Method and winding machine for making an electric component provided with a spiral-shaped winding

Abstract

A method and an automatic winding machine (20) for manufacturing an electrical component (1) provided with a support (2) inside which a winding of at least one wire (4) is housed are described. Although the winding extends helically, the wires making the winding do not twist. While the support is rotating about its axis, the wire is pushed into the grooves (6 ', 6' ') of the support by a compression roller (53) rolling on the grooves. The compression roller is guided by wire guide flanges (49, 50) that control the displacement of the compression roller such that the compression roller cuts into and travels along the full length of the groove. In one embodiment, the electrical component is provided with a first winding (3 ') on the front side (2') of the support and with a second winding (3 '') on the rear side (2 '') of the support. The two windings are made of the same wire which overlaps the periphery of the support. The press roller is displaced from the front side to the rear side to insert the wire into the slot of the second winding using a second wire guide flange (50) as a guide.

Description

(19) State Intellectual Property Office (12) Invention Patent Application (10) Application Publication Number (43) Application Publication Date (21) Application Number 202480024260.4 (22) Application Date 2024.01.17 (30) Priority Data 102023000006243 2023.03.31 IT (85) PCT International Application Entering National Phase Date 2025.09.30 (86) PCT International Application Application Data PCT / IB2024 / 050446 2024.01.17 (87) PCT International Application Publication Data WO2024 / 201148 EN 2024.10.03 (71) Applicant: Masli S.A. Address: 14 Via Riparta Alpina, Castelleone, Italy (72) Inventor: Gian Batista Paratti (74) Patent Agency: Shenzhen Mingyue Intellectual Property Agency Co., Ltd. 44304 Patent Attorneys: Sun Weifeng, Wu Cenfei (51) Int.Cl. B65H 54 / 28 (2006.01) H01F 41 / 082 (2006.01) H02K 15 / 08 (2006.01) H01F 41 / 098 (2006.01) H01F 41 / 084 (2006.01) (54) Invention Title: Method and Winding Machine for Manufacturing Electrical Components with Helical Windings (57) Abstract: A method and an automatic winding machine (20) for manufacturing an electrical component (1) are described, the electrical component (1) being provided with a support (2) in which a winding of at least one conductor (4) is housed. Although the winding extends helically, the conductor forming the winding is not twisted. As the support rotates about its axis, the conductor is pushed into the slots (6', 6'') of the support by a pressure roller (53) rolling on a slot. The pressure roller is guided by conductor guide flanges (49, 50), which control the displacement of the pressure roller so that the pressure roller cuts into and travels along the full length of the slot. In one embodiment, the electrical component has a first winding (3') on the front side (2') of the support and a second winding (3'') on the rear side (2'') of the support. Both windings are made of the same conductor, which overlaps on the periphery of the support. The pressure roller is moved from the front side to the rear side to insert the wire into the slot of the second winding using the second wire guide flange (50) as a guide. Claims 6 pages Description 15 pages Drawings 22 pages CN 121358681 A 2026.01.16 CN 1 21 35 86 81 A 1. A method of manufacturing an electrical component (1), said electrical component (1) being provided with a support (2), said support (2) having at least one side (2', 2”), and wherein,At least one helical groove (6', 6") is provided on at least one side (2', 2"), the helical groove (6', 6") being coaxial with the axis (X) of the support (2) and extending radially or predominantly radially, and wherein at least one conductor (4) forming a helical winding (3', 3") is received within the at least one groove (6', 6"), the method comprising: A) rotating the support (2) about the axis (X), B) supplying the conductor (4) to the support (2), C) inserting the conductor (4) into the groove (6', 6") by means of a pressure roller (53) arranged to roll on the groove (6', 6") and whose axis of rotation intersects the axis (X) of the support (2), and moving the pressure roller (53) radially relative to the axis (X) of the support, thereby traveling along the full length of the groove (6', 6"). 2. The method according to claim 1, wherein stage A is performed by constraining the support (2) to a drive shaft (33), the drive shaft (33) being coaxial with and rotatable about the axis (X) of the support (2). 3. The method according to claim 1 or 2, wherein stage B is performed by a wire guide tube (30) movable relative to the support (2), ensuring that the wire (4) is fed into the corresponding groove (6', 6") along a trajectory tangential to the groove (6', 6"). 4. The method according to any one of claims 1 to 3, wherein stage C is performed by abutting the pressure roller (53) against a wire guide flange (49, 50), and wherein the wire guide flange (49, 50) serves as an end stop defining the distance between the pressure roller (53) and the axis (X) of the support (2). 5. The method according to claim 4, wherein the wire guide flanges (49, 50) are arranged coaxially with and rotatable on the same axis (X) of the support (2), and wherein the wire guide flanges (49, 50) are helical or spiral-shaped, having sides (49', 50') extending between a minimum diameter portion and a maximum diameter portion, and wherein: - when the pressure roller abuts against the side (49', 50') of the wire guide flanges (49, 50) at the minimum diameter portion, the pressure roller (53) is at the minimum distance from the axis (X) of the support (2) and located at the first end of the groove (6', 6"); and - when the pressure roller abuts against the side (49, 50) of the wire guide flanges (49, 50) at the maximum diameter portion, the pressure roller (53) is at the maximum distance from the axis (X) of the support (2) and located at the second end of the groove (6', 6"). 6. The method according to claim 4 or 5, wherein, in the support member (2) and the wire guide flange (49,7. The method according to any one of claims 4-6, wherein the rotation of the wire guide flanges (49, 50) about the axis (X) of the support is controlled in one of the following ways: - the wire guide flanges (49, 50) rotate slower than the support (2), or - the wire guide flanges (49, 50) rotate at the same speed as the support (2) and are accompanied by intermittent motion. 8. The method according to any one of the preceding claims, wherein the electrical element (1) has a first winding (3') and a second winding (3”) on opposite portions of the support (2), and wherein the support is flat and has a front side (2') and a rear side (2”), a first groove (6') is provided on the front side (2'), and a second groove (6”) is provided on the rear side (2”), and wherein the support (2) has a transition region (7), the first groove (6') and the second groove (6”) intersect at the transition region (7), and wherein stage C is implemented according to the following steps: C1) The wire (4) is inserted into the first groove (6') by means of a pressure roller (53), and the pressure roller (53) is moved radially relative to the axis (X) of the support member between a position near the axis (X) of the support member (2) at the beginning of the first groove (6') and a position far from the axis (X) of the support member (2) at the end of the first groove (6'), thereby obtaining the first winding (3'). And C2) by overlapping the wire (4) on the support (2) at the transition zone (7) and leading the wire (4) from the front side (2') of the support (2) to the rear side (2”) of the support (2), and C3) by inserting the wire (4) into the second groove (6”) by means of the pressure roller (53) and moving the pressure roller (53) radially relative to the axis (X) of the support between the far position relative to the axis (X) of the support (2) at the beginning of the second groove (6”) and the near position relative to the axis (X) of the support (2) at the end of the second groove (6”), thereby obtaining the second winding (3”). 9. The method of claim 8, wherein: C1 is achieved by guiding the radial movement of the pressure roller (53) using a first wire guide flange (49), C2 is achieved by using a wire guide tube (30) movable relative to the support (2), and C3 is achieved by guiding the radial movement of the pressure roller (53) using a second wire guide flange (50), wherein the two wire guide flanges (49, 50) are coaxial with the axis (X) of the support and are located on opposite sides relative to the axis (X) of the support, and wherein, during stages C1 and C3,There is relative rotation between the support (2) and each wire guide flange (49, 50). 10. The method of claim 8 or 9, wherein the at least one groove (6', 6”) has radial segments (10, 11), and the wire (4) is inserted into the radial segments (10, 11) by: D) locking the support (2) relative to the axis (X), aligning the pressure roller (53) with the axis (X) of the support (2), and rolling the pressure roller (53) on the radial segments (10, 11) of the at least one groove (6', 6”). 11. An electrical component (1) directly manufactured using the method according to any one of the preceding claims, the electrical component (1) being provided with a support member (2) having at least one side (2', 2”), wherein at least one helical groove (6', 6”) coaxial with respect to the axis (X) of the support member (2) is provided on the at least one side (2', 2”), and wherein at least one conductor (4) forming a helical winding (3', 3”) is received within the at least one groove (6', 6”). 12. The electrical component (1) according to claim 11, wherein the conductor (4) of the helical winding (3', 3”) is not twisted. 13. The electrical component (1) according to claim 11, wherein the support member (2) is flat and has a first winding (3') on the front side (2') and a second winding (3”) on the rear side (2”). 14. The electrical component (1) according to any one of claims 11-13, wherein the winding (3', 3”) has a terminal (4', 4”) extending cantileveredly from the same side (2”) of the support (2). 15. An automatic winding machine (20) for manufacturing an electrical component (1), the electrical component (1) being provided with a support (2) having at least one side (2', 2”), and wherein at least one helical groove (6', 6”) coaxial with the axis (X) of the support (2) is provided on the at least one side (2', 2”), and wherein at least one conductor (4) forming the helical winding (3', 3”) is received in the at least one groove (6', 6”), the winding machine (20) comprising a worktable (22) and a feed unit (21) configured to feed the conductor (4) to the worktable (22). Claims 2 / 6 pages 3 CN 121358681 A Wherein, the worktable (22) includes a first spindle (31), a corresponding first drive shaft (33), devices (46, 47) for coaxially constraining the support member (2) on the drive shaft (33), a first guide flange (49), and a pressure roller (53), and wherein,The support member (2) and the first drive shaft (33) are rotatable about the axis (X) of the support member (2), and wherein the pressure roller (53) is positioned against the side (2') of the support member (2) so as to be able to roll in at least one groove (6') and is readily displaced radially relative to the axis (X) of the support member (2), and wherein the wire guide flange (49) is coaxially mounted on the first drive shaft (33) and is readily translated along the first drive shaft (33) between proximal and distal positions relative to the support member (2), and is readily rotated synchronously with and / or relative to the first drive shaft (33), and wherein the first wire guide flange (49) is helical or spiral-shaped, and the conductor (4) is inserted into the groove (6'). This is achieved by rotating the first drive shaft (33) together with the support member (2), causing the pressure roller (53) to roll on the groove (6'), while pushing the wire (4) into the groove (6'), thereby giving the pressure roller (53) radial movement relative to the axis (X) of the support member (2), wherein the radial movement of the pressure roller (53) is guided by the side (49') of the first wire guide flange (49). 16. The automatic winding machine (20) according to claim 15, wherein stage A of the method according to claim 1 is performed by the first spindle (31) and the first drive shaft (33), stage B of the method according to claim 1 is performed by the feed unit (21), and stage C of the method according to claim 1 is performed by rolling the pressure roller (53) along the full length of the groove (6') on the groove (6'), wherein the wire (4) is inserted between the groove (6') and the pressure roller (53), and the pressure roller (53) is radially translated relative to the axis (X) on the support (2). 17. The automatic winding machine (20) according to claim 15 or 16, wherein the feed unit (21) includes a wire guide tube (30) movable relative to the axis (X) of the support (2) and the first drive shaft (33), wherein the wire guide tube (30) is also oriented relative to the support (2) mounted on the first drive shaft so as to supply the wire (4) radially or tangentially relative to the side (2') of the support (2) and / or relative to the slot (6'). 18. The automatic winding machine (20) according to claim 17, wherein the feed unit (21) is a three-axis unit. 19. The automatic winding machine (20) according to any one of claims 15-18, wherein...The device (46, 47) for coaxially constraining the support (2) onto the drive shaft (33) includes two levers (46, 47) pivotally connected at the head of the first drive shaft (33) and operable to engage the inner edge (5) of the support (2). 20. The automatic winding machine (20) according to claim 19 includes a control lever (48) for controlling the levers (46, 47), wherein the control lever (48) is located inside and coaxial with the first drive shaft (33) and is translatable between a rearward position and an extended position, wherein in the rearward position the control lever (48) does not engage the levers (46, 47), the levers engage the support (2) and constrain the support onto the first drive shaft (33), and in the extended position the control lever (48) is inserted between the levers (46, 47) to disengage the levers from the support (2). 21. An automatic winding machine (20) according to any one of claims 15 to 20, wherein the worktable (22) includes a first flange retainer (34), the first drive shaft (33) is inserted into the first flange retainer (34), and wherein the first wire guide flange (49) is mounted on the first flange retainer (34) and provided with a corresponding actuator (54), the actuator controlling the rotation of the first wire guide flange (49) independently of the rotation of the first drive shaft (33) given by the first main claim 3 / 6 page 4 CN 121358681 A shaft (31), and wherein the first flange retainer (34) is translatable along the first drive shaft between a rearward position and a forward position, wherein in the rearward position the first wire guide flange (49) is away from the support (2) constrained on the first drive shaft (33), and in the forward position the first wire guide flange (49) abuts against the support (2) constrained on the first drive shaft (33). 22. The automatic winding machine (20) according to any one of claims 15 to 21, wherein the side (49') of the first wire guide flange (49) extends between the minimum diameter portion and the maximum diameter portion of the first wire guide flange (49), and the side (49') of the first wire guide flange (49) defines the end stop when the pressure roller (53) is radially displaced relative to the axis (X) of the support member (2). 23. The automatic winding machine (20) according to any one of claims 15 to 22, comprising a unit (43),The unit (43) is configured to guide and insert the wire (4) into the groove (6') of the support (2), wherein the pressure roller (53) is mounted on the unit (43), and the unit (43) is readily displaceable along three axes to insert the pressure roller (53) between the first wire guide flange (49) and the support (2), wherein the rotation axis of the pressure roller (53) is transverse to or intersects the axis (X) of the support (2) and the first drive shaft (33). 24. The automatic winding machine (20) according to claim 23, wherein the unit (43) includes an arm (52), and the pressure roller (53) is mounted on the arm (52), and the arm (52) is movable to hold the pressure roller (53) against the side (49') of the first wire guide flange (49) during rotation. 25. The automatic winding machine (20) according to any one of claims 15 to 24, comprising a clamp assembly (44) movable relative to the axis (X) and operable to cut the wire (4). 26. The automatic winding machine (20) according to any one of claims 15 to 25, wherein the support member (2) has a front side (2') and a rear side (2”), each side (2', 2”) having at least one slot (6). '、6”), and wherein, the first winding (3’) is to be formed in the slot (6’) of the front side (2’), and the second winding (3”) is to be formed in the slot (6”) of the rear side (2”), and wherein, the first spindle (31) is stationary, and the winding machine (20) further includes a second spindle (36) defined as the tailstock spindle (36), a corresponding second drive shaft (40) and a second wire guide flange (50), the second spindle (36), the corresponding second drive shaft (40) and the second wire guide flange (50) relative to the support (2) constrained to the first drive shaft (33) and the first spindle (31), the first drive shaft (33) and The first wire guide flange (49) is opposite to each other, and wherein the first drive shaft (33) and the second drive shaft (40) are coaxial with respect to the axis (X) of the support member (2), are rotatable about the same axis (X), and the second drive shaft is translatable along the axis (X) between a forward position and a rearward position. In the forward position, the second drive shaft (40) abuts against the support member (2) constrained by the first drive shaft (33) and / or against the first drive shaft (30). In the rearward position, the second drive shaft (40) is away from the support member (2) constrained by the first drive shaft (33), and a gap (60) is formed between the support member (2) and the second drive shaft (40), into which the feed unit (21) and the pressure roller (53) can be inserted. 27. The automatic winding machine (20) according to claim 26,The second wire guide flange (50) is coaxially mounted on the second drive shaft (40) and is readily translatable on the second drive shaft (40) relative to the rear side (2”) of the support (2) between a proximal and distal position, and is readily rotatable synchronously with and / or relative to the second drive shaft (40). 28. The automatic winding machine (20) according to any one of claims 26-27, wherein the worktable (22) includes a second flange retaining carriage (42), the second drive shaft (40) is inserted into the second flange retaining carriage (42), and claims 4 / 6 pages 5 CN 121358681 A Furthermore, the second wire guide flange (50) is mounted on the second flange retaining slide (42) and is provided with a corresponding actuator (58), the actuator (58) controlling the rotation of the second wire guide flange (50) independently of the rotation of the second drive shaft (40) given by the tailstock spindle (36), and wherein the second flange retaining slide (42) is translatable along the second drive shaft (40) between a rearward position and a forward position, in the rearward position the second wire guide flange (50) is away from the support member (2) constrained on the first drive shaft (33), and in the forward position the second wire guide flange (50) abuts against the rear side (2”) of the support member (2) constrained on the first drive shaft (33), opposite to the side side (2’) on which the first wire guide flange (49) acts. 29. The automatic winding machine (20) according to any one of claims 26-28, wherein the second wire guide flange (40) is helical or spiral-shaped, the same as or different from the first wire guide flange (49), and the wire (4) is inserted into the groove (6”) of the rear side (6”) of the support member (2) by rotating the second drive shaft (33) together with the support member (2) and the first drive shaft (33) to make the pressure roller (53) roll on the groove (6”) while pushing the wire (4) into the groove (6”), thereby giving the pressure roller (53) radial movement relative to the axis (X) of the support member (2); wherein the radial movement of the pressure roller (53) is guided by the side (50') of the second wire guide flange (50). 30. The automatic winding machine (20) according to claim 29, wherein the side (50') of the second wire guide flange (50) extends between the minimum diameter portion of the second wire guide flange (50) and the maximum diameter portion of the second wire guide flange (50).Furthermore, the side (50') of the second guide flange (50) defines an end stop for the pressure roller (53) when it is radially displaced relative to the axis (X) of the support (2). 31. The automatic winding machine (20) as claimed in claim 29 or 30, wherein: - stage A of the method according to claim 1 is performed by rotating the assembly formed by the first spindle (31) and the first drive shaft (33), the tailstock spindle (36) and the second drive shaft (40) and the support member (2); - stage B of the method according to claim 1 is performed using the feed unit (21); and - stage C of the method according to claim 1 is performed by causing the pressure roller (53) to roll along the full length of the groove (6”) above the rear side (2”) of the support member (2); wherein the wire (4) is inserted between the groove (6”) and the pressure roller (53), and the pressure roller (53) is radially translated relative to the axis (X) on the support member (2). 32. The automatic winding machine (20) according to any one of claims 26-31, wherein the feed unit (21) is movable to overlap the wire (4) on the support (2) and position it between the end of the first winding (3') and the beginning of the second winding (3''). 33. The automatic winding machine (20) according to any one of claims 26 to 32, comprising a clamp (41) configured to constrain the terminal (4') of the wire at the head of the second drive shaft (40). 34. The automatic winding machine (20) according to claim 33, wherein the gripper (41) is integrated into the second drive shaft (40) and includes a gripper (41') and a control shaft (41") mounted on the second drive shaft (40), wherein the control shaft (41") is inside and coaxial with the second drive shaft (40) and readily translatable along the axis (X), and wherein the grippers (41') move toward and away from each other in response to stress applied by the control shaft (41") to constrain or release the terminals (4') of the wires (4) cantilevered from or through the support (2). 35. The automatic winding machine (20) according to any of the preceding claims, wherein each wire guide flange (49, 50) rotates by its actuator at a speed lower than that of the corresponding drive shaft (33, 40).Or driven by intermittent motion at the same rotational speed. Claims 5 / 6, page 6, CN 121358681 A. Claims 6 / 6, page 7, CN 121358681 A. Method and winding machine for manufacturing electrical components with helical windings. Technical Field

