single body and used to make the main stator of a rotating electric machine;

[0031] - fig. 2 represents the stamping technique of the prior art to obtain a lamination as a single body from a foil of metallic material; - fig. 3 represents the shaped metal element of the invention according to a first embodiment;

[0032] - fig. 4 represents the shaped metal element of the invention according to a second embodiment;

[0033] - fig. 5 represents a lamination of the invention obtained by the coupling by interference of a plurality of shaped metal elements of the invention;

[0034] - fig. 6 represents the stator of the invention obtained by stacking a plurality of laminations of the invention;

[0035] - fig. 7 represents the rotor of the invention obtained by stacking a plurality of laminations of the invention;

[0036] - fig. 8 represents the rotating electric machine comprising at least the stator and / or at least the rotor of the invention;

[0037] - fig. 9 represents the laminated ferromagnetic core of the invention obtained by stacking a plurality of laminations of the invention;

[0038] - fig. 10 represents a jig on which a plurality of shaped metal elements of the shaped element of fig. 3 is arranged so as to define the shape of the stator to be obtained;

[0039] - fig. 11 represents an axonometric view of the rotating plane belonging to the apparatus for the manufacture of laminations of the invention;

[0040] - fig. 12 represents the top view of the rotating plane belonging to the apparatus for the manufacture of laminations of the invention;

[0041] - fig. 13 represents an axonometric view of the rotating plane and of the conveyors belonging to the apparatus for the manufacture of laminations of the invention;

[0042] - fig. 14 represents an axonometric view of the loading device of the apparatus for the manufacture of laminations of the invention;

[0043] - fig. 15 represents the top view of the loading device belonging to the apparatus for the manufacture of laminations of the invention;

[0044] - fig. 16 represents the bottom view of the loading device belonging to the apparatus for the manufacture of laminations of the invention;

[0045] - fig. 17 represents a detail of fig. 16;

[0046] - fig. 18 represents a sectional side view of a loading station belonging to the loading device of fig. 14, according to a first operating position;

[0047] - fig. 19 represents a sectional side view of a loading station belonging to the loading device of fig. 14, according to a second operating position; - fig. 20 represents an axonometric view of the radial thrust means according to the preferred embodiment of the apparatus of the invention in a first configuration;

[0048] - fig. 21 represents an axonometric view of the radial thrust means according to the preferred embodiment of the apparatus of the invention in a second configuration;

[0049] - fig. 22 represents an axonometric view of the radial thrust means according to an alternative embodiment of the apparatus of the invention in a first configuration;

[0050] - fig. 23 represents an axonometric view of the radial thrust means according to an alternative embodiment of the apparatus of the invention in a second configuration;

[0051] - fig. 24 represents an axonometric view of a detail of the loading station of the invention;

[0052] - fig. 25 represents a sectional side view of a detail of the loading station of the invention.

[0053] The shaped metal element of the invention, for the manufacture of laminations of a stator and / or of a rotor of a rotating electric machine or of a laminated ferromagnetic core of a static electric machine, is represented as a whole in figs. 3 and 4, where it is indicated with 1.

[0054] It can be observed that this shaped metal element 1 is adapted to be connected at two of its own sides 2 and 3 to shaped metal elements 1 of the invention that are placed adjacent to it, so as to define a lamination 100 adapted to be subsequently used to manufacture a stator 200 or a rotor 300 of a rotating electric machine 400 or to manufacture a laminated ferromagnetic core 500 of a static electric machine, represented respectively in figs. 5, 6, 7, 8 and 9.

[0055] The invention provides that on each side 2 and 3 of the shaped metal element 1 a shaped profile 4 is made that can be conjugated to a corresponding side 2 and 3 of the shaped metal element 1 placed adjacent to the first, so that the aforesaid shaped metal elements 1 can be coupled together by interference.

