Method and system for assembling a stator or rotor winding - Patents.com

Abstract

The present specification relates to a method and a system for inserting all hairpins of the kth crown in the same region of space, such that the progressively inserted hairpins can move along a geometric path so that the last hairpin of the crown can always be inserted without any hindrance as if it were the first one. After inserting the last hairpin in a special region of insertion, the crown is simply centered by removing the instrument that allowed the hairpin to be inserted again in the same region of space. For this purpose, inner and / or outer housings can be used, enabling the hairpin to follow the required profile, while rotation of the hairpin is obtained by means of cylindrical or conical pins between the different legs of the hairpin. After assembling one crown, it is possible to gradually assemble the outermost crowns on the same system, eventually completing all the windings without handling the crowns. In particular, when the innermost crown is assembled, it is lowered vertically along the winding axis in such a way as to leave the space at the top required for assembling the adjacent crowns.

Description

[Technical field]

[0001] The present disclosure relates to methods and systems for assembling a stator or rotor winding. [Background technology]

[0002] For applications in stators or rotors of electric machines such as generators or electric motors, e.g., on hybrid electric vehicles (HEVs), it is generally known and common practice to make stators or rotors in which the stator or rotor winding consists of a number of bent bar hairpins, variously interconnected with one another to achieve an electrical winding also known as a "bar winding". Such bent bar hairpins are also called "hairpin conductors" or simply "hairpins". A bar winding can be made up of one or more groups of concentric windings, sometimes known as "crowns", where each group of windings is already a winding in itself (a "winding set").

[0003] In particular, hairpins with a circular cross section (also called "round wire hairpins") or a rectangular cross section, or again hairpins whose cross-sectional shape changes along their length (for example round wire hairpins that are rectangularized in the portion housed in the slot), belong to the prior art. In this respect, a "rectangular" or "square" wire hairpin is understood in this specification to mean a wire having four substantially flat sides, each joined to an adjacent side, typically by a rounded edge. Rod-shaped hairpins are known to have a trapezoidal cross section.

[0004] The aforementioned bar-shaped hairpins are usually preformed by bending into a "U" or "P" shape starting from a straight bar-shaped hairpin. US Patent US7,480,987 describes an example of a method for preforming a straight bar-shaped hairpin to form a hairpin. A preformed "U" or "P" shaped hairpin, often also called a "preformed hairpin", typically has two legs placed side by side, of equal or different lengths, each with a free end portion and an opposite end connected to the other of the two legs by a bridge-like connecting portion. The ends protrude when inserted into a rotor or stator, and are hereafter referred to as the "free protrusion portion" and the "opposite protrusion connecting portion". The protrusion connecting portion can also be referred to as the "head portion" or the "bridge-like connected portion". The entire "head portion" of the legs of the same hairpin constitutes the so-called "bridge-like connecting portion".

[0005] 1(a), the hairpin 255 is preformed by bending a straight hairpin (not shown) to form a first leg 255a with a respective free protruding end 255aE and a second leg 255b with a respective free protruding end 255bE. At the same time, the bending shape forms a bridge-like connector 255c between the two legs 255a, 255b. In this example, the preformed hairpin has a flattened "U" shape. It is known to apply two different types of twisting to preformed hairpins, e.g., "U" or "P" shapes, to form stators of electric machines.

[0006] The stator or rotor core of a radial flux electric machine is essentially a ring with two flat faces and two cylindrical faces, from which at right angles the generator is located, parallel to the axis of rotation of the rotor of the electric machine. Hereinafter, radial, circumferential and axial directions refer to the latter axis, unless otherwise stated. One of the two cylindrical faces is at least partially adjacent to the air gap of the electric machine to which the said stator or rotor belongs and defines a series of slots in which the straight parts of the windings are accommodated. The two flat faces are divided into an insertion face or side face and a face or side face opposite to the insertion face. The part of the winding protruding from the said core is called the head. The end of the free part of the hairpin, which is mainly subject to welding, belongs to the head protruding from the face opposite to the insertion side. If there is a protruding part in the winding connected in bridge-like with the leg inserted in the stator slot, it belongs to the head protruding from the insertion side. Hereinafter, the part protruding from the insertion side is indicated as the part protruding from the insertion side, whether it is free or connected in bridge-like.

[0007] The area of ​​the stator or rotor core between one slot and the adjacent slot is called a tooth. The number of teeth is equal to the number of slots. The connecting portion of the core between the teeth is called a yoke, which defines a portion of each slot and is located opposite and opposite the slot opening over the machine air gap.

[0008] The slots can each be divided into an array of positions where the legs of a hairpin can be located. The hairpins housed in the same radial position as a slot define a so-called winding layer.

[0009] In the first type of twisting, also called "insertion side twisting", the preformed hairpins are suitably inserted into special radially aligned pockets or "slots" obtained in a twisting device adapted to deform such hairpins after insertion. The twisting device is essentially used to "spread" the legs of a "U" or "P" shape so that the two legs of each hairpin can be successively inserted into a corresponding pair of slots in the stator core after removal from the twisting device. The slots are angularly offset from one another by a predetermined distance substantially equal to the angular distance between the slots and spaced apart by the radial distance between the slot positions into which the legs are inserted and which the legs occupy respectively.

[0010] Starting with a preformed hairpin as shown in FIG. 1(a) by way of example and not limitation, the hairpin is formed in a shape suitable for its insertion into a stator (or rotor) by spreading the legs 255a, 255b and forming a bridge-like connector 255c, for example to obtain the shape of FIG. 1(b). Reference numeral 255p denotes the pitch of the hairpin, i.e. the linear or angular distance between the legs, or the distance in terms of slot pitch. Note that in this case the central apex 255c2 of the formed hairpin is a hairpin in which the cross section of the pin undergoes a 180° rotation with respect to the central plane of the hairpin (the plane that passes through the inside of the hairpin and contains the two legs). Such a rotation is useful in some layered hairpins defined below to reduce eddy currents circulating at the ends of the layers when they are welded together, in order to swap the layers (exchanging slot positions), compared to the same layers running parallel without exchanging slot positions in the transition from one leg to the other.

[0011] Patent application published as US2009 / 0178270 describes an example of a twisting method from the insertion side, in which a preformed rod-shaped pin is inserted into a pocket of a twisting device in which the hairpin has a rectangular cross section, and then twisted at a uniform pitch.

[0012] According to the prior art and with reference to Figure 2, hairpins can also be obtained by stamping, i.e. the process of pressing a straight pin into a contrast with a punch and die system. Figure 2(a) shows such a stamping pin, which does not have a cross section that rotates with respect to the central plane of the hairpin.

[0013] This stamped hairpin, or alternatively the preformed, flared hairpin obtained as described above, can be subjected to a so-called "welding side twisting", in which case a "step-like" shape of the protruding portions of legs 255a and 255b can be introduced, for example as shown in FIG. 2(b), in which leg 255a has a first straight portion 255a1, a step-like portion 255a2 and a second straight portion 255a3 (substantially corresponding to portion 255aE in FIG. 1).

[0014] 3, the shape of the stamped hairpin of the insertion protrusion, i.e., bridge-like connector 255c, may include three portions 255c1, 255c3, 255c2 (not visible in FIG. 3) starting at the connection with the second leg 255b and ending at the connection with the first leg 255a.) Portion 255c1 has a main extension direction B and a radius of curvature RB, portion 255c3 has a main extension direction A and a radius of curvature RA, and portion 255c2 has a main extension direction C (and possibly its curvature, not shown). Hereinafter, portion 255c2 is referred to as a "layer change bend", and indeed, by virtue of it, the head and leg portions of the hairpin are on different layers when inserted into the respective slots of the stator pack. Reference α1 denotes the angle between directions A and C, reference α2 denotes the angle between directions A and B, and reference α3 denotes the angle between directions B and C, which corresponds to the sum of angles α1 and α2. This is only one final possible shape of the hairpin, all other shapes with different parts and conformations of both the bridge and the legs can be used with the devices and methods according to the present specification.

[0015] There are also what are called "reverse" pins (not shown), which are hairpins with a bridge connector that bends in the opposite direction to most hairpins, but forms the same turns. These are used to connect the last layer of a crown to the first layer of the next crown.