[0001] The present invention relates to a method and winding machine for manufacturing electrical components having at least one helically extending wire winding. Background Art

[0002] Some electrical components include metal or plastic supports on which at least one wire winding, such as copper wire arranged in a helical pattern, is accommodated.

[0003] For example, WO2022 / 136548 describes a synchronous motor, particularly a rotating induction transformer, which includes a ferrite toroidal core, a primary winding housed within the toroidal core, and a secondary winding arranged on a flat rotor; wherein the primary winding and the secondary winding are inductively coupled. Both windings are helical, and the rotor is coaxially mounted relative to the toroidal core, such that the secondary winding of the rotor and the primary winding of the toroidal core are located on parallel planes separated by a certain axial distance. The flat rotor is a disc made of plastic material, and the secondary winding is inserted into or embedded in the rotor material.

[0004] Other applications of flat supports with helical windings are also known, for example in the sensor industry, measuring tools, and other fields.

[0005] The present invention relates to a method and machine for manufacturing flat, convex, and conical supports having at least one helical winding on one side, regardless of the intended use of the supported being wound.

[0006] Although this type of winding may seem at first glance to be achievable without difficulty, it is problematic.

[0007] For example, when attempting to place a wire on a flat support using a pin winding machine, whether by rotating the flat support and winding the wire in a helical trajectory or by rotating the wire guide needle of the winding machine along a helical path, the wire is prone to twisting and falling off the support.

[0008] There remains a strong need for automated winding of wires or wire bundles to produce windings that form helical extensions while avoiding stresses in the wires or wire bundles that could cause the windings to detach from the support.

[0009] DE 1281030B describes a method for winding a single wire on a cylindrical support for a light source, the support having no slots or grooves and being defined by two flanges. The method requires the use of a pressure roller, indicated by reference numeral 20 in the figure, and constraint rollers 8 and 9 for rolling over the surface of the smooth cylindrical support. The wire is wound around the cylindrical surface to form a precisely cylindrical coil with uniform turn diameters, such that each turn is in close, shoulder-to-shoulder contact with the adjacent turn.

[0010] EP2266193B1 describes a method for winding a wire around a support for manufacturing a generally cylindrical coil.The support has a smooth outer surface without grooves or slots and is defined by two flanges. The method requires a winding machine equipped with a means for rotating a coil holder relative to a feeding element to wind the wire onto the coil holder, thereby forming turns of the same diameter. The wire extending from the distribution element to the coil holder has a specific angular orientation relative to the outlet of the distribution element. In one embodiment, the machine is further equipped with: a means for rotating the coil holder relative to the distribution element to wind the wire onto the coil holder; and a pressure roller for applying pressure to the portion of the wire wound onto the coil holder; during winding, the pressure roller applies pressure to the wire in a direction not perpendicular to the surface on which the wire is wound.

[0011] The object of the present invention is to provide a method and winding machine for manufacturing an electrical component with a support, wherein the support of the electrical component has at least one section of conductive wire winding extending in a spiral shape; the method needs to be automated, highly reliable, and especially able to prevent the conductive wire from twisting.

[0012] Another object of the present invention is to provide a method and a winding machine for manufacturing an electrical component having a double-sided support member, each side of which is provided with at least one helical winding.

[0013] Accordingly, a first aspect of the present invention relates to a method as claimed in claim 1 for manufacturing an electrical component having a support member (i.e., a body) having at least one side; on which at least one helical groove is provided, coaxial with the axis (X) of the support member and extending radially or predominantly radially (i.e., the radial component is significantly greater than the axial component); and at least one conductive wire forming the helical winding is received within the groove.

[0014] The method includes:

[0015] A) rotating the support member about an axis (X), thereby causing the slot for receiving the conductive wire to rotate;

[0016] B) supplying the conductive wire to the support member near the slot;

[0017] C) inserting the conductive wire into the slot by means of a pressure roller arranged on the slot and whose axis of rotation is transverse (preferably intersecting the axis (X)) with respect to the axis (X) of the support member; while simultaneously moving the pressure roller radially relative to the axis (X) of the support member (approaching or moving away from the axis (X)), thereby allowing the conductive wire to travel along the entire length of the slot as it enters the slot under the thrust of the pressure roller.