[0056] Preferably but not necessarily, as can be observed in fig. 3, the aforesaid conjugable shaped profile 4 is made for the entire length of each of the two sides 2 and 3. This last feature advantageously allows to obtain the coupling by interference along the entire extension of the two sides 2 and 3 of two adjacent shaped metal elements 1. Consequently, in this situation, the percentage value of the loss of the magnetic flux in this coupling section with respect to a lamination manufactured as a single body is irrelevant.

[0057] Moreover, the preferred embodiment of the invention, as can be observed in fig. 3, provides that each of said sides 2 and 3 has a conjugable profile 4 shaped as a comb.

[0058] Even more in detail, as can be noted in fig. 3, this conjugable profile 4 shaped as a comb has teeth 41 and concavities 42 substantially with a triangular profile.

[0059] It is important to point out that the conjugable shaped profile 4 at the first side 2 of the shaped metal element 1 is made in such a way as to be perfectly conjugable with the conjugable shaped profile 4 made on the second side 3 of the same shaped metal element 1.

[0060] This advantageously makes it possible to make metal shaped elements 1 equal to each other for each individual type of stator, rotor or laminated ferromagnetic core, greatly simplifying the step of design and manufacture of such stator, rotor and core.

[0061] In an alternative embodiment represented in fig. 4, the conjugable shaped profile 4 made on the first side 2 of the shaped metal element 1 of the invention is a dovetail profile, while the conjugable shaped profile 4 of the second side 3 is a profile that is complementary and conjugable to the dovetail profile of the first side 2.

[0062] Also in this case, therefore, each first side 2 of each shaped metal element 1 can be coupled by interference to each second side 3 of the shaped metal element 1 placed adjacent to the first one.

[0063] In further alternative embodiments of the invention, the conjugable shaped profiles 4 of the aforesaid sides 2 and 3 can be of a different type than those described above, as long as they allow the coupling by interference of the shaped metal elements 1 placed adjacent to each other, advantageously avoiding their conjunction by welding techniques.

[0064] In this way, therefore, a conjunction and a direct contact are made between each pair of shaped metal elements 1 along the entire length of the junction zone of the sides 2 and 3, as can be observed in fig. 5.

[0065] This advantageously allows to have a minimum loss of magnetic flux along the junction zone, maintaining the efficiency of the stators, rotors and laminated ferromagnetic cores made with such shaped metal elements that is very similar to the efficiency of the stators, rotors and laminated ferromagnetic cores made with single-body laminations.

[0066] As mentioned above, the lamination 100, represented in fig. 5, for the manufacture of stators 200 or rotors 300 of a rotating electric machine 400 and for the manufacture of laminated ferromagnetic cores 500 of a static electric machine, obtained by conjoining by interference a plurality of shaped metal elements 1 at the aforesaid sides 2 and 3 with a conjugable shaped profile 4 is also part of the invention.

[0067] The stator 200 and the rotor 300 of a rotating electric machine 400 and the laminated ferromagnetic core 500 of a static electric machine, represented respectively in figs. 6, 7 and 9, obtained by stacking together a plurality of laminations made in turn by conjoining by interference a plurality of shaped metal elements 1 of the invention, are also part of the invention.

[0068] Furthermore, the rotating electric machine 400 of fig. 8, which comprises at least the stator 200 or at least the rotor 300 arranged coaxially with each other, and the static electric machine, not represented in the figures, which comprises the aforesaid laminated ferromagnetic core 500 are also part of the invention.

[0069] Finally, the invention concerns the method and the type of apparatus for the manufacture of the aforesaid laminations 100 of the invention.

[0070] In particular, the preferred embodiment of the method of the invention provides for obtaining, by means of a stamping technique, the shaped metal elements 1 at the unused portions of a metal foil on which single-body laminations are made, again by stamping.

[0071] However, in an alternative embodiment of the method of the invention, it is not excluded that said shaped metal elements 1 are obtained on a metal foil specially used to stamp the aforesaid shaped metal elements 1.