[0016] Further, referring to FIG. 4A, there is a layered ("stranded") hairpin with a cross-sectional inversion at the bending point (FIG. 4A(a)) that causes an exchange of the positions occupied by the layers. As can be seen from the type of hatching of the cross-section in FIG. 4A(a), due to said inversion or exchange of positions, the upper layer in the pair of layers in the left slot is below the other layer in the right slot. In another hairpin configuration, the inversion can be continuous along the part of the hairpin housed in the slot (FIG. 4A(b) of US3837072). A variant shown in FIG. 4B is a layered hairpin lacking an inversion, shown in patent US8552611 B2. FIG. 4C (taken from FIG. 6 of patent US6,894,417B2) shows a variation of the arrangement of the legs of a layered hairpin with double crown winding in different positions in the slot. The reference letters A and B indicate the crowns to which the legs shown in the slot belong (belonging to different hairpins).

[0017] Furthermore, there are pins called "I-pins", i.e. pins that are received in one slot and whose parts with free ends protrude from both planes of the stator core when received in the slot. Figure 4D is an example of an I-pin, which does not necessarily have all the turns shown, or even none at all, and can also be bent at the output side of the hairpin winding assembly drum. The ends of the I-pin can be welded to the ends of other pins protruding from the slot or to third party elements (e.g. busbars, eyelets) or can serve as phase terminals. The parts can be subjected to a "weld side" type of bend. An example of an I-pin can be found in the hairpins shown in references 81-83 of document US7622843B2. "W-pins" are also known, see, again, for example, patent US7,622,843B2 and figure 4E. The W-pins can be formed by welding a stamped hairpin to the I-pin or by welding a fourth pin to three I-pins. Again, the W-pin does not necessarily have to make all the turns shown, but could simply have none and bend at the output side of the hairpin winding assembly drum.

[0018] With exemplarily reference to FIG. 4F (available from US10749399B2), there are also so-called "inversion hairpins", i.e. hairpins that can be formed by spreading the legs (rather than the insertion-side twisting method described above) or by stamping with a "press and die" system, characterized in that the legs in the respective slots occupy the same radial position, i.e. they belong to the same layer. Thus, their ends on the twist side will be bent in the same direction. In practice, the protrusions on the side of the bridge-like connector can be bent in the same tangential direction or take a V-shape. At least two layer-changing bends of the connector parts are necessary.

[0019] Finally, there are pairs of hairpins whose homologous legs belong to different layers (FIG. 4G) or to the same layer (FIG. 4H) and are constructed and dimensioned such that they overlap.

[0020] Hereinafter, all of the above types of hairpins as well as I-pins and W-pins will be included in the definition of "hairpin."

[0021] After being subjected to the first type of twisting or stamping, the hairpins are generally pre-assembled in a winding set, as described above. The pre-assembly apparatus will generally have a set of slots in which the legs of each hairpin will be inserted, the set having the same number of slots in the stator as the windings are associated with, and will generally be different from the twisting apparatus.

[0022] Next, the winding sets are inserted together into the slots of the stator core from their first surface (the so-called "insertion side" or "insertion surface"), with each free portion protruding from a second surface opposite the first surface of the core (the so-called "welding side" or "connection side" or "welding surface" or "flank surface").

[0023] Depending on the particular winding pattern to be obtained, the free portion of the hairpin protruding from the side opposite the insertion side can be inserted, for example, into a pocket made in a suitable twisting fixture, after which a second type of twisting, also called "twisting from the weld side", is performed. This twisting fixture is intended to bend and twist the free portion of the pin in order to properly shape such free portion and thus to make the proper electrical connection between the pins in order to complete the winding. The patent application published under the number US2009 / 0302705 describes an example of a method for weld side twisting of the above-mentioned type.

[0024] Systems for assembling electrical windings for stators and / or rotors are known. In this document, assembling is understood to mean creating an electrical winding from a set of pins, which is then ready to be transferred to the stator or rotor. The assembling can also be performed directly on the stator or rotor.

[0025] In particular, the system known from patent document WO 2019 / 215514 A1 uses a hairpin inserter outside the winding containment means, which does not allow for radial movement of the hairpins and does not allow for facilitating automatic insertion of the last hairpin of a sector, which must be placed across the sectors. Moreover, such a solution does not take into account the insertion of reverse pins and inversion pins.

[0026] A system is also known from patent document WO2018 / 039806 A2, which divides the storage means into several arcs of a circle that can be opened by rotating relative to one another to insert the last hairpin of a winding (or winding sector). Such storage means are complex to manufacture and the relative methods of assembling the windings can only be applied to such storage means. Moreover, such a solution requires more structures with respect to those already known and widely used to obtain the individual windings.

[0027] Patent document US2020 / 336054 describes a system for assembling winding groups, in which hairpins are inserted directly into slots in a storage means, which then move by means of guides integrated directly in the storage means, but this system cannot possibly be applied to other, more common storage means. Moreover, such a solution does not take into account the insertion of reverse pins and inverted pins.

[0028] However, in pursuit of today's increasingly stringent time-cycle specifications, a need is nevertheless felt to assemble the windings all in one system in order to more easily insert the windings into the stator pack. Summary of the Invention

[0029] Scope and Objectives of the Present Specification SUMMARY OF THE PRESENT EMBODIMENT It is an object of the present invention to provide a method and system for assembling a stator or rotor winding that completely or partially overcomes the problems and deficiencies of the prior art.

[0030] The object of the invention is a method and a device for assembling a stator or rotor winding according to the appended claims.

[0031] The earlier Italian application No. 102021000032159 is incorporated herein by reference. [Brief description of the drawings]

[0032] Now referring specifically to the figures of the accompanying drawings, which are described by way of non-limiting examples,