[0018] The method solves the problem of conductive wire torsion: in fact, by rotating the support member about an axis (X) (and thus causing the slot to rotate), but without rotating the conductive wire itself (neither about the axis (X) nor about its own axis), the conductive wire can be inserted into the slot without torsion. Specifically, the conductive wire can be continuously fed along a straight path (e.g., a path tangent to the groove) between the pressure roller and the groove, without any twisting or independent rotation due to the shape of the wire (i.e., its cross-sectional shape).

[0019] In other words, when the support rotates about the axis (X),The conductor remains tangential to the slot and stationary relative to the same axis (X), moving forward only along its own length to insert into the slot.

[0020] Thanks to this design, high-quality, durable windings can be manufactured on the support – the internal stress caused by the initial torsion of the conductor itself will not cause it to detach from the slot during use.

[0021] For the purposes of this invention, “spiral winding” refers to a radially or primarily radially layered winding: the conductive wires are stacked in layers to increase the winding diameter. This definition excludes coil windings of equal diameter. Radial layering can be achieved when the support is flat; primary radial layering is achieved when the support is not flat (e.g., conical).

[0022] For simplicity, “conductive wire” will be referred to as “conductor” below. It should be noted that the term “conductor” in this document encompasses the following types: single conductive wire, Litz wire (i.e., a wire made of multiple strands of conductive wire twisted together), and parallel conductive wire bundles that may be pre-pressed, carburized, or wrapped. Furthermore, the term "wire" can refer indiscriminately to any of the above types, regardless of the cross-sectional shape of the wire (e.g., circular, square, or rectangular).

[0023] Preferably, stage A is implemented by locking the support member onto a drive shaft coaxial with and rotatable about the support member axis (X).

[0024] Preferably, stage B is implemented by a wire guide tube movable relative to the support member along at least three axes and oriented relative to the support member—ensuring that the wire is delivered to the corresponding slot along a trajectory tangential to the slot. Thus, the wire is not induced to twist during the insertion of the wire into the slot by the pressure roller.

[0025] Preferably, stage C is implemented by abutting the pressure roller against a wire guide flange that serves as an end stop or cam—the wire guide flange is used to set the distance between the pressure roller and the support member axis (X). Thus, the pressure roller is guided by the wire guide flange, forced to travel along the full length of the slot and roll thereon without slipping. The shape of the wire guide flange is designed such that, through the rotation of the support member, the pressure roller is guided and always kept in the position corresponding to the "groove that moves below the pressure roller, page 2 / 15, CN 121358681 A".

[0026] Preferably, the wire guide flange is also coaxially arranged with the support member shaft (X) and can rotate about the same shaft (X). The wire guide flange is spiral or helical, with its side extending between the minimum diameter portion and the maximum diameter portion. Whenever the pressure roller abuts against the side of the wire guide flange and is located at the minimum diameter portion, the pressure roller is at the minimum distance from the support member shaft (X) (e.g., at the first end of the groove, such as the beginning of the groove); whenever the pressure roller abuts against the side of the wire guide flange and is located at the maximum diameter portion, the pressure roller is at the maximum distance from the support member shaft (X) (e.g., at the second end of the groove, such as the end of the groove). In practical applications, even if the pressure roller is mounted on a CNC unit (e.g., with three-axis movement function),The wire guide flange also ensures that the pressure roller always moves along the groove.

[0027] Preferably, the shape of the spirally extending groove is complementary to the cross-section of the wire, so that the wire is inserted by an interference fit. More preferably, the wires inserted into the groove form slightly spaced coils (not in contact with each other), precisely because the groove itself has width.

[0028] This method is preferably achieved by setting relative rotation between the components to keep the side of the wire guide flange at the pressure roller aligned with the axial direction of the groove.

[0029] Therefore, the rotation of the wire guide flange about the support axis (X) is controlled in one of the following ways:

[0030] • The rotational speed of the wire guide flange is slower than the rotational speed of the support; or

[0031] • The wire guide flange rotates at the same speed as the support but with intermittent motion—that is, the support and the wire guide flange rotate at the same speed about the axis (X) for a period of time, and then the support continues to rotate while the wire guide flange remains stationary for a period of time.

[0032] Preferably, the electrical component has a first winding and a second winding, respectively arranged at opposite positions on the support. The support member is flat and has a front side and a rear side: the first slot of the first winding is located on the front side, and the second slot of the second winding is located on the rear side. The support member has a transition area—the first slot and the second slot meet at a circular fan-shaped periphery of the support member. In this configuration, stage C is performed according to the following steps:

[0033] C1) Inserting the wire into the first groove through the pressure roller and moving the pressure roller radially relative to the support shaft (X)—from the beginning of the first groove, at a position near the shaft (X), to the end of the first groove, at a position far from the shaft (X), thereby obtaining a first winding;

[0034] C2) Overlapping the wire in the transition area of ​​the support edge and leading the wire from the front side to the rear side of the support;

[0035] C3) Inserting the wire into the second groove through the pressure roller and moving the pressure roller radially relative to the support shaft (X)—from the beginning of the second groove, at a position far from the shaft (X), to the end of the second groove, at a position near the shaft (X), thereby obtaining a second winding.

[0036] In practice, when the support member is a flat shape with two opposing sides, the first winding is formed by inserting a wire into the central region of the front side of the support member and moving the pressure roller radially toward the periphery of the front side of the support member (this radial movement is guided by the wire guide flange); the second winding is formed by inserting a wire into the peripheral region of the rear side of the support member and moving the pressure roller toward the central region of the rear side of the support member. The wires overlap in the transition area at the edge of the support member, so that the first winding and the second winding can be made with the same wire.

[0037] More specifically,Stage C1 is achieved by guiding the radial movement of the pressure roller through a first wire guide flange; stage C2 is achieved through a wire guide tube that can move and be oriented relative to the support; stage C3 is achieved by guiding the radial movement of the pressure roller through a second wire guide flange. Both wire guide flanges are coaxial with the axis (X) of the support and are on opposite sides relative to the support. During stages C1 and C3, there is relative rotation between the support and each wire guide flange (as previously stated, i.e., different rotational speeds or intermittent movement of the wire guide flanges, as described on page 3 / 15 of the specification, 10 CN 121358681 A).

[0038] Preferably, the electrical component has two terminals (i.e., the two ends of the wire extending from the cantilever of the support). To achieve automated fabrication of these two terminals, each slot preferably has a radial segment relative to the support shaft (X), and the insertion of the wire into the radial segment is achieved by:

[0039] D) locking the support relative to the shaft (X), aligning the pressure roller with the shaft (X), and driving the pressure roller to roll on the radial segment of the slot—thereby moving the pressure roller radially and keeping the pressure roller's rotation axis in a parallel plane with the shaft (X).

[0040] After the wire is inserted into the radial segment of the slot, the end of the wire is pulled out to extend from the support cantilever, and then cut to the desired length.

[0041] A second aspect of the invention relates to an electrical component directly manufactured by the above method.

[0042] The electrical component includes a support (or body) having at least one side (preferably two opposing sides); at least one helical groove coaxial with the support shaft (X) is provided on the at least one side; and a conductive wire forming a helical winding is accommodated in the groove.

[0043] Thanks to the method, the conductive wires of the helical winding (or each helical winding in the case of multiple windings) do not twist, and therefore there is no internal stress.

[0044] The conductors inserted into the helical slots are layered in a substantially radial or predominantly radial direction (rather than axial), and the coils formed by the conductors thus have a minimum diameter and a maximum diameter.

[0045] As mentioned above, the support is preferably flat (e.g., circular, disc-shaped), with a first winding on its front side and a second winding on its rear side. The terminals of the windings cantilever out from the same side of the support (e.g., only from the rear side).

[0046] Another aspect of the invention relates to an automatic winding machine for manufacturing the above-mentioned electrical components.

[0047] The winding machine includes a workstation and a feeding unit—the latter configured to feed conductive wires to the workstation. The workstation includes a first spindle (preferably stationary relative to the frame), a corresponding first drive shaft, means for coaxially constraining the electrical component support on the drive shaft, a first conductor guide flange, and pressure rollers.

[0048] The support member of the electrical component and the first drive shaft are rotatable about the axis (X) of the support member.

[0049] The pressure roller can abut against the side of the support member.This allows the roller to roll on at least one groove; and the pressure roller can be radially displaced relative to the axis (X) of the electrical component support. The first wire guide flange is coaxially mounted on the first drive shaft and can translate along the first drive shaft between a proximal position and a distal position relative to the support. Furthermore, the first wire guide flange can rotate synchronously with and / or relative to the first drive shaft.

[0050] The first wire guide flange is helical or spiral-shaped; the wire insertion into the groove is achieved by rotating the first drive shaft together with the electrical component support, causing the pressure roller to roll on the groove, thereby simultaneously pushing the wire into the groove. By causing the pressure roller to move radially relative to the support axis (X), it is forced to conform to the trajectory of the groove (i.e., roll along the groove); this radial movement is guided by the side of the first wire guide flange—the side acts as a cam for the pressure roller, along which the pressure roller moves.

[0051] Preferably, stage A of the method according to claim 1 is implemented via the first spindle and the first drive shaft; stage B is implemented via the feeding unit; stage C is implemented by rolling the pressure roller along its entire length on the groove (while the wire is inserted between the groove and the pressure roller) and radially translating the pressure roller relative to the axis (X) of the electrical component support on the support.

[0052] Preferably, the feeding unit includes a wire guide tube—which is movable relative to the axis (X) and shared by the electrical component support and the first drive shaft. The wire guide tube may also be oriented relative to the support mounted on the first drive shaft, thereby supplying the wire in a direction orthogonal to the side of the support and / or radially or tangentially relative to the groove. For example, the wire guide tube may be mounted on a CNC manipulator or a three-axis machine.

[0053] In one embodiment, the device for coaxially constraining the support member to the drive shaft includes two levers—the levers are pivotally connected to the head of the first drive shaft and operable to engage the inner edge of the support member. For example, an electrical component support member has a central hole coaxial with the shaft (X), and the levers on the first drive shaft are operable to engage the central hole of the support member. A control lever for controlling the levers is coaxially housed inside the first drive shaft and is translatable between the following positions:

[0054] • Rearward position: the control lever is not engaged with the levers, the levers remain engaged and constrain the support member to the first drive shaft (normally closed position);

[0055] • Extended position: the control lever is inserted between the levers, disengaging the levers from the support member.

[0056] The workstation preferably includes a first flange retaining slide—in which the first drive shaft is inserted. A first wire guide flange is mounted on the first flange retaining slide and has a corresponding actuator—the actuator is used to control the rotation of the first wire guide flange.And this rotation is independent of the rotation transmitted from the first spindle to the first drive shaft. The first flange retaining slide can translate along the first drive shaft between a rearward position and a forward position:

[0057] • Rearward position: the first guide flange maintains a distance from the support (constrained on the first drive shaft);

[0058] • Forward position: the first guide flange abuts against the support (constrained on the first drive shaft). Obviously, the first drive shaft can rotate within the first flange retaining slide.

[0059] The side of the first guide flange preferably extends between the minimum diameter portion and the maximum diameter portion: as mentioned above, this side defines an end stop when the pressure roller is radially displaced relative to the support shaft (X).

[0060] The winding machine preferably includes a guide insertion unit—configured to guide and insert the wire into a slot in the support; the pressure roller is mounted on the unit, and the unit is displaceable along at least three axes to insert the pressure roller between the first wire guide flange and the support, and the rotation axis of the pressure roller is transverse to or intersects (preferably intersecting) the axis (X) of the support and the first drive shaft. The unit preferably includes an arm (52) on which the pressure roller is mounted; the arm is movable to hold the pressure roller against its side during rotation of the wire guide flange.