[0072] In particular, this alternative provides for optimally defining the stamping positioning of each single shaped metal element 1 in order to make the most of the entire area of the same metal foil.

[0073] Subsequently, the method of the invention, as can be observed in fig. 10, provides for arranging the shaped metal elements 1 in a jig 600 which comprises a plurality of seats 601 which conjointly define the shape of the stator 200, of the rotor 300 or of the laminated ferromagnetic core 500 to be obtained. In the example of fig. 10 a jig 600 for the manufacture of a stator 200 is represented clearly.

[0074] Finally, the method of the invention provides for fixedly coupling, by pressing, the aforesaid shaped metal elements 1 previously arranged in the relative seats 601 of the jig 600, so that each side 2 or 3 with a conjugable shaped profile 4 of each shaped metal element 1 is coupled by interference with the side 2 or 3 of the shaped metal element 1 placed adjacent to it.

[0075] In this way, the shaped metal elements 1 are fixedly constrained to each other, obtaining a lamination that will be subsequently used to make a stator 200 or a rotor 300 or a laminated ferromagnetic core 500, substantially with the same performance as a stator, a rotor and a laminated ferromagnetic core made with laminations obtained as a single body.

[0076] With regard to the aforesaid jig 600, it preferably has a perimeter ring 602, which surrounds the seats 601, adapted to contain perimetrally the shaped metal elements 1 inserted in the various seats 601 of the jig 600 itself. In particular, this perimeter ring 602, as visible in fig. 10, has suitable housings 603, turned inwards, in each of which a pressing element 604 is inserted which is associated with elastic thrust means 605, arranged between the housing 603 and the same pressing element 604, in such a way as to radially force said pressing element 604 towards the centre of the perimeter ring 602.

[0077] This feature, advantageously, allows to keep the various shaped metal elements 1 properly inserted in the seats 601 of the jig 600 and between them all perfectly in position during the pressing operation.

[0078] Once these shaped metal elements 1 are joined together by interference through the pressing operation, during the subsequent step of extraction of the lamination 100 by the pick-up means, the thrust exerted by the pressing elements 604 is overcome by the thrust exerted by the lamination 100 being extracted, in a direction orthogonal to the perimeter ring 602. In this way, the pressing elements 604 are translated radially outwards allowing a smooth and unconstrained exit of the same lamination 100 from the jig 600.

[0079] The method of the invention described above, preferably, is implemented by means of the apparatus 800 for the manufacture of the laminations 100, said apparatus also being the subject-matter of the invention and represented as a whole in figs. 11 and 13.

[0080] Referring to fig. 11 , it can be observed that the apparatus 800 of the invention comprises a machining unit 801, provided with a rotating plane 802, called “carousel” in the technical jargon, preferably circular in shape and rotatably coupled to motorization means 805 by means of a drive shaft 806.

[0081] In particular, according to the preferred embodiment described herein, as can be observed in fig. 12, the aforesaid rotating plane 802 supports on its own upper surface 803, preferably but not necessarily, four jigs 600 arranged along four radii r of the same rotating plane 802 that are divergent from each other by 90°.

[0082] The aforesaid rotating plane 802 of the machining unit 801 is configured to be placed in rotation around its own centre 804 in a discrete manner, so that each jig 600 can assume temporarily four static positions that are divergent from each other by 90°, defined below respectively as the first position for loading the jig 600 (indicated with A in fig. 12), the second position for loading the jig 600 (position B), the position C for pressing the shaped metal elements 1 and the position D for picking up the lamination 100.

[0083] In different embodiments of this second type of apparatus 800 of the invention, it is, however, not excluded that the number of the aforesaid provided loading positions is greater than two and, consequently, the number n of jigs 600 arranged on the upper surface of the rotating plane 802 and the number n of total static positions that each of said jigs 600 can assume on the rotating plane 802 is greater than four.

[0084] In particular, the n radii r of the aforesaid rotating plane 802 at which the jigs 600 are arranged and, in addition, the n static positions that each jig 600 can assume are divergent from each other by an angle equal to 3607n.