[0033] [Figure 1] FIG. 1 shows, in (a), a preformed flattened U-shaped hairpin and, in (b), a formed hairpin according to the prior art. [Diagram 2] FIG. 2 (a) shows the stamped hairpin, and (b) shows the hairpin after weld-side twisting. [Diagram 3] FIG. 3 is a top view of the hairpin of FIG. 2(a) according to the prior art. [Figure 4A] FIG. 4A shows a layered ("stayed") hairpin with a cross-sectional inversion at the bend point (a) and a continuous displacement along the portion of the hairpin housed within the slot (b) according to the prior art. [Figure 4B] FIG. 4B shows a layered hairpin. [Figure 4C] FIG. 4C shows a variation of the leg of a prior art layered hairpin in which the double crown winding is in a different position in the slot. [Figure 4D] FIG. 4D shows an example of an I-pin according to the prior art. [Figure 4E] FIG. 4E shows an example of a "W pin" according to the prior art. [Figure 4F] FIG. 4F shows an example of an "inverted hairpin" according to the prior art. [Figure 4G] FIG. 4G shows an example of overlapping hairpins in different layers according to the prior art. [Figure 4H] FIG. 4H shows an example of overlapping hairpins in the same layer according to the prior art. [Figure 5A] FIG. 5A illustrates the first conceptual step of assembling according to an embodiment of the present disclosure. [Figure 5B] FIG. 5B illustrates a second conceptual step of assembling according to an embodiment of the present disclosure. [Figure 5C] FIG. 5C illustrates a third conceptual step of assembling according to an embodiment of the present disclosure. [Figure 5D] FIG. 5D illustrates a fourth conceptual step of assembling according to an embodiment of the present disclosure. [Figure 5E] FIG. 5E illustrates a fifth conceptual step of assembling according to an embodiment of the present disclosure. [Figure 6] FIG. 6 shows theoretical hairpin reference positions according to one embodiment of the present disclosure. [Figure 7] FIG. 7 shows a sketch of the average profile of a hairpin and the trajectory of its movement for the assumptions set in Model 1, according to one embodiment of the present disclosure. [Figure 8] FIG. 8 shows the hairpin arrangement of FIG. 7 in (a) a top view and (b) a side perspective view. [Figure 9A] FIG. 9A shows the average profile of the hairpin and a sketch of the trajectory of its movement for the assumptions set in Model 2. [Figure 9B]FIG. 9B shows a sketch of the average hairpin profile and the trajectory of hairpin movement for the assumptions set in Model 2. [Figure 10] FIG. 10 shows the hairpin arrangement of FIGS. 9A-9B more realistically, in (a) a top view and (b) a side perspective view. [Figure 11A] FIG. 11A shows the average profile of the hairpin and a sketch of the trajectory of the hairpin's movement for the assumptions set in Model 3. [Figure 11B] FIG. 11B shows a sketch of the average hairpin profile and the trajectory of hairpin movement for the assumptions set in Model 3. [Figure 12] FIG. 12 shows the hairpin arrangement of FIGS. 9A-9B more realistically, in (a) a top view and (b) a side perspective view. [Figure 13] FIG. 13 illustrates one embodiment of a crown support system with a diaphragm. [Figure 14] FIG. 14 shows one embodiment of a support system with coaxial discs. [Figure 15] FIG. 15 shows one embodiment of a crown support system where the crowns all rest at the same level with respect to the axis of symmetry of the windings. [Figure 16] FIG. 16 illustrates a housing for assembling the windings as a single prototype body according to an embodiment herein. [Figure 17] FIG. 17 shows characteristic dimensions of the container of FIG. [Figure 18] FIG. 18 shows a housing formed as a set of clamps or blades. [Figure 19] Figure 19 shows a double crown winding with two reverse hairpins. [Figure 20] FIG. 20 shows an insertion and movement device for inserting and moving the first reverse hairpin into the winding of FIG. [Figure 21] FIG. 21 shows a reverse hairpin that approaches the crown via rotation of the housing (means for rotating the housing not shown) and the structure of the insertion and transfer system. [Figure 22] FIG. 22 shows the steps of FIG. 21 on the opposite side of the container. [Figure 23] FIG. 23 shows the steps following those of FIG. [Figure 24] FIG. 24 shows an insertion and transfer system for inserting and transferring a reverse hairpin according to one embodiment of the present disclosure. [Diagram 25] FIG. 25, like FIG. 24, shows a standard hairpin insertion and transfer system means. [Figure 26] FIG. 26 shows the abutment conditions of a standard hairpin for the insertion and transfer system. [Figure 27] FIG. 27 shows the situation after insertion of the first hairpin, followed by sheathing of the first reverse hairpin. [Figure 28] FIG. 28 shows the situation of FIG. 27 after the container has been rotated. [Figure 29] FIG. 29 illustrates a step of assembling a spiral widening profile according to one embodiment of the method herein. [Diagram 30] FIG. 30 shows the opening of a reverse hairpin of an insertion and transfer system according to one embodiment of the method herein. [Diagram 31] FIG. 31 shows the insertion of the final canonical hairpin (layers 3-4) according to one embodiment of the methods herein. [Diagram 32] FIG. 32, like FIG. 31, shows the insertion of the last standard hairpin (layers 3-4) in a top view of the entire crown (with the last hairpin omitted to allow for the insertion and positioning of the rest of the transfer system to be seen). [Diagram 33] FIG. 33 is a top view of a terminated mid-crown according to one embodiment of the methods herein. [Diagram 34] FIG. 34 shows a reverse hairpin inserted and a first standard hairpin inserted on either side according to one embodiment of the methods herein. [Diagram 35]FIG. 35 shows (a) the realignment of the hairpin insertion and (b) the rotation after the latter insertion according to one embodiment of the present specification, with the initial and final positions of the second reverse hairpin highlighted. [Diagram 36] FIG. 36 illustrates another configuration of an inserter according to one embodiment of the present disclosure. [Figure 37] FIG. 37 shows a receptacle in alignment that inserts a standard hairpin after the second pair of reverse hairpins. [Figure 38] FIG. 38 illustrates the widening and narrowing of the circumference of the crown according to one version of one embodiment of the methods herein. [Figure 39] FIG. 39 shows the situation of FIG. 38 with two pairs of reverse hairpins. [Diagram 40] FIG. 40 illustrates the simultaneous insertion of parallel hairpins according to one embodiment of the present specification. [Diagram 41] FIG. 41 shows the interference of some hairpins with the housing in the situation of FIG. [Diagram 42] FIG. 42 shows a structure for housing the hairpin in the situation of FIG. [Diagram 43] FIG. 43 shows a storage structure for a tilted hairpin according to one embodiment of the present specification. [Diagram 44] FIG. 44 illustrates a top view of the insertion of both radially tapered hairpins according to one embodiment of the present disclosure. [Diagram 45] FIG. 45 illustrates, in accordance with one embodiment of the present specification, (a) a geometrically defined hairpin with two legs and (b) the minimum insertion area of ​​the legs of the hairpin. [Diagram 46] FIG. 46 illustrates a stator with I-pin, reverse pin, inverted pin, and standard pin type hairpins according to one embodiment of the present disclosure. [Figure 47] FIG. 47 illustrates an example of assembling I-pins in series from the insertion side according to one embodiment of the present disclosure. [Figure 48] FIG. 48 illustrates the insertion of an inversion pin according to one embodiment of the present disclosure. [Figure 49]FIG. 49 illustrates an example of an inverted pin inserter according to one embodiment of the present disclosure. [Figure 50] FIG. 50 is a perspective view of an embodiment of an insertion and transfer system according to a two-piece embodiment herein. [Figure 51] FIG. 51 shows the left portion of FIG. 50 in two further views. [Figure 52] FIG. 52 shows a portion of FIG. 50 with the sliding surface of the hairpin highlighted. [Diagram 53] FIG. 53 shows a portion of FIG. 50 in a rear perspective view with the sliding surface of the hairpin highlighted. [Figure 54] FIG. 54 shows a portion of FIG. 52 with another sliding surface of the hairpin highlighted. [Figure 55] FIG. 55 shows a portion of FIG. 53 with another sliding surface of the hairpin highlighted. [Figure 56A] FIG. 56A is a top view of the first portion of FIG. [Figure 56B] 56B is an inner side view of the first portion of FIG. 50. FIG. [Figure 56C] FIG. 56C is a side view of the first portion of FIG. 56A from the first circumferential end. [Figure 56D] FIG. 56D is a rear view of the first portion of FIG. 56A. [Figure 57A] FIG. 57A shows the system of FIG. 50 in use with the hairpin axially inserted into the slot in the winding storage means. [Figure 57B] FIG. 57B shows the next step in the insertion of FIG. 56A, where the storage means is rotated to displace the hairpin. [Figure 58A] FIG. 58A is a top view of the state of the hairpin inserted from above into the hairpin sector under assembly. [Figure 58B] FIG. 58B shows the next step in the insertion of FIG. 58A, where the storage means is rotated to displace the hairpin. [Figure 59] FIG. 59 is a perspective view of the step in which the first hairpin inserted in the sector is radially displaced to make room for the insertion of the last hairpin. [Figure 60A] FIG. 60A shows that the two parts of the insertion and transfer system sometimes rotate to accommodate the size of a particular crown hairpin, especially in the case of overlapping hairpins. [Figure 60B] FIG. 60B shows the system of FIG. 60 in use, with overlapping hairpins axially inserted into slots in the winding containment means (slots not shown for simplicity). [Figure 60C] FIG. 60C shows the next step in the insertion of FIG. 60B, where the overlapping hairpins are displaced as the containment means rotates (slots not shown for simplicity). [Figure 61A] FIG. 61A is a top view of the situation in FIG. 60B. [Figure 61B] FIG. 61B is a top view of the situation in FIG. 60C. [Figure 62A] FIG. 62A shows the system of FIG. 60A in use with the reverse hairpin axially inserted into a slot in the winding containment means (slot not shown for simplicity). [Figure 62B] FIG. 62B shows the next step in the insertion of FIG. 62A, where the reverse hairpin is displaced as the containment means rotates (slots not shown for simplicity).

[0034] It should be noted here that, as those skilled in the art can easily understand from the description, elements of different embodiments can be combined together to provide further non-limiting embodiments respecting the technical concept of the present invention.

[0035] This specification also relates to the prior art for its implementation with respect to detailed features not described, such as minor elements commonly used in the prior art in solutions of the same type.

[0036] Whenever an element is introduced, it is understood that there can be "at least one" or "one or more."

[0037] Where a list of elements or features is recited herein, it is understood that the teachings herein "comprise" or, alternatively, "consist of" such elements.

[0038] When features are listed in the same sentence or bulleted list, one or more of the individual features may be included in the description without relating them to other features on the list. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] In pursuit of today's increasingly stringent time cycle specifications, there is a need to have all the windings assembled on the same system for easier insertion into the stator pack.

[0040] Manual testing showed that the hairpins could be easily inserted into the stator pack by hand, but only up to a point: this is when the crown starts to take shape and the insertion of the hairpin is hindered by the partially assembled crown. Consider the worst case, when inserting the last hairpin of the crown, both the right and the left get in the way. It was confirmed that by slightly "spreading" both ends of the partially assembled crown and vice versa, the last hairpin can easily "drop" into its slot.

[0041] This observation clearly needs to be incorporated into an automated device such as that described below.

[0042] Below, the crown is described, however, it is not necessarily individually identifiable and therefore more generally it is understood to mean a set of hairpins that have already been inserted into the windings in the assembly step.