[0061] The winding machine preferably also includes a clamp assembly (44)—movable relative to an axis (Y) orthogonal to the axis (X) (or simultaneously relative to axes X and Y), and operable to cut the wire at the terminal.

[0062] One embodiment of the winding machine is configured to manufacture an electrical component version with windings on both sides of the support. At this time, the first main shaft is stationary; the winding machine also includes a second main shaft (defined as a tailstock main shaft (36)), a corresponding second drive shaft (40) and a second wire guide flange (50). The tailstock main shaft, the second drive shaft and the second wire guide flange are opposite to the support (constrained on the first drive shaft), the first main shaft and the first wire guide flange. The first drive shaft and the second drive shaft are coaxial with respect to the support shaft (X) and can rotate about the same axis; the second drive shaft can translate along the axis (X) between the following positions:

[0063] • Forward position: the second drive shaft abuts against the support constrained on the first drive shaft and / or directly abuts against the second drive shaft;

[0064] • Rearward position: the second drive shaft moves away from the support constrained on the first drive shaft, and a gap (60) is formed between the support and the second drive shaft - the feeding unit, pressure roller and clamp assembly can be inserted into the gap.

[0065] The second guide flange is coaxially mounted on the second drive shaft and can translate along the second drive shaft between a proximal position and a distal position relative to the rear side of the support member, and can rotate synchronously with and / or relative to the second drive shaft. In practice,Two wire guide flanges can be arranged on opposite sides relative to the electrical component support; both flanges can rotate independently of each other and their respective drive shafts according to a specific motion law.

[0066] In this embodiment of the winding machine, the workstation includes a second flange holding slide in which the second drive shaft is inserted and can rotate freely. The second wire guide flange is mounted on the second flange holding slide and is provided with a corresponding actuator for controlling the rotation of the second wire guide flange, which is independent of the rotation transmitted to the second drive shaft by the tailstock spindle. The second flange holding slide can be translated along the second drive shaft between a rearward position and a forward position:

[0067] • Rearward position: the second wire guide flange maintains a distance from the support (constrained on the first drive shaft);

[0068] • Forward position: the second wire guide flange abuts against the rear side of the support (constrained on the first drive shaft) - opposite to the side of the front wire guide flange.

[0069] For example, when the first winding and the second winding are the same, the workstation can be configured as a mirror image relative to the support: that is, the first spindle, the first drive shaft, and the first wire guide flange are located on the front side of the support, and the tailstock spindle, the second drive shaft, and the second wire guide flange are located on the rear side of the support, and the two wire guide flanges are substantially the same in shape.

[0070] Typically, the spiral or helical shape of the second wire guide flange is the same as or different from that of the first wire guide flange.

[0071] The process of inserting the wire into the groove on the rear side of the support is achieved by rotating the second drive shaft together with the support and the first drive shaft, causing the pressure roller to roll on the groove, while pushing the wire into the groove, thereby giving the pressure roller radial movement relative to the axis (X) of the support. Similar to the description above for the first winding, the radial movement of the pressure roller is guided by the side of the second wire guide flange to form the second winding.

[0072] The side of the second conductor guide flange also extends between the minimum diameter portion and the maximum diameter portion, and its side serves as a limiting stop when the pressure roller is radially displaced relative to the support axis (X). In this embodiment of the automatic winding machine:

[0073] • Stage A is implemented by rotating the assembly consisting of the first main shaft and the first drive shaft, the tailstock main shaft and the second drive shaft, and the support;

[0074] • Stage B is implemented by the feeding unit of the winding machine;

[0075] • Stage C is implemented by causing the pressure roller to roll along its entire length on the rear groove of the support (at which time the conductor is inserted between the groove and the pressure roller), and by radially translating the pressure roller relative to the support axis (X) on the support.

[0076] The second winding is manufactured after the first winding is manufactured. The feeding unit is movable.The conductor is overlapped on the support and positioned between the end of the first winding and the beginning of the second winding.

[0077] The automatic winding machine preferably includes a clamp—configured to constrain the terminals of the conductive wire at the head of the second drive shaft. For example, the clamp may be integrated into the second drive shaft, including jaws mounted on the second drive shaft and a control shaft; the control shaft is located inside and coaxial with the second drive shaft and is translatable along the axis (X); the jaws, in response to stress applied by the control shaft, may move toward or away from each other to constrain or release conductor terminals extending from the support cantilever or through the support hole.

[0078] As described in the method, each conductor guide flange of the automatic winding machine is rotated by its actuator at a speed lower than that of the corresponding drive shaft, or driven at the same speed with intermittent motion, to cause the pressure roller to cut into the groove.

[0079] Further features and advantages will become clearer from the description of some preferred but non-exclusive embodiments of the method of manufacturing the stator, which are depicted by way of example rather than limitation with the aid of the accompanying drawings, in which:

[0080] FIG1 is a rear perspective view of an electrical component obtained directly by the method according to the invention;

[0081] FIG2 is a front view (front view) of the electrical component shown in FIG1;

[0082] FIG3 is a sectional view of the electrical component shown in FIG1 along a diametrical plane;

[0083] FIG4 is a left front perspective view of a winding machine according to the invention in a first configuration;

[0084] FIG5 is an enlarged view of the winding machine shown in FIG4, which particularly shows the worktable for forming a helical winding on the support of the electrical component;

[0085] FIG6 is an enlarged view of the winding machine shown in FIG4, which particularly shows the worktable in a right front view;

[0086] Figure 7A is an enlarged view of the winding machine shown in Figure 4.The workbench is shown in particular in top view;

[0087] FIG7B is an axial sectional view of the workbench of the winding machine shown in FIG4 along a vertical plane;

[0088] FIG8A is a right perspective view of the workbench of the winding machine shown in FIG4 in a second configuration;

[0089] FIG8B is an axial sectional view of the workbench of the winding machine shown in FIG8A along a vertical plane;

[0090] FIG8C is a left front perspective view of the workbench of the winding machine shown in FIG4 in a second configuration;

[0091] FIG9 is an axial sectional view of the workbench of the winding machine shown in FIG4 along a vertical plane in a third configuration;

[0092] FIG10 is a right front perspective view of a portion of the workbench of the winding machine shown in FIG4 in a third configuration;

[0093] FIG11 is a top and partial rear perspective view of a portion of the workbench of the winding machine shown in FIG4 in a fourth configuration;

[0094] FIG12 is a schematic elevation view of the electrical components of a portion of the workbench of the winding machine shown in FIG4 at three consecutive moments during the manufacture of a helical winding;

[0095] FIG13 is a front view of a portion of the workbench of the winding machine shown in FIG4;

[0096] FIG14 is a left front perspective view of a portion of the workbench of the winding machine shown in FIG4 in the fifth configuration;

[0097] FIG15 is a left front perspective view of a portion of the workbench of the winding machine shown in FIG4 in the sixth configuration;

[0098] FIG16 and FIG17 are rear and top perspective views of a portion of the workbench of the winding machine shown in FIG4 after the sixth configuration, showing the completion process of the electrical components;

[0099] FIG18 is a left front perspective view of a portion of the workbench of the winding machine shown in FIG4 during the insertion of the automatic clamp to cut the wire;

[0100] FIG19 is an axial sectional view along the vertical plane of the workbench of the winding machine shown in FIG4 during the insertion of the automatic clamp to cut the wire;

[0101] FIG20 is a left front perspective view of a portion of the workbench of the winding machine shown in FIG4 when the electrical components are completed and ready for unloading. Detailed Description

[0102] Figures 1-3 show an electrical element 1 obtained according to the method of the present invention, which will now be described.

[0103] Specifically, Figure 1 is a rear perspective view, Figure 2 is a front view, and Figure 3 is a diametrical cross-sectional view of the electrical element 1 taken along a vertical plane containing its axis X.

[0104] The electrical element 1 includes a support 2 on which at least one winding 3', 3" made of wire 4 is provided. In the example shown in the figures, the support 2 is a circular and substantially flat disk shape, having a front side 2' and a back side 2" and a central through hole 5. Specification 7 / 15 pages 14 CN 121358681 A

[0105] On at least one of the two sides 2' and 2" and preferably on both sides,The support member 2 has at least one helical groove 6', 6" (Fig. 3) for accommodating the corresponding windings 3', 3"". In the example shown in the figure, the front side 2' of the support member 2 has a helical groove 6' in which the primary winding 3' is accommodated; while the back side 2" has another helical groove 6", in which the secondary winding 3" is accommodated.

[0106] For the grooves 6' and 6" with helical structures, it means that the groove has a structure that extends radially and gradually increases in diameter, with the starting section having the smallest diameter and the ending section having the largest diameter. In order to obtain the windings 3', 3" and the conductors 4, the stacking needs to be done radially relative to the axis X. When the support 2 is not flat (e.g., conical or arc-shaped), the stacking of the conductors 4 will be primarily radial relative to the axis X to obtain windings 3', 3"".

[0107] The first winding 3' and the second winding 3" can each be made as: a single conductor 4; or a strand 4 formed by twisting multiple conductors together (e.g., Litz wire); or a bundle of parallel conductors pre-pressed and carburized to maintain an initial orderly arrangement.

[0108] In Example 1 shown in the figure, the two windings 3' and 3" are specifically obtained by: accommodating a single Litz wire 4 in slots 6' and 6" which crosses from the front 2' to the back 2" at the transition zone 7 between the two slots 6' and 6". Thus, the same conductor 4 is first wound on one side 2', 2" and then on the other side 2", 2', transitioning at the transition zone 7: in the transition zone 7, the first winding 3' extends from the front 2' to the back 2" and becomes the second winding 3". In fact, the transition zone is a groove or cut formed circumferentially on the support 2 at the periphery of the support 2.

[0109] In the example shown, the Litz wire 4 (hereinafter referred to as wire 4 for simplicity) has a square cross-section, consistent with the cross-sectional shape of the slots 6' and 6" . However, typically, wire 4 as well as slots 6' and 6" can be made with cross-sections of different shapes (e.g., circular).

[0110] Another feature different from that shown in the figure is the number of windings 3', 3" and the corresponding slots 6', 6" on each side 2', 2" of the support member 2: for example, the support member 2 may have two primary windings 3' and corresponding two slots 6', and two secondary windings 3" and corresponding two slots 6", and their (primary or secondary windings) helices are interwoven.

[0111] In the example shown in the figure, the support member 2 has two through holes 8 and 9 aligned with the central through hole 5. The function of these two through holes 8 and 9 is to accommodate the terminals 4' and 4" of the two windings 3' and 3" so that the terminals 4' and 4" extend cantileveredly from the same back side 2" of the support member 2.

[0112] Thus, in the example shown in the figure, a single wire 4 extends from the first terminal 4',A first winding 3' is formed on the front side 2' of the support member 2', and then a second winding 3'" is formed across the support member 2 at the transition zone 7, finally terminating at the second terminal 4". It can be seen that slots 6' and 6" each have radial segments 10 and 11 for guiding the wire 4 from slots 6' and 6" to through holes 8 and 9.

[0113] The electrical component 1 shown in the figure can be used, for example, as the rotor of an electric motor.

[0114] Typically, the support 2 is not necessarily a disc with flat sides 2', 2”, for example, it can be convex or conical, and can be applied to different fields—not only for the manufacture of electric motors, but also for the manufacture of sensors, actuators, measuring tools, etc.

[0115] FIG4 shows a left front perspective view of a winding machine 20 according to the invention, which realizes a method for the automated manufacture of the claimed electrical component 1. In the example shown in the figure, the machine 20 is self-supporting.