[0085] In general, this second type of the apparatus 800 of the invention provides, for the reasons that will be clarified below, for the presence of at least two loading positions, a pressing position and a picking position.

[0086] Returning to the preferred embodiment of the apparatus 800, as can be observed in fig. 13, it also comprises a loading unit 810 provided with a magazine, not represented in the figures, adapted to contain a plurality of the aforesaid shaped metal elements 1. A plurality of conveyors 812, represented in fig. 13, is operatively connected to this magazine.

[0087] Each of the aforesaid conveyors 812 also has its own distal end 813 with respect to the magazine, facing an upper surface 700a of a loading device 700, which in turn, as will be defined more precisely below, has its lower surface 700b, opposite to said upper surface 700a, facing the upper surface 803 of the aforesaid rotating plane 802, at one of the two loading positions A or B.

[0088] In detail, the loading device 700, which is represented in figs. 14 to 22, provides for two loading stations 701 and 702, each arranged in overlap to one of the two loading positions A or B.

[0089] Each loading station 701 and 702 comprises a plurality of housings 703 accessible at the upper surface 700a and shaped to accommodate, each, a plurality of shaped metal elements 1.

[0090] For this reason, each of these housings 703 is facing above one of the aforesaid conveyors 812, which in turn have an opening 814 at the aforesaid distal end 813, so that the shaped metal elements 1 are transported, in sequence, by each conveyor 812 from the aforesaid magazine inside one of these housings 703.

[0091] To facilitate this transport, preferably but not necessarily, each of these conveyors 812 has along its own development vibrating means configured precisely to move the shaped metal elements 1 along the conveyor 812 from the magazine to the relative loading station 701 and 702.

[0092] Even more in detail, as can be observed in figs. 18 and 19, these housings 703 of the two loading stations 701 and 702 are defined in such a way as to be below partially facing a specific seat 601 that is distinct from the other seats 601 to which the remaining housings are partially facing, in such a way that, as will be defined more precisely below, when a jig 600 passes over both the two loading positions A and B, in all the aforesaid seats 601 there is a single shaped metal element 1 present.

[0093] According to the preferred embodiment of the apparatus 800 of the invention represented in fig. 13, which provides that each jig 600 comprises an even number of seats 601, precisely twelve seats 601 for the shaped metal elements 1, as can be clearly observed in fig. 15, overall the two loading stations 701 and 702 comprise, in turn, the same number of housings 703, i.e. in the case of the preferred embodiment twelve housings 703, and relative conveyors 812, defined overall on the two loading stations 701 and 702.

[0094] Half of these housings 703, i.e. six housings 703 are defined in the first loading station 701, so as to be partially facing at six seats 601 of a jig 600, when said jig is arranged in the first loading position A. As regards the other six housings 703, they are defined, as can always be observed in fig. 15, at the second loading station 702, so as to be partially facing the remaining six seats 601 remained empty of the same jig 600, when the latter is placed at the second loading position B.

[0095] Even more in detail, according to the preferred embodiment of the apparatus 800 of the invention, it is provided that the first six housings are adapted to be partially facing at a first group of seats 601 of the jig 600 that are spaced out from each other by other seats not belonging to said first group.

[0096] In other words, in the event that the jig 600 has twelve seats 601, as provided for by the preferred embodiment described herein, said housings 703 of the first loading station 701 are configured, for example, so as to be partially facing at the group of seats 601 comprising the first, the third, the fifth, the seventh, the ninth and the eleventh seat. In this case, therefore, each seat 601, belonging to the first group, is spaced out with respect to the other seats 601 of the same group by a seat 601 left temporarily free.

[0097] Likewise, in the second loading position B, the housings 703 of the second loading station 702 are defined so as to be partially facing at a second group of seats 601 of the jig 600 that are spaced out from each other and free after performing the first loading that has taken place at the first loading position A.