[0043] Assembly modeling principles One of the first things to do when considering the feasibility of assembling according to the specifications for a particular product is to re-adapt the product (stator) model to the process under consideration: the subgroups of the model need to be re-adapted, not by steps (as in the final product), but by crowns, i.e. the final assembly will consist of as many subgroups as there are crowns, and all hairpins belonging to the same crown will be inside a subgroup.

[0044] All hairpins are inside a subgroup (e.g., assembly 1-2, assembly 3-4, etc.) and are individually configured and appropriately constrained (different strategies can be used for this, e.g., connecting the terminals of all hairpins to the circumference and the ridge of a control surface).

[0045] If the assembly is done from inside to outside, as is often the case, it is a good idea to create assemblies that simulate the various assembly steps. For example, the assembly of crown 3-4 for a product with 6 wires per slot would be simulated as an inner assembly with a fully assembled subgroup "assembly 5-6" and another subgroup "assembly 3-4" in the assembly steps. This is the closest modeling of the real process.

[0046] In the subgroup, the crown widening required for the insertion of the last hairpin needs to be simulated since this is the most critical aspect of the assembly to ensure that there is no interference between the hairpins resting against each other.

[0047] After determining the minimum widening that allows the insertion of the last hairpin, an assessment of the inclination of the hairpin legs is performed, since the greater the widening, the more the widened legs will be inclined, bringing them closer together.

[0048] Such inclination, which may be negligible in some specific cases, and an assessment of the space remaining between adjacent legs will determine the dimensions of the crown containment system. Such a containment is structurally similar to a stator pack, but with a wider slot to expand the width of the crown. To achieve containment, the assessed expansion must not allow the legs to cross each other without leaving useful space for the containment.

[0049] After laying out the ground rules, several possible models are introduced that represent different assembly strategies.

[0050] Basic Concepts

[0051] Let us assume that all hairpins are assembled in one special container. For the initial analysis, we will consider only one, i.e., the kth, winding crown.

[0052] One of the objectives of this specification is to insert all hairpins of the kth crown in the same region of space (and therefore in different regions of the sector of the relative rotation) so that the hairpins inserted gradually can move along a geometric path in such a way that the last hairpin of the crown can always be inserted without any hindrance as if it were the first one. After inserting the last hairpin in a special region of insertion, the crown is simply centered by removing the instrument that allowed the hairpin to be inserted again in the same region of space.

[0053] At this point, the storage stops and you can insert the hairpin. Insertion and Transfer System It is provided that when the housing moves along the housing, the aforementioned spatial area is not always the same, but moves circumferentially as a function of the insertion.

[0054] For this purpose, inner and / or outer housings may be used, allowing the hairpin to conform to the required profile.

[0055] After assembling one crown, it is possible to gradually assemble the outermost crowns on the same system, eventually completing all the windings without handling the crowns.Preferably, when the innermost crown is assembled, it is lowered vertically along the winding axis, leaving the space at the top required for assembling the adjacent crowns.

[0056] A simple schematic diagram of the various possible steps to be followed is shown below in the case of a four-wire slot stator with two independent crowns.

[0057] 5A, the first step involves inserting a hairpin into the inner crown CI. The assembly level LA and the end assembly level LFA are shown.

[0058] With reference to Figure 5B, the second step involves removing the system that made it possible to insert the hairpin in the first step, and the crown then centers naturally. CH indicates the bridge-like connector of the hairpin.

[0059] Referring to Figure 5C, the third step involves lowering the assembled crown to the "assembly end level" and the insertion of the hairpins of the outer crown CE begins.

[0060] With reference to FIG. 5D, the fourth step involves removing the system that made it possible to insert the hairpin in the third step and then allowing the crown to center itself.

[0061] Referring to Figure 5E, the fifth step involves lowering the assembled crown to the "assembly end level". In fact, assembly level LA is shown, and assembly end level LFA is shown. At this point winding has been achieved.

[0062] Although in this specification we refer to a "crown" for the sake of simplicity, this term must be understood in a broad sense, including the case where a set of hairpins has already been inserted. Another way to refer to this set is a "sector". Thus, a winding is made up of one or more sectors. A sector can include one or more layers, each layer made up of a circumferential arrangement of hairpins.

[0063] Hairpin insertion method

[0064] It has been said that it is advantageous, though not essential, to provide a widening of one or more portions of the crown to be assembled in order to insert all the hairpins of one crown from the same area of ​​space.

[0065] This paragraph aims to present some possible scenarios that were considered and rapid prototyping with 3D printing.

[0066] Every shaped hairpin has a shape that allows it to occupy a defined position within the stator pack; for example, in a stator with six wires per slot, the hairpin for layer 3-4 is designated to form neither the innermost nor the outermost crown, but rather an intermediate crown.

[0067] "Theoretical hairpin position" defines the position of the hairpin in the stator pack in each layer as a perfectly vertical position, ie, no radial displacement / widening.

[0068] Model 1

[0069] Model 1 makes the following assumptions: - inserting hairpins of a general crown k into spatial regions other than the theoretical hairpin location, especially into larger diameters; - the gradually inserted hairpin follows a circular type profile for a given angular sector (approximately 2π / 3 radians for a standard hairpin) which is a function of the hairpin pitch, and takes the same position as the theoretical hairpin position; - The last hairpin can be inserted by widening / displacing the first inserted hairpin towards the outer diameter of the stator.

[0070] 6 illustrates this situation, where PAG denotes the trajectory of the outer legs of the hairpins of the winding 100 during the assembly step in the circumferential assembly containment 300 (more generally, the "circumferential containment of the hairpins" during the assembly of the windings), PAT denotes the trajectory of the heads of the hairpins (bridge-like connectors), CBI the hairpins during insertion, and CB1-2 the hairpins already inserted in layer 1-2. The central black dot denotes the axis 50 perpendicular to the drawing, which is the axis along which the windings 300 are assembled, i.e. which coincides with the axis of rotation of the circumferential containment system 300 (this axis is present in all embodiments).

[0071] Figure 7 depicts the average profile of the hairpin and a sketch of the trajectory of the hairpin's movement for the set assumptions.

[0072] In this model, - All hairpins are inserted at the positions indicated as "CBI" in Figure 7; - after inserting a general hairpin, it is thrust towards the inner diameter so as to occupy the layer associated with it, i.e. the theoretical hairpin position; and - In this way, the hairpins positioned at the pitch of the stator slots are rotated together to ensure space for the next hairpin, and so on.

[0073] In order for the initially inserted hairpin to not occupy the final "inserted hairpin" position when it has completed a circumference of about 2π / 3 radians (or another suitable arc as a function of pitch), it must follow a "leg widening profile" for the bottom of the hairpin and a "head widening profile" for the hairpin ridge (Figure 7), i.e., the hairpin can tilt outward slightly while at the same time being prone to deviating from the circumferential trajectory of the layer.

[0074] After the last hairpin is inserted, it is possible to self-center the crown by simply removing the (fixing) system that allowed the "inserted hairpin" to be in that particular area of ​​space. Figure 8 shows the placement of the hairpin according to Figure 7 in (a) a top view and (b) a side perspective view, as a more realistic drawing.

[0075] In addition to a system that allows the first inserted hairpin to follow the desired widening profile, a receptacle may also be required for the assembled crown, particularly for the hairpin to the right of the "inserted hairpin," to ensure that the gradually inserted hairpin does not interfere with the insertion of hairpins that have not yet been inserted.

[0076] Model 2

[0077] Model 2 assumes that: - inserting hairpins of common crown k into regions of space that coincide with theoretical hairpin positions; and - The hairpins that are gradually inserted follow a helical profile (by means of a guide, not shown), such that the first inserted hairpins splay outwards and the last hairpins splay inwards.

[0078] 9A and 9B sketch the average profile of the hairpin and the movement trajectory of the hairpin (helical, PSAT) relative to the set assumptions.

[0079] As you can guess, in this model: - the process of inserting the hairpin becomes even easier with respect to the previous model: in fact, the hairpin is placed in a circumference that coincides with that of the two layers to which it has rights, but is not forced to occupy a larger diameter (although it should be noted that from practical evidence it is possible to visually and test that the hairpin can easily be made to occupy a slightly larger diameter than the one for which it was designed); - the hairpin, which is gradually inserted, must follow a spiral type profile; - After inserting the last hairpin (again in the theoretical hairpin position - PTCB), it is possible to obtain the assembled crown by simply removing the spiral container: the crown is self-centering.