[0116] The machine 20 includes:

[0117] - a feed unit 21 configured to supply wire 4, preferably pre-tensioned to a nominal tension value;

[0118] - a worktable 22 in which the support 2 is constrained and the windings 3', 3” are formed in the worktable 22;

[0119] - a movable unloading station 23 for unloading the completed electrical component 1, i.e., the electrical component provided with windings 3', 3”. 121358681 A 1.

[0120] The feed unit 21 is located directly adjacent to the worktable 22. Specifically, the feed unit 21 is located above the worktable 22 and slightly rearward relative to the worktable 22. The worktable 22 is located above the unloading station 23, which includes a tray 24 on which the completed electrical components 1 fall and are transported by the tray 24 toward the unloading area on the track 25.

[0121] FIG5 is an enlarged view of FIG4, showing in particular the feed unit 21 and the worktable 22. The feed unit 21 is fixed to the support structure 26 of the machine 20 and includes a carriage 27 which is easily reciprocated along an axis X parallel to the worktable 22. In the illustrated example, the axis is horizontal. Translation of the carriage 27 is controlled by at least one worm gear actuator 28. Arm 29 extends from carriage 27 toward table 22. A wire guide tube 30 is cantilevered on arm 29 and is configured to be oriented vertically and horizontally (i.e., perpendicular to axis X and parallel to axis X). The wire guide tube 30 receives the wire 4 from above and is properly oriented relative to the support 2 being machined, as described below. Specifically, the wire guide tube 30 is rotatably mounted on pin 29' (FIG. 6) extending cantilevered from arm 29 so as to be able to swing 180° between a vertical position and a horizontal position. However, it should be noted that the horizontal position of the wire guide tube 30 (i.e.,The position parallel to axis X) is used to manufacture the terminals 4' and 4' of windings 3' and 3" of electrical component 1 shown in Figures 1 to 3, and the vertical position of the wire guide tube 30 (i.e., the position perpendicular to axis X) is used to manufacture helical windings 3' and 3" on support 2.

[0122] Figure 6 is a right front perspective view of worktable 22. Referring to Figures 5 and 6, worktable 22 includes:

[0123] - a fixed spindle 31, which is fixed to structure 26 and driven by motor 32 for transmitting rotation on axis X to drive shaft 33 of the same spindle 31. In the example shown, the drive between motor 32 and fixed spindle 31 is belt driven;

[0124] - a first flange retaining carriage 34, which has a first wire guide flange 49 (also referred to as wire guide cap 49) on the side near the fixed spindle 31; the carriage is coaxially mounted to drive shaft 33 and can be mounted along axis X on drive shaft 33 (especially on track 37). (Above) reciprocating. Wherein, the first wire guide flange 49 is helical or spiral-shaped, used to guide the movement of the pressure roller 53, and to insert the wire 4 into the groove 6' on the front side 2' of the support member 2.

[0125] - Constraint mechanism 35 (as shown in FIG7B) for constraining the support member 2 to the drive shaft 33, and the support member 2 is coaxial with the shaft X;

[0126] - Tailstock main shaft 36, the tailstock main shaft 36 is constrained to the structure 26, and due to the thrust applied by the actuator 38 provided on the same tailstock main shaft 36, the tailstock main shaft 36 can move relative to the structure 26 toward and away from the fixed main shaft 31 on the track 37. The tailstock main shaft 36 is also equipped with a power source: reference numeral 39 indicates the corresponding electric motor, which is arranged to directly drive the tailstock main shaft 36. The tailstock main shaft 36 includes a drive shaft 40, which is opposite to the drive shaft 33 of the fixed main shaft 31, and is coaxial with the drive shaft 33 of the fixed main shaft 31 on the shaft X;

[0127] - A clamp 41, which is integrated into the drive shaft 40 of the tailstock spindle 36 and configured to constrain the terminals 4', 4" of the windings 3', 3";

[0128] - On the side of the tailstock spindle 36, a second flange retaining slide 42 with a second wire guide flange 50 (also referred to as a wire guide cap 50) is provided - the slide 42 is coaxially mounted with the drive shaft 40 and can reciprocate along the axis X on the drive shaft 40; wherein the second wire guide flange 50 is helical or spiral-shaped and is used to guide the movement of the pressure roller 53 and to insert the wire 4 into the groove 6" on the second side 2" of the support member 2.

[0129] - A unit 43 for guiding and inserting the wire 4 into the slots 6', 6" of the support member 2, wherein the unit 43 is constrained to the support structure 26 and is easily movable on three axes, which allows it to be inserted between the first wire guide flange 49 and the support member 2 being machined, and between the second wire guide flange 50 and the support member 2 being machined.In order to mate with the wire guide flanges 49 and 50 and to achieve correct insertion of the wire 4 into the slots 6', 6" of the support member 2; Specification 9 / 15 page 16 CN 121358681 A

[0130] - Clamp assembly 44 for cutting wire 4.

[0131] As can be seen in FIG6, a seat 45 is provided on the drive shaft 33 of the fixed spindle 31, and the wire guide tube 30 is inserted into the seat 45 when the drive shaft 33 is in a stationary state (i.e., neither rotating about axis X nor translating along axis X).

[0132] Figure 7A shows a top perspective view of the worktable during the initial stage of the method according to the invention. An external manipulator (not shown) is used to move the support 2 to the position shown in the figure, where the front side 2' faces the flange holding carriage 34, and specifically, to key the support 2 onto the drive shaft 33 of the fixed spindle 31. The key connection of the support 2 onto the drive shaft 33 is achieved by a constraint mechanism 35 (visible in Figure 7B), which operates according to the command of the corresponding actuator. Thus, the tailstock spindle 36 moves toward the fixed spindle 31 until it reaches the position where the drive shaft 40 abuts against the rear side 2” of the support 2, and the support 2 remains pressed between the two drive shafts 33 and 40.

[0133] By inserting the horizontally arranged wire guide tube 30 into the seat 45 formed in the drive shaft 33 of the fixed spindle 31, the feed unit 21 is lowered so that the arm 29 and the pin 29' reach the height of the support 2. Subsequently, arm 29 and wire guide tube 30 move toward support member 2, causing wire guide tube 30 to insert terminal 4' of wire 4 into through hole 9 present on support member 2. Thus, terminal 4' protrudes from support member 2 in the opposite direction to wire guide tube 30. At this time, gripper 41 integrated in drive shaft 40 of tailstock spindle 36 begins to function: gripper 41 is operated, its jaws 41' closing onto terminal 4', thereby restricting terminal 4' to prevent wire 4 from slipping off support member 2 during winding. Jaws 41' are hinged to drive shaft 40 and can be operated on command.

[0134] In this configuration, drive shafts 33 and 40 are stationary and do not rotate about axis X. Flanges keep carriages 34 and 42 away from support member 2, on the one hand allowing gripper 41 to intervene, and on the other hand allowing wire guide tube 30 to be inserted into seat 45 and allowing terminal 4' to be inserted into through hole 9 of support member 2.

[0135] FIG7B shows the worktable 22, which is constructed the same as the worktable shown in FIG7A, but is presented as a cross-sectional view taken along a vertical plane passing through axis X.

[0136] As can be noted, the gripper 41 is inside the drive shaft 40 of the tailstock spindle 36: the gripper 41 includes a control shaft 41”, which is inside the drive shaft 40 and movable relative to the drive shaft 40 along axis X.The gripper 41' is opened and closed.

[0137] The wire guide tube 30 is provided with two side-by-side rollers 30' and 30" which together define the path of the wire 4. Specifically, the wire 4 extends between rollers 30' and 30" and may be wound around a portion of one of the two rollers 30' and 30" to form a curve.

[0138] The constraint mechanism 35 has the function of constraining the support 2 to the drive shaft 33 of the fixed spindle 31 for the duration of the entire work cycle. The constraint mechanism 35 includes two levers 46, 47 hinged to the drive shaft 33; each lever includes a hook-shaped end that can be inserted into the central through-hole 5 of the support 2. In the configuration shown in FIG. 7B, the levers 46, 47 pass through the central through-hole 5 of the support 2 in a fully open state, and the hook-shaped ends engage with the edge of the through-hole 5. This position is the normal holding position of the levers 46, 47. In order to release the support 2 and allow it to fall onto the tray 24 by gravity, the separation of the levers 46, 47 is achieved by an actuator within the drive shaft 33: this actuator is a control lever 48, which is coaxial with the drive shaft 33 and can slide in a corresponding seat between the rearward and forward positions shown in FIG. 7b; in the rearward position, the control lever does not interfere with the levers 46, 47. Therefore, the levers remain fully open; in the forward position, the control lever 48 wedges between levers 46 and 47, bringing them closer together and disengaging their respective hook ends from the edge of the central through-hole 5 of the support 2. To maintain the levers 46 and 47 in their usual engaged position, the levers 46 and 47 are preferably subjected to the thrust of an elastic element (e.g., a coil spring mounted on each pin of levers 46 and 47).

[0139] FIG8A is a right perspective view of the worktable 22 at the later stage of the work cycle. The construction shown in FIG8A differs from that shown in FIG7A and 7B, pages 10 / 15, 17 CN 121358681 A, in that the wire guide tube 30 moves rearward into the seat 45 and rotates 90° counterclockwise about pin 29', thereby being in a vertical position by radially orienting the wire 4 relative to the axis X and the support 2. The movement of the wire guide tube 30 causes the wire 4 to undergo local deformation, so that a section of the wire is parallel to the radial segment 10 of the groove 6' on the front side 2'. Then, preparation for insertion is made. Drive shafts 33 and 40 remain stationary.

[0140] FIG8B is a cross-sectional view taken along a vertical plane passing through axis X, and shows a worktable 22 with the same construction as FIG8A. The end 4' of the wire 4 is held between the jaws 41” of the gripper 41, bends through the through hole 9 of the support 2 and enters the wire guide tube 30, then flows through rollers 30' and 30” to the feed unit 21. At this time, all parts of the worktable 22 are stationary.

[0141] FIG8C shows the same construction in a left perspective view.The closed position of the grippers 41' of the clamp 41 can be observed more clearly, and these grippers are constraining the end 4' of the wire 4.

[0142] Figure 9 is a cross-sectional view taken along a vertical plane through axis X, showing the configuration of the worktable 22 further back than the configuration shown in Figures 8A to 8C, corresponding to the initial stage of the formation of the first winding 3'.

[0143] Specifically, in Figure 9, the second flange retaining carriage 42 (i.e., the one located on the side of the tailstock main shaft 36) translates on the drive shaft 40 and reaches the end of its stroke position, at which point the second guide flange 50 abuts against the rear side 2” of the support member 2. In this position, the drive shaft 40 and the second guide flange 50 rotate together with the support member 2 about the axis. On the opposite side of the support member 2, the first flange retaining carriage 34 (i.e., the one located on the side of the fixed main shaft 31) translates on the drive shaft 33 and reaches the forming end position, at which point the first guide flange 49 is next to but not against the front side 2’ of the support member 2: in fact, there is still a minimum clearance between the front side 2’ of the support member 2 and the first guide flange 49, which is sufficient to avoid mechanical interference when the first guide flange 49 rotates relative to the support member 2, which will be explained in detail below. In this position, the drive shaft 33 rotates integrally with the support member 2 on the axis X, while the first guide flange 49 can rotate relative to the drive shaft 33, and thus relative to the support member 2.

[0144] The wire 4 remains pressed between the support 2 and the side of the first wire guide flange 49 facing the support 2.

[0145] As described below, the configuration just described will allow the support 2 to remain rotated, thereby allowing the wire guide flange 49 to rotate relative to the support 2; while the unit 43 is used to guide the wire 4 and insert it into the slot 6' present on the front side of the support 2.