[0098] In practice, taking up the previous example, the housings 703 defined on the second loading station 702 are partially facing at the second group of seats 601 comprising the second, fourth, sixth, eighth, tenth and twelfth seat.

[0099] In this case, therefore, each seat 601 belonging to the second group is spaced out with respect to the seats 601 of the same group by a seat 601 that already has a shaped metal element 1.

[0100] In this way, the shaped metal elements 1, as will be discussed below, are arranged in the jig 600, by means of the first and second loading operation, on two different levels.

[0101] This arrangement on two levels is made necessary as the shaped metal elements 1 are configured, as mentioned above, to be coupled to each other by interference by means of a pressing action. Therefore, when these shaped metal elements 1 are arranged in two adjacent seats 601 of the jig 600, their sides 2 and 3 with a shaped conjugable profile 4 are overlapped on each other. Therefore, it would be extremely complicated to arrange shaped metal elements 1 on adjacent seats 601 of the jig 600 at the same instant, or at least their simultaneous arrangement could lead to their mutual position which would be inadequate to allow the implementation of the subsequent pressing operation.

[0102] In the alternative embodiments of the apparatus 800 of the invention which provide for a number of loading positions greater than two, the loading principle remains the same. In particular, for each loading position, the loading device 700 is adapted to arrange the shaped metal elements 1 at a group of seats 601 spaced out from each other.

[0103] In particular, unlike the preferred embodiment described herein, multiple seats 601 could be provided interposed between two seats 601 in which the shaped metal elements 1 are loaded at the same instant.

[0104] In order to obtain the alternating overlap on two different levels of the shaped metal elements 1 in a jig 600 at the second loading position B, it is necessary, during the translation of the jig 600 from the first position A to this second loading position B, to lower the bottom of the jig 600 with respect to the aforesaid perimeter ring 602.

[0105] In this way it is possible to define a space, between the shaped metal elements 1 already positioned in the jig 600 during said first loading position A and the upper surface of the perimeter ring 602 of the jig 600, having a thickness substantially corresponding to the thickness of a shaped metal element 1.

[0106] Therefore, even in the second loading position B the single shaped metal element 1 inserted in a still empty seat 601 will rest with its own sides 2 and 3 on the sides 2 and 3 of the adjacent shaped metal elements 1 already inserted at the first loading position A. The lowering and subsequent raising of the bottom of the jig 600 during its translation in the various loading positions A and B are made possible by cam means placed at the bottom of the rotating plane 802 and mechanically cooperating with the same jigs 600.

[0107] With regard, in particular, to the loading stations 701 and 702, as already mentioned and as visible in figs. 14 to 25, each of them provides the aforesaid housings 703 accessible from the upper surface 700a of the loading device 700, so that the shaped metal elements 1 coming from the conveyors 812 can be temporarily stowed in the same housings 703. According to the invention, as visible in fig. 15, said housings 703 are distributed on each of the two loading stations 701 and 702 along a circumference C1 with smaller diameter than the diameter of the circumference C2 along which the seats 601 of the jig 600 are defined. In other words, these housings 703 are only partially facing the seats 601 of the jig 600 as they are radially inwardly misaligned with respect to the aforesaid seats 601.

[0108] At the lower surface 700b of the loading device 700, each of these housings 703 instead has an opening 703a aligned with the relative seat 601 of the jig 600 and therefore misaligned outwards with respect to the remaining portion of the housing 703, as is also visible in figs. 18 and 19. This allows to block the involuntary exit of the various shaped metal elements 1 inserted in the housing 703 from the aforesaid lower surface 700b. In order to allow the exit of a single shaped metal element 1, each housing 703, at this opening 703a, is configured to allow to translate only and exclusively the shaped metal element 1 arranged more in proximity to the same opening 703a, in a radial direction outwards. In this way, said shaped metal element 1 is brought into alignment with said opening 703a and with the underlying seat 601, so that it can exit from the housing 703 and be arranged at said seat 601.