[0080] FIG. 10 shows the arrangement of hairpins according to FIGS. 9A and 9B as a more realistic drawing, with (a) a top view and (b) a side perspective view.

[0081] Model 3

[0082] Model 3 assumes that: - inserting a hairpin of general crown k into an area of ​​space other than the theoretical hairpin location; in particular, into a larger diameter; and - The hairpins inserted gradually follow a spiral-shaped profile, with the first inserted hairpins spreading outwards and the last ones spreading slightly inwards (thanks to the protrusions like 421 in Fig. 26, but more emphatically).

[0083] 11A and 11B sketch the average profile of the hairpin and the trajectory of its movement relative to the set assumptions (again, the PSAT is a helical trajectory).

[0084] As can be observed, this model is very similar to the previous one with the only difference being the spiral shape: in this case, it is not symmetrical about the critical circumference of the layer.

[0085] FIG. 12 shows the arrangement of hairpins according to FIGS. 11A-11B in a more realistic view, with (a) a top view and (b) a side perspective view.

[0086] Assembled Crown Lifting System

[0087] Experimental tests have shown that when there are several crowns to be assembled, it is better, if possible, to keep the crowns of the assembly steps at a higher level and the crowns of the already assembled ones at a lower level, since it is in fact easier to widen the crowns of the assembly steps, since otherwise, if they were at the same level z as the already assembled ones, the widened hairpins would knock on the latter and be forced to widen.

[0088] Therefore, a system capable of managing different crown heights (commonly referred to as an "axial support system") is needed.

[0089] As a first solution, it was thought to consider a movable system that would act as a support for the ends of the hairpin, and thus, by moving such a support, it was thought possible to vary the height of the crown.

[0090] Various solutions have been proposed. One solution is the "wedge" support system, i.e. with radially extending dowels, each forming a support for one or more legs of a hairpin of different crowns and layers, which has the following characteristics and advantages: i. Pneumatic cam movement, average complexity; ii. Very little wear over time; iii.When the wedge is opened, a gap may appear, which may cause problems with the support of the hairpin; iv. It has a relatively small volume, radial to the windings only (it does not have to occupy any part underneath the stator).

[0091] Another solution is the optional "Diaphragm" support system 320 (see FIG. 13), which has the following features and advantages: i. Pneumatic or electrical operation, average complexity; ii. The presence of the layer leads to high wear over time; iii. Small dimensions (convenient support surface of about 3-4 mm) and radial winding direction only (no need to occupy the area below the stator); iv. The blade LM can be fully closed to support the crown or can be opened to thread the entire winding through after assembly.

[0092] A further solution is the coaxial disc support system (see FIG. 14), which is a simple system with the following features and advantages: i. Pneumatic axial movement of each disc (n°3), less complex; ii. Not wear out over time; iii. Space is required below the stator.

[0093] Examination of the coaxial disk support systems C1, C2, and C3 has resulted in the identification of a number of operational criticalities, despite their relative simplicity in the initial approach.

[0094] In particular, the higher level of the assembled crown requires, first of all, a movement system to move from below to above, and then a thrust system to push from above to below, all of which results in large dimensions, especially if we take into account that at the top of the winding there is also a system for gripping and inserting the hairpin.

[0095] It was further found that the base plate for supporting the hairpins must consist of several coaxial disks, one for each crown. However, since the hairpins have a certain mobility even after assembly, the terminals can become dislodged (both inwards and outwards) from the supporting disks. This creates problems, especially for the first hairpins to be inserted into the crowns, which are placed in a non-configured position and the formation of the crown itself is impaired.

[0096] A different operation, always using a coaxial disc system, is that of providing for the lowering of the discs each time a crown is completed: instead of pushing the crown to be assembled together with the corresponding disc upwards, as in the previous case, the assembled crown is brought to a lower level.

[0097] For example, if the assembly system involves proceeding from the innermost crown to the outermost crown, the innermost disk will drop to the bottom as the crowns are assembled, but this method can always create a situation where some pins rest on different disks, thus compromising the assembly of the windings.

[0098] Despite the advantages offered by a system allowing free management of different heights of the crowns, an assembly system 330 in which the crowns are all set at the same level z (the same height as the bridge-like connectors, i.e. with respect to the axis of symmetry of the winding, 331 shows the holes for the longest legs of several hairpins, see fig. 15) was also studied in depth. In fact, it makes it possible to avoid the automation required to manipulate the support system, to reduce dimensions and costs, and in particular to solve the problem of managing the edges.

[0099] Thus, given that the assembly systems employed so far essentially provide for radial displacement / widening of the crowns and possibly simple inward retraction (but not thrust), it is theoretically possible to assemble the crowns from the innermost crown to the outermost crown, all at the same level. In fact, the presence of an already assembled innermost crown does not prevent the formation of the outermost crown.

[0100] The shape of the support surface can be configured based on the length of the pins, which are not all the same, and it is therefore possible to model the support surface according to two different criteria: - The support surface is modelled so that the chignons are at the same height, so it is necessary to take into account the different lengths of the standard pins and provide pits for the phase terminals and jumpers. - In order to simplify the modeling of the support surface as much as possible, pits SC are provided only in parts where the length differs significantly, such as phase terminals and some jumpers. As a result, the height of the crown head is not exactly the same, but a difference of about 4 to 5 mm is not a problem.

[0101] In either case, taking into account the presence of a pit for the longest pin, the support surface must follow the rotation of the crown. Rotation means are not shown in any of the embodiments since these means are known per se.

[0102] A system for storing the crown during assembly

[0103] In this section you can see how the system for supporting the hairpins during assembly of the crown and the support of the already assembled crown was designed.

[0104] The requirements include: - Space between hairpins to allow for widening; - Slot for stator pack type; - Consistency with available volumes.

[0105] 16, a first version of the storage support 300 was made as a single body, the purpose of which was to dimension the walls that bound the space or slot 350 (for inserting the legs of the hairpin) and the size of the slot itself (spaces or slots are also present in the case of non-integral storage). The angular distance between the two slots relative to the axis 50 is called the "slot pitch".

[0106] In particular, with reference to FIG. 17, there are three dimensions to be determined: - minimum thickness d3 of the walls between the slots 350; - the maximum height d1 of the container 300; - Pin protrusion d2 (at least 15-20mm).

[0107] These three values ​​depend on the geometric characteristics of the stator, and indeed the greater the crown widening required to insert the last hairpin, the smaller the minimum distance between the pins for a given height, which determines the thickness of the housing wall.

[0108] The widening will be as large as the thickness of the plate, the "S" bend where the layer jump is obtained (this also depends on the number of layers to be jumped), the average diameter of the crown to be assembled, and the number of stator slots (as this affects the opening angle of each hairpin).

[0109] From the models obtained in the laboratory, it was found that good containment is achieved if it has a height equal to about half the leg of the hairpin PDT and can be arranged so that the downward protrusion of the hairpin is about 20-30 mm. Based on currently available materials on the market, for structural and strength reasons, the minimum thickness of the containment wall must be at least 1 mm.

[0110] Considering how to manage the realignment of the crown and the insertion into the pack after the formation of the winding 100 is completed, a housing 300' (circumferential housing means in which spaces or "slots" 350' are formed and into which the legs of the hairpins are inserted) made of a set of blades or clamps 310' supported by a special structure 320' is used, as shown in FIG. 18. In this case, the circumferential housing means 300' is formed as a set of radial blades 310', projecting radially with respect to said winding axis 50 and outwards towards said winding 100, in which slots are defined. Preferably, said radial blades have a horizontal wedge-shaped cross section, i.e. perpendicular to said winding axis and tapering towards said winding axis. This system has the advantage that the housing walls can be moved radially and can be moved back and forth by an inner cam.

[0111] The dimensions of the walls of the blade 310' of the clamp 300' are calculated for storage as a single unit, but the radial thickness is increased by moving the walls of the blade further forward so that they act as spacers for the legs of the hairpin and align them as best as possible (see further on in this specification). The walls of the blade may be wedged so that they do not butt up against each other in the radially approaching step.

[0112] In this configuration, the dimensions of the slot can be varied during insertion, starting out larger and ending up with a smaller dimension, or the dimensions can remain constant during the process and narrow at the end.

[0113] The dimensions of the slot are in fact a function of the orthogonal opening of the leg and the cross section of the leg. It is verified how much the hairpin needs to be tilted in order to favorably displace the hairpin to be inserted.