[0146] FIG10 is a right perspective view of the details of the workbench 22 in the configuration shown in FIG9 (i.e., the initial stage of forming the first winding 3' on the front side 2' of the support 2). By observing this figure, the drive shafts 33 and 40 rotate 90° counterclockwise in sync, and therefore the support 2 also rotates 90° in sync. This initial rotation brings the initial segment 51 of the first winding 3' to a specific angular position on the axis X, which is just suitable for the wire 4 to cooperate with the guide insertion unit 43.

[0147] At this time, the end 4' of the wire 4 is constrained by the clamp 41 on the drive shaft 40, and a segment of the wire 4 has been inserted into the bracket 2. The initial segment 51 of the wire 4 is wound around the sector of the wire guide flange 49 by means of the aforementioned 90° rotation.

[0148] The guide insertion unit 43 includes an arm 52 provided with a pressure roller 53. The guide insertion unit 43 is movable relative to the support structure 26 of the machine 20 by means of a specific actuator (visible in the figure, but not numbered).These actuators are used to move arm 52 radially relative to axis X in two directions at wire guide flange 49. In other words, arm 52 can move radially toward or away from axis X. The function of pressure roller 53 is to apply axial thrust (i.e., thrust parallel to axis X) to wire 4 so that wire 4 is inserted into groove 6' and through the entire length of groove 6' while support 2 is kept rotating.

[0149] As shown in FIG10, arm 53 abuts against side 49' of wire guide flange 49: during rotation of wire guide flange 49, arm 52 with pressure roller 53 moves backward, thereby moving radially away from axis X, precisely because wire guide flange 49, which acts as a cam, guides it. In fact, during the manufacture of the first winding 3', wire guide flange 49 acts as a cam and arm 52 acts as a follower.

[0150] Specifically, the pressure roller 53 is designed to roll along grooves 6', 6" to traverse the entire length of the groove. For this purpose, it can be positioned relative to the support 2 such that the axis of rotation is radial and coincides with (or collinear with) the axis X of the support and the axis X of the drive shafts 33 and 40: by controlling the radial movement of the pressure roller 53 during the rotation of the support 2, the pressure roller 53 is able to roll along the entire groove 6'.

[0151] FIG10 is a partial top rear perspective view of the worktable including the support 2, the first flange retaining carriage 34, the first wire guide flange 49, the second flange retaining carriage 42, and the second wire guide flange 50. The actuator 54 of the first wire guide flange 49 is clearly visible in this figure. It is an electric motor with its axis parallel to the drive shaft 33, which transmits motion to the first wire guide flange 49 via a gear 55 housed on the first flange retaining carriage 34; this transmission process is independent of the rotation of the drive shaft 33, and consequently also independent of the rotation of the support 2.

[0152] Specifically, the actuator 54 is an electronically controlled motor, whose function is to drive the first wire guide flange 49 to rotate synchronously relative to the drive shaft 33, and can also achieve intermittent rotation by alternating the rotation and stopping of the first wire guide flange 49 according to a preset time interval.

[0153] Due to this detail, when manufacturing the first winding 3', the first wire guide flange 49 will rotate around the axis X according to its own motion law given by the actuator 54 - this rotation is independent of the continuous rotation of the drive shaft 33 at a constant speed - thereby guiding the pressure roller 53 so that the motion trajectory of the pressure roller 53 matches the contour of the groove 6'.

[0154] In other words, the method controls the radial displacement of the pressure roller 53 relative to the axis X, so that while the pressure roller 53 rolls above the groove 6', the groove 6' moves below the pressure roller 53 due to the rotation applied to the support member 2; the radial displacement of the pressure roller 53 is applied by the first wire guide flange 49.In particular, it is applied by the side 49' of the first wire guide flange 49 of the rearward push arm 52.

[0155] Since the first wire guide flange 49 is helical or spiral, its side 49' has a minimum diameter and a maximum diameter:

[0156] - Whenever the pressure roller 53 abuts against the side 49' of the first wire guide flange 49 at the minimum diameter, the pressure roller 53 is at the minimum distance from the axis X and above the initial section of the slot 6';

[0157] - Whenever the pressure roller 53 abuts against the side 49' of the first wire guide flange 49 at the maximum diameter, the pressure roller 53 is at the maximum distance from the axis X and above the end section of the slot 6' at the transition zone 7.

[0158] FIG12 is a schematic diagram that helps to understand what has just been described above. In particular, FIG12 shows three schematic elevation views a-c of a portion of the workbench of the electrical component 1 and the winding machine 20, corresponding to three consecutive moments in the process of manufacturing the first helical winding 3'.

[0159] In views a, b, and c, axis X is perpendicular to the plane of the figures; therefore, the guide insertion unit 43 and the wire guide tube 30 are shown in side view form, while the support 2 is shown in front view form.

[0160] Figure 12(a) shows the machine 20 in the initial stage of making the first winding 3': its construction is the same as that shown in Figures 9 to 10. After the terminal 4' of the wire 4 is clamped by the clamp 41, the wire guide tube 30 is rotated to a vertical position (at this time, a section of the wire 4 has been inserted into the initial section 10 of the slot 6'), the carriages 34 and 42 reach the end of their stroke, the drive shafts 33 and 40 separate and abut against opposite sides of the support 2, the second wire guide flange 50 abuts against the rear side of the support 2, while the wire guide flange 49 is close to the front side 2' of the support 2 but does not abut against it, but rather against the wire 4.

[0161] The wire guide tube 30 is made perpendicular to axis X, i.e., aligned with axis X above it. The conductor 4 is partially wound around the side 49' of the first conductor guide flange 49; the side 49' is preferably polished to prevent damage to the conductor 4 as it slides toward the support 2. The pressure roller 53 abuts against the side 49' of the first conductor guide flange 49 at its minimum diameter and is therefore located at the point closest to the axis X. Specification 12 / 15 pages 19 CN 121358681 A

[0162] Specifically, the axis of rotation of the pressure roller 53 is collinear (or coincident) with the axis X of the support 2, i.e., the pressure roller 53 is arranged radially. The conductor 4 is tangent to the groove 6' at the contact point between the pressure roller 53 and the support 2.

[0163] The manufacture of the first winding 3' begins at this point.

[0164] Referring to FIG12(b),The drive shafts 33 and 40 rotate synchronously with the support member 2 and the second wire guiding flange 50 at a constant rotational speed V2 (shown in the figure as counterclockwise). Since the first winding 3' of the support member 2 has a total of 4.25 turns of wire 4 between the end 4' and the transition region 7, the support member 2 needs to rotate 4.25 turns, that is, the drive shafts 33 and 40 rotate four and a quarter turns.

[0165] During the rotation of the support member 2, the first wire guiding flange 49 is driven to rotate by the corresponding actuator 54 through the gear 55 (Figure 11) so that it only rotates one turn within the time when the support member completes 4.25 turns of rotation. As described above, this motion characteristic of the first wire guiding flange 49 can be achieved in two ways:

[0166] - by rotating the wire guiding flange 49 at a speed lower than that of the support member 2 (V49 < V2), or

[0167] - by rotating the first wire guiding flange 49 at the same speed as the support member 2 (V49 = V2), but performing intermittent motion and then stopping the first wire guiding flange 49 at time intervals.

[0168] In the example shown in the figure, the second method is adopted. The setting of the motion law of the first wire guiding flange 49 can be manually completed during the commissioning phase of the machine 20, for example, through empirical testing, or by manually moving the first wire guiding flange 49 and implementing it through the control unit of the machine 20 with self-learning ability.

[0169] Regardless of the method used to control the rotational speed of the first wire guiding flange 49, the result obtained is that the pressure roller 53 rolls above the entire length of the groove 6' - by pushing the wire 4 into the groove, and the wire 4 is inserted in an interference fit here.

[0170] When the wire 4 is inserted into the groove 6, it is beneficial that no torsion is generated in the wire 4 itself: the wire is pushed by the pressure roller 53 with a force parallel to the axis X. Therefore, the wire 4 inserted into the groove 6' is not easily disengaged, and no mechanical stress is generated in the support member 2, which is beneficial to improving the quality and service life of the first winding 3'.

[0171] Figure 12(c) shows the final stage of manufacturing the first winding 3', at this time the support member 2 has completed four turns of rotation and is completing the last quarter turn of rotation, and the wire 4 is in the transition region 7. The first wire guiding flange 49 is about to complete its single turn of rotation, and the pressure roller 53 is about to reach the maximum diameter of the first wire guiding flange 49, corresponding to the structure "step 56".

[0172] Due to the fact that the pressure roller 53 does not cause torsion in the wire 4 when inserting the wire 4, when the electrical component 1 is used, the wire 4 will not be easily disengaged from the corresponding groove 6'.

[0173] The step 56, which is also visible in Figures 8C, 10, and 11, marks the difference between the minimum diameter and the maximum diameter of the spiral structure formed by the first wire guiding flange 49.

[0174] When the support member 2 and the first wire guiding flange 49 stop after completing their respective rotations, the first winding 3' is completed,At this point, the wire 4 is ready to cross the support 2 via the transition zone 7 and be guided to the rear side 2” of the support 2.

[0175] Figure 13 precisely illustrates this situation: it is a frontal elevation view of a portion of the workbench 22, showing the moment when the wire 4 is dragged by the wire guide tube 30 to the other side (or opposite side) of the support 2 as it passes through the transition zone 7. The wire guide tube 30 is arranged axially and possibly radially relative to the axis of rotation X so that the wire 4 cuts into the beginning of the slot 6” present on the rear side 2” of the support 2.

[0176] It should be noted that the formation path of the first winding 3’ is: starting from the through hole 9 (i.e., the central region) of the support 2 along the slot 6’, spiraling towards the edge of the front side 2’; while the second winding 3”” is formed in the opposite direction – from the edge of the rear side 2” of the support 2 back to the through hole 8 in the central region. As such, the starting point of the slot 6” is located in the transition zone 7, and the ending point is located in the through hole 8.

[0177] FIG14 is a left front perspective view showing the removal of wire 4 at the same time as shown in FIG13. Under this configuration, the fabrication of the second winding 3” can begin.

[0178] It should be noted that in the example shown in the figure, windings 3' and 3” are substantially the same, that is, the two helices formed by windings 3' and 3” have the same geometric features. Therefore, the second wire guide flange 50 has the same shape as the first wire guide flange 49. In FIG14: reference numeral 50' indicates the side of the second wire guide flange 50, and reference numeral 57 indicates the step between the minimum and maximum diameters of the flange 50.

[0179] In fact, it can be clearly seen by observing other figures (e.g., FIG8A) that the assembly formed by the second flange retaining carriage 42, drive shaft 40 and the second wire guide flange 50 is approximately mirror-symmetrical to the assembly formed by the first flange retaining carriage 34, drive shaft 33 and the first wire guide flange 49.

[0180] The actuator 58 of the second wire guide flange 50 is also mounted on the second flange retaining slide 42. This actuator 58 is used to drive the second wire guide flange 50 to rotate via the gear 59 and according to the provided motion law.

[0181] The fabrication of the second winding 3” requires the following to begin:

[0182] - by eliminating the gaps left so far, the first wire guide flange 49 is brought against the front side 2' of the support 2, and

[0183] - the second wire guide flange 50 is moved away from the rear side 2” of the support 2 to allow these elements to rotate relative to each other.

[0184] The guide insertion unit 43 is repositioned, and the pressure roller 53 is above the step 57 and abuts against the side 50' of the second wire guide flange 50 at the minimum diameter of the second wire guide flange 50.

[0185] At this time, the drive shafts 33 and 40 rotate synchronously.And rotates integrally with the support member 2 and the first wire guiding flange 49. The wire 4 is pushed into the groove 6” by the pressure roller 53.