[0109] In order to operate this radial translation of the shaped metal element 1 closer to the opening 703a, each of the loading stations 701 and 702, at the centre of this circumference C1 along which the housings 703 are defined, has radial thrust means 704 configured to operate the thrust radially outwards of these shaping metal elements 1 for all the housings 703, in such a way as to allow precisely these shaped metal elements 1 to exit through the opening 703a and to be arranged in the relative seats 601.

[0110] According to the preferred embodiment of the invention, as can be observed in the details of figs. 20 and 21 , said radial thrust means 704 comprise a linear actuator 705, in particular a pneumatic or hydraulic cylinder 706, arranged in said loading station 701 and 702 so that its piston 707 is movable along the axis passing orthogonally in the centre of said circumference C1. A truncated conical element 708, with its own taper turned downwards, is connected to the free end 707a of said piston 707. Said truncated conical element 708 is configured to be shifted, along said axis, from a raised position, visible in fig. 18, to a lowered position, visible in fig. 19, and vice versa. Furthermore, the radial thrust means 704 of each loading station 701 and 702 comprise a plurality of pushers 709, each arranged between a housing 703 and the central portion in which said truncated conical element 708 is arranged. Each of these pushers 709 is configured to translate in a radial direction between an extended position, visible in fig. 19, and a retracted position, visible in fig. 18, and vice versa. In particular, each of these pushers 709 has an oblique wall 709a turned towards the truncated conical element 708, which is complementary and opposed to the oblique wall of the same truncated conical element 708, while, at the end 709b opposite to said oblique wall 709a, each pusher 709 is shaped so as to come into contact with the shaped metal element 1 arranged more in proximity to said opening 703a and so as to push it radially outwards in order to align it with said opening 703a and allow it to exit from the relative housing 703.

[0111] Furthermore, elastic return means 710 configured to force said pusher element 709 towards the aforesaid retracted position are associated with each of said pushers 709.

[0112] Therefore, when the piston 707 and the truncated conical element 708 are in the raised position, the various pushers 709, thanks to the thrust of the aforesaid elastic return means 710, are kept in the retracted position and do not exert any radial thrust on the aforesaid shaped metal element 1. Therefore, all the shaped metal elements 1 present in the various housings 703 cannot exit from the latter, as represented in fig. 18.

[0113] When, on the other hand, the jig 600 is located exactly below one of the two loading stations 701 or 702, the piston 707 of the radial thrust means 704 of the specific loading station is actuated so as to shift the truncated conical element 708 from the raised position towards the lowered position. During this axial movement, as can be observed in fig. 19, the side wall of the truncated conical element 708 couples with the oblique walls 709a of the various pushers 709, forcing the latter to translate radially outwards and consequently shifting radially outwards the shaped metal elements 1 closer to the openings 703a of the various housings 703. These shaped metal elements 1 are then brought into alignment with the opening 703a of each housing 703, so that by gravity they can exit from the relative housing 703 and access one of the seats 601 of the jig 600.

[0114] According to the preferred embodiment of the invention, as can be observed in figs. 24 and 25, at each housing 703 slider elements 711 are also provided which are configured to exert an elastic downward thrust of the shaped metal element 1 when it is brought into a position aligned with the opening 703a. In particular, these slider elements are four slider elements 711 arranged so as to exert this downward thrust at the four vertices of the shaped metal element 1.

[0115] Still preferably, each of said slider elements 711 comprises a pin 712 pushed downwards by a traction spring 713 arranged above.

[0116] Advantageously, the presence of such slider elements 711 guarantees a greater rapidity and a greater accuracy in the exit of the shaped metal element 1 from the housing 703.

[0117] It is not excluded, however, that according to alternative embodiments of the invention such slider elements 711 are not provided.