[0114] Since the hairpins are concatenated within the winding, it is preferred that all of the slots be the same size.

[0115]

[0043] Embodiments in which there is a reverse hairpin to jump layers

[0116] So far we have considered the simpler case of windings according to hairpin technique, i.e. where the hairpins all have the same opening angle and the crowns are independent of each other.

[0117] We would now like to explain the concepts herein in the context of electrical windings providing for the use of reverse hairpins.

[0118] We start by considering only one reverse hairpin for each layer jump.

[0119] In particular, the above discussion considers a six-wire slot stator with only one reverse hairpin for the intralayer jumps (one between layers 2 and 3, and one between layers 4 and 5). Consider the conditions for obtaining winding 100R2 of FIG. 19. Hairpin 255-R, colored dark gray, is a different reverse-type hairpin than the other hairpins 255.

[0120] Since the products under consideration are 6-slot devices, we will divide them into three main groups: - Group 1 - formation of the medial crown, - Group 2 - formation of the intermediate crown, - Group 3 - formation of the outer crown.

[0121] The two reverse-type hairpins 255-R provided in the winding diagram to be obtained are inserted into groups 2 and 3, respectively.

[0122] The spatial arrangement of standard hairpins 255 for different crowns is that described in Model 3 (the widening profile of the standard hairpins is of the spiral type, and they are inserted in regions of space other than the theoretical hairpin position, see below for details).

[0123] Furthermore, the following is assumed: The assembled winding 100R2 is obtained from the construction of the innermost crown, gradually moving towards a larger diameter; A reverse hairpin 255-R connecting two crowns is always inserted during the construction of the outermost crown between the two crowns; In the formation of a crown with a reverse hairpin, the first hairpin inserted is of the reverse type; The "formation level" and the "end of formation level" coincide.

[0124] I-pin type hairpins are not considered here because they are inserted last when all hairpins are assembled. and movement A system can be provided.

[0125] In this case, based on the assumptions made: - A reverse hairpin 255-R between the inner crown and the intermediate crown must be inserted during the step of constructing the intermediate crown (group 2); - The reverse hairpin 255-R between the intermediate crown and the outer crown must be inserted first during the step of constructing the outer crown (group 3).

[0126] There may not be a single level and therefore a single work surface.

[0127] For Group 1, in this type of system under consideration, despite having 48 slots, the inner crown is characterized by having 47 standard hairpins due to the presence of reverse pins and I-pin hairpins (only in this specific example) throughout the winding.

[0128] The way these are managed and inserted is as shown in Model 3: the hairpins are all inserted in the same region of space other than the theoretical hairpin location. The insertion of the last hairpin is possible due to the distance covered by the previously inserted hairpins in the helical and non-circular profile.

[0129] By employing the same method as above, the presence of one less standard hairpin creates an "empty space region" that is needed to accommodate the legs of the reverse hairpin that connects the inner crown to the middle crown.

[0130] It is noteworthy that this spatial area is obtained thanks to the presence of the blades of the clamp (or, in the case of fixed accommodation, through the walls between the slots 350), so that the legs of the hairpin belonging to the inner crown have a unique position in the circumferential direction without the possibility of having significant clearances.

[0131] Referring to group 2, since the reverse hairpin is the first one connecting the inner crown and the middle crown, based on the assumptions in this group, not only must the reverse hairpin be inserted, but it must also be inserted before the standard hairpins belonging to the middle crown (hairpins belonging to the third and fourth layers).

[0132] Regardless of whether the hairpin is of reverse or standard type, there is one reverse hairpin and all the steps that make it possible to assemble the intermediate crown with a single insertion system are repeated in detail below. In all embodiments, the stator winding or rotor winding can be assembled by means of circumferential storage means, removable insertion and moving means and relative rotation means.

[0133] Step 1: Positioning the Reverse Hairpin

[0134] First, insert and move the reverse hairpin 255-R (connecting the inner crown and the middle crown). system 400 (as shown in Figure 20) , Zhou direction end Tapered section 410 and the opposite end 420 in the storage circumferential direction, which serve as a guide for the inserted hairpin. Tapered section 430 (t Apered portion : The reverse hairpin is positioned according to Model 3 shown above using the theoretical hairpin position (including the portion where the thickness decreases or increases depending on the reference direction) (and the reverse hairpin is inserted in a region of space other than the theoretical hairpin position).

[0135] Circumferential end Tapered section 410 is, system 400 is an example of a circumferential end element (which can be replicated on the opposite end in the case of an embodiment with the insertion and movement device in two separate parts, see below). the law of nature, The element or elements are configured to cause camming of the hairpins radially inwards and / or outwards of said sectors upon actuation of the relative rotation means. Tapered section 410 moves the hairpins that are outside the means 400 in the area corresponding to the wedge radially by the sector so that the sector opens into two hairpin edges and a free area for inserting the last hairpin of the sector is formed between these two edges. In other words, as shown for example in FIG. Tapered section 410 is the same Tapered section acts on one circumferential end of the means 400 by radially displacing the hairpins of the sector in the area where it is introduced, while system At the opposite end of 400, the hairpin comes to rest, so that a radial opening is formed in the sector where the last hairpin can be inserted again through the means 400 (see FIG. 31). Tapered section Or, the "guide and storage end" is tapered in a direction opposite to the relative rotation direction of the circumferential storage means 300, 300', 300" on a plane perpendicular to the rotation axis 50, and the guide and storage end 410 is disposed at a predetermined distance from the relative rotation axis 50 of the circumferential storage means 300. The guide and storage end 410 is inserted and moved with the relative rotation of the circumferential storage means 300, 300', 300". system 400, 400 II , 400 IVThe circumferential storage means 300, 300', 300" are arranged at a predetermined distance from the relative rotation axis 50 of the circumferential storage means 300, 300', 300" so as to guide and store the already inserted hairpins of the sectors advancing toward the system 400, 400 II , 400 IV is a removable means.

[0136] Insertion and movement of hairpins in all embodiments system 400(400 II , 400 IV , 600) are means for insertion, displacement and / or orientation (generally, movement), not for elastic bending. It is not possible to take advantage of the elasticity of the hairpins, as this would cause problems with rubbing against other hairpins. Furthermore, system 400 can be different for each sector as the dimensions of the sectors vary, or it can be unique with the ability to vary dimensions.

[0137] In fact, in the figures of each embodiment, system 400(400 II , 400 IV Although the means is depicted as being made up of a single block, it may be made up of several movable blocks for processing hairpins of different sizes. In this case, the various blocks are moved and then during operation of the means system The interlocking can be performed in different ways, via interlocking elements or via different elements that hold the different blocks in place. Enter, Transfer motion and / or orientation system The sizing capability of does not change its functionality, as explained below.

[0138] Insertion and Movement system may be configured to insert a hairpin along the slot and displace a hairpin inserted in a sector radially inward and / or outward of the sector.

[0139] ( Removable ) Insertion and Movement system (400, 400 II , 400 IV , 600) are configured such that a previously progressively inserted hairpin is radially moved from a first angular position relative to said winding axis, in which hairpins already inserted in the winding do not interfere with hairpins yet to be inserted, to a second angular position relative to said winding axis corresponding to said respective region.

[0140] According to one aspect of the present disclosure, once the last hairpin of a sector is inserted, the removable insertion and movement system 400, 400 II , 400 IV , 600 are removed. If they are resized, they can be inserted into the respective areas of the new sector, otherwise other differently sized means are used in such areas.

[0141] In this step it is worth making sure that the intermediate crown is positioned so that the space SLR required to house the reverse hairpin is aligned with the axis of the reverse hairpin. See the so-called "initial crown alignment". In other words, the circumferential housing means and the insertion and movement system are positioned relative to one another to define a minimum insertion area of ​​the reverse hairpin in said slot.

[0142] Step 2: Inserting the Reverse Hairpin

[0143] Referring to Figure 21, at this stage, all that remains is to fully insert the hairpin so that the "formation level" coincides with the "formation end level". Removable Insertion and Transfer system 400 is further illustrated in FIG.

[0144] In this initial analysis, assume that hairpin 255-R is lowered until one of its two legs (which for simplicity are identical to one another) abuts an abutment surface.