[0186] As described above for the first wire guiding flange 49, the second wire guiding flange 50 can also be operated in two ways:

[0187] - By rotating the second wire guiding flange 50 at a speed lower than that of the support member 2 (V50 < V2), or

[0188] - By rotating the second wire guiding flange 50 at the same speed as the support member 2 (V50 = V2), but with an intermittent motion, and then stopping the second wire guiding flange 50 at time intervals.

[0189] The latter is the preferred mode adopted in the illustrated example, which can be set empirically or achieved by using the self-learning program of the electronic device of the machine 20.

[0190] Due to the combination of the double-rotation motors of the support member 2 and the second wire guiding flange 50, the pressure roller moves along the entire length of the groove 6” and inserts the wire 4 therein, finally completing the production of the second winding 3”.

[0191] FIG. 15 is a left front perspective view of the workbench 22, showing the subsequent stage: As described above, the second winding 3” has been completed by the pressure roller 53 rolling along the groove 6” from the edge of the support member 2 towards the center. Currently, the second terminal 4” needs to be fabricated. The tailstock spindle 36 moves backward along the axis X together with the second flange holding carriage 42, thereby forming a gap 60 between the second wire guiding flange 50 and the support member 2. The support member 2 still maintains its connection with the drive shaft 33 through the restraint effect exerted by the lever 47.

[0192] At this time, in order to facilitate the insertion of the wire 4 into the end segment 11 extending radially towards the axis X in the groove 6”, the guiding insertion unit 43 operates a second tool relative to the arm 52: This second tool is the second inclined arm 61, which is provided with an auxiliary cylindrical pressure element 62 for guiding the wire 4. In fact, the auxiliary pressure element 62 provides a temporary winding surface for the wire 4. By partially winding around the auxiliary pressure element 62, the wire 4 is deflected, thereby disengaging from the helical segment of the groove 6” and entering the straight radial segment 11 of the groove 6”. The auxiliary pressure element 62 remains in working state throughout the entire process of the wire 4 being inserted into the straight radial segment 11 of the groove 6”.

[0193] FIGS. 16 and 17 are rear and top perspective views of the workbench 22 during the fabrication of the terminal 4”, presenting the states at consecutive time points. FIG. 16 shows a time point during the interpolation process: DESCRIPTION 14 / 15 pages 21 CN 121358681 A

[0194] - The movement of the guiding insertion unit 43,

[0195] - The rotation of the support member 2 (observed as clockwise in the drawing), and

[0196] - The movement for repositioning the wire guiding tube 30 (rotating around the pin 29' and adding lifting and moving the pin 29'),

[0197] These movements are coordinated and regulated by the control unit of the machine 20,To precisely achieve insertion of the wire 4 into the radial segment 11 of the slot 6”.

[0198] For example, as shown in FIG16, the support 2 is rotated to vertically orient the radial segment 11 of the slot 6”, thereby allowing the unit 43 to continue inserting the wire 4 in a vertical motion until the through hole 9 is reached.

[0199] Alternatively, as shown in FIG17, the support 2 is rotated to horizontally orient the radial segment 11 of the slot 6”, thereby allowing the unit 43 to continue inserting the wire 4 in a horizontal motion until the through hole 9 is reached. It can be noted that the wire guide tube 30 is rotated and adjusted to a horizontal position so that the terminal 4” is parallel to the axis X.

[0200] FIG18 is a left front perspective view of a portion of the worktable 22 of the winding machine 20 at a subsequent point in time after the terminal 4” fabrication described in FIG16 and 17 is completed. The rotation of drive shafts 33 and 40 stops, and the tailstock spindle 36 moves rearward together with the flange retaining carriage 42 to form a gap 60 for the clamp assembly 44 to be inserted. The movement of the clamp assembly is perpendicular to axis X. The clamp assembly 44 cuts the wire 4, completing the fabrication of the terminal 4” of the electrical component 1.

[0201] FIG19 is an axial sectional view (cut along a vertical plane) of the worktable 22 in the same configuration as FIG18, i.e., the moment when the clamp assembly 44 is inserted into the gap 60, cuts the wire 4, and completes the fabrication of the terminal 4”. The figure shows the state of the clamp assembly cutting the wire 4 at the terminal 4” from the front, at which time the wire guide tube is arranged parallel to axis X.

[0202] FIG20 shows a left front perspective view of the worktable 22 in the configuration shown in FIG18 and FIG19 at a subsequent point in time. At this point, the clamp assembly 44 has cut the wire 4, and the electrical component 1 has been determined to be completed and ready to be unloaded onto the tray 24 of the carriage 23. Unloading is achieved by gravity: by inserting the control lever 48 between the levers 46 and 47 to fully open them, thereby disengaging from the support member 2.

[0203] In the described example, the first winding 3' and the second winding 3" are substantially the same, and therefore, the wire guide flanges 49 and 50 have the same geometry. However, in general, windings can have different geometries, and correspondingly, the wire guide flanges 49 and 50 can also be made in different shapes.

[0204] Furthermore, it should be noted that in the example shown in the figure, the electrical component 1 includes two opposing windings 3' and 3" that are located on opposite sides 2' and 2" of the support member 2. However, the described method is also applicable to manufacturing electrical components 1 with only a single winding. Obviously, if the support member 2 is convex or conical,The process of inserting the wire 4 into the corresponding slot is also achieved through the axial movement of the guide insertion unit 43 and the pressure roller 53—the guide insertion unit and the pressure roller will follow the contour of the support surface. Instruction manual page 15 / 15, 22 CN 121358681 A; Instruction manual figure 1 / 22, 23 CN 121358681 A, Figure 3; Instruction manual figure 2 / 22, 24 CN 121358681 A, Figure 4; Instruction manual figure 3 / 22, 25 CN 121358681 A, Figure 5; Instruction manual figure 4 / 22, 26 CN 121358681 A, Figure 6; Instruction manual figure 5 / 22, 27 CN 121358681 A, Figure 7A; Instruction manual figure 6 / 22, 28 CN 121358681 A, Figure 7B; Instruction manual figure 7 / 22, 29 CN 121358681 A, Figure 8A; Instruction manual figure 8 / 22, 30 CN 121358681 A, Figure 8B; Instruction manual figure 9 / 22, 31 CN 121358681 A, Figure 8C Figure 9 of the instruction manual, page 10 / 22, CN 121358681 A; Figure 10 of the instruction manual, page 11 / 22, CN 121358681 A; Figure 11 of the instruction manual, page 12 / 22, CN 121358681 A; Figure 12 of the instruction manual, page 13 / 22, CN 121358681 A; Figure 13 of the instruction manual, page 14 / 22, CN 121358681 A; Figure 14 of the instruction manual, page 15 / 22, CN 121358681 A; Figure 15 of the instruction manual, page 16 / 22, CN 121358681 A; Figure 17 of the instruction manual, page 17 / 22, CN 121358681 A; Figure 17 of the instruction manual, page 19 / 22, CN 121358681 A; Figure 18 of the instruction manual, page 40, CN 121358681 A; Figure 19 of the instruction manual, page 41, CN 121358681 A. 121358681 A Figure 18 Instruction Manual Drawings, Page 20 / 22, 42 CN 121358681 A Figure 19 Instruction Manual Drawings, Page 21 / 22, 43 CN 121358681 A Figure 20 Instruction Manual Drawings, Page 22 / 22, 44 CN 121358681 A,

Claims

1. A method of manufacturing an electrical component (1), which electrical component (1) is provided with a support (2), which support (2) has at least one side surface (2', 2"), and wherein, On said at least one lateral face (2', 2'') is provided at least one helical groove (6', 6''), said helical groove (6', 6'') being coaxial with the axis (X) of the support (2) and extending radially or mainly radially, and wherein at least one wire (4) forming a helical winding (3', 3'') is housed in said at least one groove (6', 6''), The method comprises: A) rotating the support (2) around the axis (X), B) supplying the wire (4) to the support (2), C) inserting the wire (4) into the groove (6', 6'') by means of a press roller (53) arranged to roll on the groove (6', 6'') with its axis of rotation intersecting the axis (X) of the support (2) and moving the press roller (53) radially with respect to the axis (X) of the support (2) so as to travel along the entire length of the groove (6', 6'').

2. The method of claim 1, wherein, Phase A is performed by constraining the support (2) on a drive shaft (33) coaxial with the axis (X) of the support (2) and rotatable around the axis (X).

3. The method of claim 1 or 2, wherein, Phase B is performed by means of a wire guide tube (30) movable with respect to the support (2), ensuring that the wire (4) is fed into the respective groove (6', 6'') with a trajectory tangent to the groove (6', 6'').

4. The method according to any of the preceding claims 1 to 3, wherein, Phase C is performed by abutting the press roller (53) against a wire guide flange (49, 50), and wherein the wire guide flange (49, 50) acts as an end stop defining the distance between the press roller (53) and the axis (X) of the support (2).

5. The method of claim 4, wherein, The wire guide flange (49, 50) is arranged coaxial with the axis (X) of the support (2) and rotatable on the same axis (X), and wherein the wire guide flange (49, 50) is helical or spiral, having lateral faces (49', 50') extending between a minimum diameter portion and a maximum diameter portion, and wherein: - when the press roller abuts against the lateral face (49', 50') of the wire guide flange (49, 50) at the minimum diameter portion, the press roller (53) is at a minimum distance from the axis (X) of the support (2) and is located at a first end of the groove (6', 6''), and - when the press roller abuts against the lateral face of the wire guide flange (49, 50) at the maximum diameter portion, the press roller (53) is at a maximum distance from the axis (X) of the support (2) and is located at a second end of the groove (6', 6'').

6. The method of claim 4 or 5, wherein, A relative rotation occurs between the support (2) and the wire guide flange (49, 50).

7. The method of any one of claims 4-6, wherein, The rotation of the wire guide flange (49, 50) around the axis (X) of the support is controlled according to one of the following ways: - the wire guide flange (49, 50) is rotated slower than the support (2), or - the wire guide flange (49, 50) is rotated at the same speed as the support (2) with an intermittent motion.

8. The method of any of the preceding claims, wherein, The electrical element (1) has a first winding (3') and a second winding (3") on opposite portions of the support (2), and wherein the support is flat and has a front side (2') and a rear side (2"), a first slot (6') being provided on the front side (2') and a second slot (6") being provided on the rear side (2"), and wherein the support (2) has a transition zone (7) where the first slot (6') and the second slot (6") meet, and wherein, Phase C is implemented in the following steps: C1) obtaining the first winding (3') by inserting the wire (4) into the first slot (6') by means of a pressure roller (53) and moving the pressure roller (53) radially with respect to the axis (X) of the support between a proximal position with respect to the axis (X) of the support (2) at the beginning of the first slot (6') and a distal position with respect to the axis (X) of the support (2) at the end of the first slot (6'), and C2) obtaining the second winding (3") by overlapping the wire (4) on the support (2) at the transition zone (7) and leading the wire (4) from the front side (2') of the support (2) to the rear side (2") of the support (2), and C3) obtaining the second winding (3") by inserting the wire (4) into the second slot (6") by means of the pressure roller (53) and moving the pressure roller (53) radially with respect to the axis (X) of the support between a distal position with respect to the axis (X) of the support (2) at the beginning of the second slot (6") and a proximal position with respect to the axis (X) of the support (2) at the end of the second slot (6").

9. The method of claim 8, wherein: C1 is implemented by guiding the radial movement of the pressure roller (53) using a first wire guide flange (49), C2 is implemented by using a wire guide tube (30) movable with respect to the support (2), and C3 is implemented by guiding the radial movement of the pressure roller (53) using a second wire guide flange (50), wherein the two wire guide flanges (49, 50) are coaxial with the axis (X) of the support and are located on opposite sides with respect to the axis (X) of the support, and wherein there is a relative rotation between the support (2) and each wire guide flange (49, 50) during phases C1 and C3.