[0118] Further, an alternative embodiment of the invention could provide that the radial thrust means 704, as can be observed in figs. 22 and 23, are constituted by a rotating electric actuator 714, in particular an electric motor, on the shaft 714a of which a cam 715 is associated, configured to push the aforesaid pushers 709 following the rotation of said rotating electric actuator 714 and of the relative cam 715.

[0119] Returning then to the description of the apparatus 800, once the jig 600 is completely filled with a plurality of shaped metal elements 1, the rotating plane 802 of the machining unit 801 is rotated by 90° so that the same jig 600 assumes the aforesaid pressing position C, indicated in fig. 12.

[0120] The apparatus 800 of the invention, in fact, comprises, at the pressing position C, pressing means, not represented in the figures, adapted to force the coupling by interference of the shaped metal elements 1 inside the jig 600, thus implementing the pressing step of the method of the invention.

[0121] Simultaneously with this pressing operation, the apparatus 800 of the invention loads, in the manner described above, the shaped metal elements 1 on the jigs 600 of the machining unit 801 currently arranged in the first and second loading position A and B.

[0122] When the loading and pressing operations in the respective jigs 600 are ended, the rotating plane 802 is again rotated by 90° so that the jig 600, on which the pressing has been performed, is arranged in the picking position D, at which the completed lamination 100 is picked up.

[0123] Preferably, but not necessarily, the lamination 100 is picked up by pick-up means external to the apparatus 800 of the invention.

[0124] Based on the foregoing, it is therefore understood that the shaped metal element of the invention achieves all of its intended purposes. In particular, the invention achieves the aim of manufacturing shaped metal elements that, when conjoined together, allow laminations to be obtained with a yield only a few percentage points lower than the laminations made as a single body.

[0125] For this reason, the aim of manufacturing shaped metal elements that allow to obtain laminations that can be used to make the main stator and / or rotor of a rotating electric machine and the laminated ferromagnetic core of a static electric machine, and not only laminations for the stator and the rotor of the exciter, is also achieved.

[0126] Another aim achieved is to obtain shaped metal elements from portions of metal foil previously considered as scraps.

[0127] Consequently, the aim of manufacturing shaped metal elements that allow a reduction in the costs for the manufacture of the rotors and the stators of the rotating electric machines and of the laminated ferromagnetic cores of the static electric machines is also further achieved.

[0128] In the executive phase, executive variants may be made to the shaped metal element of the invention, to the lamination, to the stator, to the rotor, to the laminated ferromagnetic core, to the rotating electric machine and to the static electric machine of the invention and, finally, to the method and to the two types of apparatus, for the manufacture of the aforesaid laminations of the invention which executive variants, although not represented and not described herein, should they fall within the content of the claims that follow, will all be considered protected by the present patent.

[0129] Where the technical features set out in the claims are followed by reference signs, these have been attached for the sole purpose of increasing the intelligibility of the claims and, accordingly, such reference signs do not have any limiting effect on the scope of protection of each element identified by way of example.