[0145] Step 3: Reverse hairpin storage

[0146] Considering that the reverse hairpin 255-R is inserted in a position different from the final one PFR that should be in the winding (always possible according to one aspect of the present description), it is essential to guide it to its correct destination. It is adapted to perform a continuous rotation by one or more slot pitches around the rotation axis 50 by relative rotation means (not shown), which are connected to the storage means 300 for the hairpin and the hairpin and the insertion means and the movement means. system 400 and advantageously separate, this applies to each embodiment), the relative rotation of the inserter with respect to the housing (when the inserter is at rest, this is due to the clockwise rotation of the housing as observed from the insert side. When the housing is stationary, it is the inserter rotating circumferentially in the opposite direction, this applies to each embodiment), the slot pitch, and the insertion and movement It depends on the system geometry. In other words, the reverse hairpin 255-R, shown in dark grey in FIG. 21, must assume the “final reverse hairpin position” PFR.

[0147] The rotation of the hairpin 255-R is allowed thanks to the storage system 300, which also rotates the inner crown, which is integral with it. Let us analyze in detail how this rotation occurs. From the bottom view as in FIG. 22, it appears that during rotation, the inserted reverse hairpin (255-R, dark grey) is dragged by the storage 300 on the one hand and guided by the removable insertion and movement system 400 on the other hand. Due to the presence of the chamfer or taper 430 on the inserter, the right leg of the hairpin instantly touches its tangent line. Thereby, the hairpin tends to move to the ideal final position as shown in FIG. 23. This figure highlights the difference between the ideal final position 255-RI (grey) of the reverse hairpin and the actual position 255-RF (dark grey). It should be noted that after rotation, the left leg of the dark grey hairpin, i.e. the leg of the hairpin belonging to the innermost crown, is located on a larger diameter. However, this is not a problem. As will be seen below, the advancement of the standard hairpin 255 tends to fully deploy the reverse hairpin 255-R.

[0148] Tapered section 43 0 is , system 400 and is part of a shaped bridge 480 (see FIG. 20 for a view on a plane perpendicular to the axis 50) located between the two insertion openings in the case of hairpins. The shaped bridge is an example of one or more elements configured to radially displace already inserted hairpins as a function of the circumferential position of the hairpins of each sector upon activation of the relative rotation means, so that there is a free space in the insertion area between the hairpins occupying the sector for the insertion of the last one of the sectors. According to one embodiment of the present specification, the tapered portion 430 is located on the leg of the hairpin on the rear side with respect to the direction of rotation, the tapered portion 430 widening in the direction of relative rotation.

[0149] FIG. 24 shows (for illustration purposes) the insertion of a reverse hairpin without a housing into the inner crown 100-CI during assembly.

[0150] Step 4: Positioning the first standard hairpin

[0151] After the reverse hairpin is in place, one can begin to insert a standard type hairpin 255 into the inner crown 100-CI, as shown in FIG. 25. As with the reverse hairpin, the first thing to do is insert and movement The key is to correctly place the hairpin in the pits 440U+440S / 440R of the system. As depicted, the pits can be bifurcated to have the possibility to insert both standard and reverse hairpins. There is an initial single pit part 440U from which two pits 440S and 440R are bifurcated for standard and reverse hairpins, respectively. Note that both 440S and 440R are aligned with the bending direction of the bridge connector of the hairpin.

[0152] Step 5: Insert the first standard hairpin

[0153] At this stage, the hairpin is simply fully inserted so that the "formation plan" and the "end of formation plan" match.

[0154] Considering that the standard hairpin is inserted in a position different from the final position 255-ST of the winding, it is essential to guide the hairpin to the correct target position. This is due to the rotation of the housing by the slot pitch (clockwise as seen from the insertion side) and the insertion direction depicted for the reverse hairpin. and movement This is possible thanks to the geometry of the system.

[0155] However, unlike the reverse hairpin, the standard hairpin 255 is guided during the rotation of both legs by an insertion system and at the same time by a housing that allows its rotation. In particular, the tangency conditions in this case are those shown in FIG. 26 and allow the access of the standard hairpin. Tapered section 430 is on the right.

[0156] Unlike the reverse hairpin case, here we can see that the distance between the "final theoretical position" 255-I and the "real final position" is essentially zero. It is noteworthy that this hairpin insertion is possible because the previously inserted reverse hairpin does not interfere. Since the standard hairpin sits on top of the previously inserted reverse hairpin, the reverse hairpin is forced to take the "theoretical final position" as mentioned above.

[0157] Bulge 421 at end 420 provides accommodation for a standard hairpin.

[0158] Steps 6 : Positioning, inserting and accommodating the second standard hairpin

[0159] By the same mechanism suggested through steps 4 and 5, all remaining standard hairpins belonging to the intermediate crown 100-CIN can be inserted for their formation.

[0160] Figures 27 and 28 show the housing of the second standard hairpin. After inserting the second standard hairpin into the initial position 255-S, the state of Figure 27 is obtained. Again, clockwise rotation by the slot pitch allows the hairpin to be housed in the final position 255-E as in Figure 28.

[0161] It is worth noting here that, again, each incrementally inserted hairpin rests on top of the previously inserted hairpin and does not in any way interfere with the positioning or containment of the hairpin under consideration.

[0162] Next, we consider and analyze in detail what happens when, after inserting k standard hairpins, the first inserted standard hairpin 255 and the reverse hairpin 255-R are brought together in the insertion and transfer system 400.

[0163] Steps 7: Formation of a spiral widening profile

[0164] After inserting a certain number of hairpins, which varies depending on the product under consideration, the situation in Fig. 29 is obtained. The first inserted standard hairpin 2551 is again located in the insertion and transfer system 400, which has a shape (for example, the shape of a wedge 411 as depicted in the figure) such that it follows what is referred to here as a "standard hairpin distance profile". As the hairpins are gradually inserted and thus the outer housing rotates, the first hairpin no longer moves on a circular type profile, but starts to form a spiral type widening profile, allowing the positioning, insertion and storage of all the remaining hairpins until the end.

[0165] Steps 8 :Opening of the reverse hairpin in the insertion system

[0166] Even though the reverse hairpin is first inserted into the mid-crown, it does not have to cover the previously depicted "distance profile" 411. This can be easily deduced by referring to FIG. 30. In fact, in this step, due to the opposite bending direction of the head 255-RT of the reverse hairpin, the reverse hairpin 255-R temporarily abandons the other hairpins and instead follows a helical widening profile. Reconnection only occurs after removing the insertion and transfer system 400, thus completing the mid-crown.

[0167] Steps 7 and Step 8 So, you can use very different shapes, but the insert and movement It is important to point out that the shape of the parts of the system is particularly important.

[0168] Steps 9 : Positioning, inserting and accommodating the last standard hairpin

[0169] Once the last hairpin has been positioned and therefore inserted, the situation of Figures 31 and 32 is obtained. The accommodation of the last (standard) hairpin 255 is permitted by a slot pitch rotation, as was done previously for the other standard hairpins. Again, the insertion and movement It is noteworthy that the reverse hairpin 255-R, which reappears correctly near the system, does not cause an obstruction.

[0170] Steps 10 :Additional rotation and removal of the insertion system

[0171] Insert and movement Before removing the system (by sliding it off from the top), make sure the last hairpin inserted is inserted. and movement To ensure that the system is clear of the inner abutment, it may be appropriate to make an additional rotation to avoid misalignment. and movement After removal of the system, the hairpins displaced by the shape of the inserter close naturally towards the axis of rotation of the first layer, resulting in an assembled crown.

[0172] Group 3: Outer crown preparation

[0173] The assembly of the outer crown can be carried out using a similar procedure to that employed for the assembly and achievement of the intermediate crown, as it can include the insertion of reverse hairpins (between the second and third layers) and standard hairpins. The resulting windings can then be inserted into the stator pack.

[0174] Consideration of a system with multiple reverse hairpins for layer jumps

[0175] In the previous section it was shown that it is possible to manage windings with only one reverse hairpin for intralayer jumps. It is interesting to extend the concept to apply to the case where there are different reverse hairpins in the two windings. In particular, we refer to a product in which there are reverse hairpins 255-R adjacent to each other and offset from each other by a multiple of the slot pitch (for example, 180° for winding 100R4), as in Figure 33.

[0176] The assembly of the proposed winding 100R4 can be obtained by following at least three strategies, as shown below, in which the "formation level" and the "formation end level" can coincide.

[0177] In the first approach, we extend the concepts applied in the previous chapter to the case of products with only one reverse hairpin per layer jump.