10. The method of claim 8 or 9, wherein, The at least one slot (6', 6") has a radial section (10, 11), and inserting the wire (4) into the radial section (10, 11) is implemented by: D) locking the support (2) with respect to the axis (X), aligning the pressure roller (53) with the axis (X) of the support (2), and rolling the pressure roller (53) on the radial section (10, 11) of the at least one slot (6', 6").

11. An electrical component (1) directly manufactured with the method according to any one of the preceding claims, the electrical component (1) being provided with a support (2) having at least one side face (2', 2"), and wherein, At least one helical slot (6', 6") coaxial with respect to the axis (X) of the support (2) is provided on said at least one side (2', 2") and wherein at least one wire (4) forming a helical winding (3', 3") is housed in said at least one slot (6', 6").

12. The electrical element (1) according to claim 11, wherein The wire (4) of the helical winding (3', 3") is not twisted.

13. The electrical element (1) according to claim 11, wherein The support (2) is flat and has a first winding (3') on the front side (2') and a second winding (3") on the rear side (2").

14. The electrical element (1) according to any one of claims 11-13, wherein The windings (3', 3") have terminals (4', 4") extending in cantilevered fashion from the same side (2") of the support (2).

15. An automatic winding machine (20) for manufacturing an electrical element (1) provided with a support (2) having at least one lateral face (2', 2"), and wherein, At least one helical slot (6', 6") coaxial with respect to the axis (X) of the support (2) is provided on said at least one side (2', 2") and wherein at least one wire (4) forming a helical winding (3', 3") is housed in said at least one slot (6', 6"), The winding machine (20) comprises a worktable (22) and a feeding unit (21) configured for conveying the wire (4) to the worktable (22), wherein the worktable (22) comprises a first main shaft (31), a corresponding first drive shaft (33), means (46, 47) for coaxially constraining the support (2) on the drive shaft (33), a first wire guide flange (49) and a pressure roller (53), and wherein the support (2) and the first drive shaft (33) are rotatable about the axis (X) of the support (2), and wherein the pressure roller (53) is positionable against a side (2') of the support (2) so as to be able to roll on at least one slot (6'), and is susceptible to radial displacement with respect to the axis (X) of the support (2), and wherein the wire guide flange (49) is coaxially mounted on the first drive shaft (33) and is susceptible to translation along the first drive shaft (33) between a proximal position and a distal position with respect to the support (2), and is susceptible to synchronous rotation with the first drive shaft (33) and / or to relative rotation with respect to the first drive shaft (33), and wherein the first wire guide flange (49) is helical or spiral and the insertion of the electrically conductive wire (4) into the slot (6') is achieved by rotating the first drive shaft (33) together with the support (2), by rolling the pressure roller (53) on the slot (6'), while pushing the wire (4) into the slot (6'), thus imparting a radial motion of the pressure roller (53) with respect to the axis (X) of the support (2), wherein the radial motion of the pressure roller (53) is guided by a side (49') of the first wire guide flange (49).

16. The automatic coiling machine (20) according to claim 15, wherein Phase A of the method according to claim 1 is performed by means of the first main shaft (31) and the first drive shaft (33), Phase B of the method according to claim 1 is performed by means of the feeding unit (21), Phase C of the method according to claim 1 is performed by rolling the pressure roller (53) along the entire length of the slot (6') with the wire (4) interposed between the slot (6') and the pressure roller (53) and with the pressure roller (53) translating radially on the support (2) with respect to the axis (X).

17. The automatic coiling machine (20) according to claim 15 or 16, wherein The feeding unit (21) comprises a wire guide tube (30) movable with respect to the support (2) and to the axis (X) of the first drive shaft (33), wherein the wire guide tube (30) is also orientable with respect to the support (2) mounted on the first drive shaft (33) so as to supply the wire (4) orthogonally with respect to the lateral face (2') of the support (2) and / or radially or tangentially with respect to the slot (6').

18. The automatic coiling machine (20) according to claim 17, wherein The feeding unit (21) is a three-axis unit.

19. The automatic coiling machine (20) according to any one of the preceding claims 15-18, wherein, The means (46, 47) for coaxially constraining the support (2) on the drive shaft (33) comprise two levers (46, 47) pivoted at the head of the first drive shaft (33) and operable to engage the inner edge (5) of the support (2).

20. The automatic coiling machine (20) according to claim 19, comprising a control lever (48) for controlling the levers (46, 47), wherein, The control lever (48) is located inside and coaxial to the first drive shaft (33) and is translatable between a retracted position, in which it does not engage the levers (46, 47) which engage the support (2) and constrain it on the first drive shaft (33), and an extended position, in which it is interposed between the levers (46, 47) causing them to disengage the support (2).

21. The automatic coiling machine (20) according to any one of the preceding claims 15 to 20, wherein, The worktable (22) comprises a first flange holder (34) in which the first drive shaft (33) is inserted, and wherein the first wire guide flange (49) is mounted on the first flange holder (34) and is provided with a respective actuator (54) which controls the rotation of the first wire guide flange (49) independently of the rotation imparted to the first drive shaft (33) by the first main shaft (31), and wherein the first flange holder (34) is translatable along the first drive shaft between a retracted position, in which the first wire guide flange (49) is distanced from the support (2) constrained on the first drive shaft (33), and an advanced position, in which the first wire guide flange (49) abuts against the support (2) constrained on the first drive shaft (33).

22. The automatic coiling machine (20) according to any one of the preceding claims 15 to 21, wherein, The side surface (49') of the first wire guide flange (49) extends between a minimum diameter portion of the first wire guide flange (49) and a maximum diameter portion of the first wire guide flange (49) and defines the end stop of the pressure roller (53) with respect to the axis (X) of the support (2) when the pressure roller (53) is radially displaced.

23. The automatic winding machine (20) according to any one of the preceding claims 15 to 22, comprising a unit (43) configured for guiding and inserting the wire (4) in the slot (6') of the support (2), wherein, The pressure roller (53) is mounted on the unit (43) and the unit (43) is apt to be displaced along three axes to insert the pressure roller (53) between the first wire guide flange (49) and the support (2), wherein the rotation axis of the pressure roller (53) is transversal or intersecting to the axis (X) of the support (2) and of the first driving shaft (33).

24. The automatic coiling machine (20) according to claim 23, wherein, The unit (43) comprises an arm (52) and the pressure roller (53) is mounted on the arm (52) and the arm (52) is movable to keep the pressure roller (53) against the side surface (49') of the first wire guide flange (49) during the rotation of the first wire guide flange (49).

25. The automatic winding machine (20) according to any one of the preceding claims 15 to 24, comprising a pair of tongs (44) movable with respect to the axis (X) and operable to cut the wire (4).

26. The automatic coiling machine (20) according to any one of the preceding claims 15 to 25, wherein, The support (2) has a front side (2') and a rear side (2"), each side (2', 2") having at least one slot (6', 6") and wherein a first winding (3') is to be formed in the slot (6') of the front side (2') and a second winding (3") is to be formed in the slot (6") of the rear side (2"), and wherein the first main shaft (31) is stationary and the winding machine (20) further comprises a second main shaft (36) defined as a tailstock main shaft (36), a corresponding second driving shaft (40) and a second wire guide flange (50), the second main shaft (36), the corresponding second driving shaft (40) and the second wire guide flange (50) being opposite to the first main shaft (31), the first driving shaft (33) and the first wire guide flange (49) with respect to the support (2) constrained to the first driving shaft (33), and wherein the first driving shaft (33) and the second driving shaft (40) are coaxial with respect to the axis (X) of the support (2), rotatable about the same axis (X) and the second driving shaft is translatable along the axis (X) between a forward position, in which the second driving shaft (40) abuts against the support (2) constrained to the first driving shaft (33) and / or against the first driving shaft (30), and a rearward position, in which the second driving shaft (40) is distanced from the support (2) constrained to the first driving shaft (33) and a gap (60) is formed between the support (2) and the second driving shaft (40) in which the feeding unit (21) and the pressure roller (53) are insertable.

27. The automatic coiling machine (20) according to claim 26, wherein said second wire guide flange (50) is coaxially mounted on said second drive shaft (40) and is apt to translate on said second drive shaft (40) between a proximal position and a distal position with respect to the rear side (2") of said support (2) and is apt to rotate in synchronism with said second drive shaft (40) and / or to relatively rotate with respect to said second drive shaft (40).

28. The automatic coiling machine (20) according to any one of the preceding claims 26-27, wherein, said worktable (22) comprises a second flange holding carriage (42) in which said second drive shaft (40) is inserted and wherein said second wire guide flange (50) is mounted on said second flange holding carriage (42) and is provided with a corresponding actuator (58) which controls the rotation of said second wire guide flange (50) independently of the rotation imparted to said second drive shaft (40) by said tailstock spindle (36) and wherein said second flange holding carriage (42) is apt to translate along said second drive shaft (40) between a rearward position in which said second wire guide flange (50) is distanced from said support (2) constrained on said first drive shaft (33) and a forward position in which said second wire guide flange (50) abuts against the rear side (2") of said support (2) constrained on said first drive shaft (33) opposite to said side face (2') on which said first wire guide flange (49) acts.

29. The automatic coiling machine (20) according to any one of the preceding claims 26-28, wherein, said second wire guide flange (40) is helical or spiral, identical or different from said first wire guide flange (49) and the insertion of said wire (4) in the slot (6") of the rear side (6") of said support (2) is achieved by rotating said second drive shaft (33) together with said support (2) and said first drive shaft (33) causing said compression roller (53) to roll on said slot (6") while pushing said wire (4) into said slot (6") thereby imparting a radial movement of said compression roller (53) with respect to the axis (X) of said support (2); wherein said radial movement of said compression roller (53) is guided by a side face (50') of said second wire guide flange (50).

30. The automatic coiling machine (20) according to claim 29, wherein, said side face (50') of said second wire guide flange (50) extends between a minimum diameter portion of said second wire guide flange (50) and a maximum diameter portion of said second wire guide flange (50) and defines an end stop for said compression roller (53) when radially displaced with respect to said axis (X) of said support (2).

31. The automatic wire winding machine (20) of claim 29 or 30, wherein: - phase A of the method according to claim 1 is performed by rotating the assembly formed by said first spindle (31) with said first drive shaft (33), said tailstock spindle (36) with said second drive shaft (40) and said support (2), - the phase B of the method according to claim 1 is performed with said feeding unit (21), and - the phase C of the method according to claim 1 is performed by rolling said pressure roller (53) along the whole length of said slot (6") of the rear side (2") of the support (2) above said slot (6"), with said wire (4) interposed between said slot (6") and said pressure roller (53), and with said pressure roller (53) radially translating on said support (2) with respect to said axis (X).

32. The automatic coiling machine (20) according to any one of claims 26-31, wherein, Said feeding unit (21) is movable to overlap said wire (4) on said support (2) and to position it between the end of said first winding (3') and the beginning of said second winding (3").

33. The automatic winding machine (20) according to any one of claims 26 to 32, comprising a gripper (41) configured for constraining a terminal (4') of said wire at a head of said second drive shaft (40).

34. The automatic coiling machine (20) according to claim 33, wherein Said gripper (41) is integrated in said second drive shaft (40) and comprises a jaw (41') and a control shaft (41") mounted on said second drive shaft (40), and wherein said control shaft (41") is inside and coaxial to said second drive shaft (40) and is apt to translate along said axis (X), and wherein the jaws (41') move towards and away from each other in response to a stress exerted by the control shaft (41") to constrain or release a terminal (4') of a wire (4) overhanging from or passing through the support (2).

35. The automatic coiling machine (20) according to any one of the preceding claims, wherein, Each wire guide flange (49, 50) is rotated by its actuator at a lower rotation speed than the corresponding drive shaft (33, 40), or is driven with intermittent motion at the same rotation speed.

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