Claims

CLAIMS1 ) Apparatus (800) for the manufacture of a lamination (100) for the manufacture of stators (200) or rotors (300) of a rotating electric machine (400) or of a laminated ferromagnetic core (500) of a static electric machine, said lamination (100) comprising a plurality of shaped metal elements (1 ) coupled together by interference at the conjugable shaped sides (2, 3) of said shaped metal elements (1 ), said apparatus (800) comprising:- a machining unit (801) provided with a rotating plane (802), preferably of circular shape, rotatably coupled to motorization means (805) by means of a drive shaft (806), said rotating plane (802) having at its own upper surface (803) at least four jigs (600) arranged along the directions defined by four radii (r) of said rotating plane (802) that are divergent from each other by 90°, said rotating plane (802) being adapted to be placed in rotation in a discrete manner so that each of said four jigs (600) is adapted to assume temporarily four defined static positions that are divergent from each other by 90°: first position (A) for loading said jig (600), second position (B) for loading said jig (600), position (C) for pressing the shaped metal elements (1 ) and position (D) for picking up said lamination (100);- a loading unit (810) comprising a magazine adapted to contain a plurality of said shaped metal elements (1 ), a plurality of conveyors (812) and a loading device (700), said plurality of conveyors (812) being operatively connected to said magazine, each of said conveyors (812) having its own distal end (813), with respect to said magazine, facing an upper surface (700a) of said loading device (700), which in turn has its lower surface (700b), opposite to said upper surface (700a), facing said upper surface (803) of said rotating plane (802), at one of said two loading positions (A, B), said loading device (700) providing two loading stations (701 , 702), each arranged in overlap to one of said two loading positions (A, B); each of said loading stations (701 , 702) comprising a plurality of housings (703) accessible at the upper surface (700a) and shaped to accommodate, each, a plurality of said shaped metal elements (1 ), said housings (703) being below partially facing one of said seats (601 ) that is distinct with respect to the remaining seats (601 ) to which the remaining housings (703) are partially facing, so that when a jig (600) passes over both said two loading positions (A, B), in all said seats (601 ) there is a single shaped metal element (1 ) present;said apparatus (800) being characterized in that said housings (703) are distributed on each of said two loading stations (701 , 702) along a circumference (C1 ) of smaller diameter than the diameter of the circumference (C2) along which said seats (601 ) of said jig (600) are defined so that said housings (703) are misaligned with respect to said seats (601 ); at said lower surface (700b) of said loading device (700), each of said housings (703) having an opening (703a) aligned with the relative seat (601 ) of said jig (600) and therefore misaligned outwards with respect to the remaining portion of the housing (703); in order to be able to allow the exit of a single shaped metal element (1 ) from one of said housings (703), each of said housings (703), at said opening (703a), is configured to allow said shaped metal element (1 ) arranged more in proximity to said opening (703a) to translate in a radial direction outwards, so that said shaped metal element (1 ) is brought into alignment with said opening (703a) and with said seat (601 ).2) Apparatus (800) according to claim 1 , characterized in that each of said loading stations (701 , 702) provides, in a central position of said circumference (C1 ) along which said housings (703) are defined, radial thrust means (704) configured to operate the thrust radially outwards of said shaped metal elements (1 ) arranged closer to said opening (703a) for all said housings (703), in such a way as to allow said shaped metal elements (1 ) to exit through said opening (703a) and to be arranged in the relative seats (601 ).3) Apparatus (800) according to claim 2, characterized in that said radial thrust means (704) comprise:- a linear actuator (705), in particular a pneumatic or hydraulic cylinder (706), arranged in said loading station (701 , 702) so that its piston (707) is movable along the axis passing orthogonally in the centre of said circumference (C1 );- a truncated conical element (708) connected to the free end (707a) of said piston (707) and having its own taper turned downwards; said truncated conical element (708) being configured to be shifted, along said axis, from a raised position to a lowered position and vice versa;- a plurality of pushers (709), each arranged between a housing (703) and the central portion in which said truncated conical element (708) is arranged, each of said pushers (709) being configured to translate in a radial direction between an extended position and a retracted position; each of saidpushers (709) has an oblique wall (709a) turned towards said truncated conical element (708), which is complementary and opposed to the oblique wall of said truncated conical element (708), while, at the end (709b) opposite to said oblique wall (709a), each of said pushers (709) is shaped so as to come into contact with the shaped metal element (1 ) arranged more in proximity to said opening (703a) so that, when said pusher (709) is translated towards said extended position, it is configured to push said shaped metal element (1 ) radially outwards so as to align it to said opening (703a) and allow it to exit from the relative housing (703);- elastic return means (710) associated with each of said pushers (709) and configured to force said pusher (709) towards said retracted position.4) Apparatus (800) according to claim 3, characterized in that it comprises, for each of said housings (703), slider elements (711 ) configured to exert an elastic downward thrust of the shaped metal element (1 ) when said shaped metal element (1 ) is brought into a position aligned with said opening (703a).

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