[0178] Therefore, the basic idea is to prioritize reverse hairpins during the crown formation step, with the following assumptions: - The reverse hairpin connecting the two crowns is always inserted during the construction of the outermost crown between the two crowns; - the assembled windings are obtained from the manufacture of the innermost crown, gradually moving towards larger diameters; - In the formation of a crown in which a reverse hairpin is present, the first hairpin inserted is of the reverse type; - All hairpins (standard and reverse hairpins) are located in regions of space other than the final theoretical position associated with that hairpin, resulting in the insertion and movement The system is inserted, in particular, into the larger diameter.

[0179] Each crown can have a different system (for the stator under consideration, the insertion system of the middle and outer crowns must be such that it can accommodate both standard and reverse hairpins). Any hairpins of the I-pin type are inserted last, after all the hairpins of the multi-leg type have been assembled.

[0180] The method of managing and inserting the hairpins is that of Model 3. The small number of standard hairpins results in "void regions" - these are the spaces required to accommodate the reverse hairpins.

[0181] Next, two or more reverse hairpins are inserted in succession, also parallel, at different angular positions, before starting the assembly of the second crown shown in Figures 34 and 35 (rotating the housing clockwise and then rotating counterclockwise to return to the initial position for inserting the second reverse hairpin). Then, the first standard hairpin is placed in correspondence with the other two reverse hairpins, and standard hairpins are added as above until the second crown (middle) is completed. An empty housing reverse rotation (realignment) may be required to insert the first standard hairpin. The intermediate crown can be closed and obtained by removing the inserter (only after performing an empty rotation of a certain multiple of the slot pitch, and also to avoid removal of the hairpins).

[0182] The outer crown can be obtained by applying the same concepts as seen in the intermediate crown.

[0183] The problem with this first approach is that the initial insertion of every reverse hairpin may result in the need to introduce an additional containment system to prevent the hairpin from "falling" outwards.

[0184] In the second preferred assembly strategy, the aim is to avoid the use of such an additional containment system, as in the previous method, that may be required to support the reverse hairpins when they are all initially inserted. This is made possible by invalidating assumption 3. Thus, the following assumptions are obtained: - The reverse hairpin connecting the two crowns is always inserted during the construction of the outermost crown between the two crowns; - the assembled winding is obtained from the construction of the innermost crown, gradually moving towards larger diameters; - In the case of crowns with reverse hairpins, the first hairpin inserted is of the reverse type; - All hairpins (standard and reverse) are placed in a region of space other than the final theoretical position associated with that hairpin, and movement They are inserted into the system, in particular with a larger diameter.

[0185] Different inserts for each crown and movement (Conveniently, in the stator under consideration, the system for inserting the intermediate and outer crowns is adapted to accommodate both standard and reverse hairpins.) I-pin type hairpins are not considered, since they are inserted last when all multi-legged hairpins are combined.

[0186] As can be observed, the model assumptions are the same as the scenario presented above, with the only difference being that reverse hairpins are not given significant preference over standard hairpins in the general crown formation step.

[0187] For assumptions 1 and 2, the crown assembled first is the innermost one and furthermore, similar to the previous scenario, contains only standard hairpins.

[0188] Therefore, we focus our discussion on the formation of the intermediate crown. This step involves the positioning of two consecutive reverse hairpins. However, in this stage, instead of inserting the remaining reverse hairpin that is not adjacent to the already inserted hairpin (as in the prior art), a standard hairpin is positioned, inserted, and accommodated above the pair of already inserted reverse hairpins.

[0189] Then, after inserting a certain number of standard hairpins, the same technique is used to insert standard hairpins until they approach the theoretical position of the remaining reverse hairpins (not yet inserted, e.g., at 180° to the first pair), in which case the insertion of standard hairpins must be stopped before they occupy the space required for the reverse hairpins so that the missing reverse hairpins can be accommodated.

[0190] To insert the remaining two reverse hairpins, alignment must be performed, with the inserter positioned at the corresponding angular position, followed by insertion of the third and fourth reverse hairpins for the first pair.

[0191] Insert and movement It should be noted that the system itself is also capable of accommodating a previously inserted standard hairpin (which, thanks to its particular shape, can be of different types, in the example shown, results in a rounded thickening 421 of the inserter end in the direction of rotation). However, to better highlight such a function and to make it more effective, the thickening is not rounded at the end, but forms a circular arc (looper chamfer followed by a thickening arc), as in FIG. 36. and movement Such modifications implemented in the system allow for the inclusion of a previously inserted standard hairpin, facilitating the sequential initial alignment required to insert both the missing reverse hairpin and the standard hairpin.

[0192] Another interesting observation concerns what happens when initial alignment is applied to finish inserting the interrupted standard hairpin after inserting the second "puck" of reverse hairpins 255-R. In this regard, FIG. 37 shows that the standard hairpin 255 entering the looper chamfer 435 (the rounded portion is not needed when reverse hairpins are moved) is inserted at the end of the insertion. and movement The system itself shows how the hairpins are stored, which reduces the chance of them becoming stuck during the alignment process.

[0193] At this point, you can insert the remaining hairpins, all of which are standard, by aligning them so that they are inserted exactly where the standard hairpins stopped, and continue this process until the first half circle is complete.

[0194] At this point, alignment is required to insert a standard hairpin into the other half circle.

[0195] Then, to allow for the insertion of the last hairpin, similar to the situation in FIG. 29, the first standard hairpin is inserted until it begins to cover the spiral shape.

[0196] The construction of the outer crown can be carried out by following the same reasons as explained for the intermediate crown.

[0197] This exemplary method is also suitable for cases where the reverse hairpins are randomly arranged.

[0198] The case analyzed above is where the two "packs" of adjacent reverse hairpins are at a maximum distance (i.e., 180° apart), but as explained above, this can be adapted to any distance.

[0199] In the third assembly strategy, the method is completely different from the two previously analyzed. The following assumptions are made: - the assembled windings are obtained from the structure of the innermost crown, gradually moving towards the larger diameter; - The reverse hairpin is inserted after all the crowns are partially assembled; - All standard hairpins are located in regions of space other than the final theoretical position associated with that hairpin, thus and movement are inserted into the system, in particular, these are inserted into larger diameters; - (Optionally) For size reasons, it is possible to provide a different system for each crown / sector (except for providing a system with movable elements).

[0200] I-pin type hairpins are not considered in this study because they are inserted last once all the multi-leg type hairpins have been combined.

[0201] As inferred from the assumptions, in this method all standard hairpins are inserted into all crowns, nevertheless starting from the innermost crown, using the same method as has been adopted up to now. After a partially assembled winding is obtained, the reverse hairpins are inserted into the crowns, using special insertions modeled as necessary. and movement It is inserted by a system which performs a double function, both as a guide for the reverse hairpin to be inserted and as an element for spreading the crown, allowing its insertion and therefore also its containment.

[0202] This third method is quite complicated, taking into account that the insertion of a common reverse hairpin between two crowns is allowed only in the following cases: - the outermost crown is expanded by a radial amount equal to the height of the plate; and - The innermost crown is offset inwardly by a radial amount equal to the height of the plate.

[0203] Figure 38 shows the widening and narrowing of the circumference of the crown (dash-dotted lines). It should be noted further that if there are reverse hairpins adjacent to each other, it is more convenient to insert them simultaneously, rather than one at a time. In fact, otherwise the previously inserted reverse hairpin would also have to be pushed inwards.

[0204] It is worth noting that the minimum distance between the two circumferences highlighted in the diagram is equal to twice the height of the plate (in this case 2x1.8=3.6 mm).

[0205] FIG. 39 shows two circumferences for a second pair of reverse hairpins.

[0206] In any case, it is preferable to always insert the reverse hairpins from the innermost crowns. With reference to FIG. 39, the outermost set of reverse hairpins is inserted first by spreading the middle crowns and tightening the inner crowns, and then the innermost reverse hairpin is inserted by spreading the outer crowns and tightening the middle crowns inwards. It is worth noting that when the middle crowns are compressed, the innermost reverse hairpins are also subjected to this radial force. They tend to occupy a smaller diameter than the theoretical diameter of the associated layer.

[0207] Parallel Hairpin Embodiment

[0208] In one study, a winding was considered having the following non-limiting characteristics: - Plate size 2.16x3.16; - 4 wires per slot x 48 slot windings; - hairpin leg height PDT=160mm; and - Parallel type winding with two types of hairpins between layers 1-3 and between layers 2-4.

[0209] The objective of the study carried out was to estimate the space required to insert the hairpin from the top and form the winding as provided by the process according to one aspect of the present specification, and to evaluate the dimensions of the inner housing wall always required for assembly.

[0210] The study was carried out by differentiating the methods of hairpin insertion.

[0211] Referring to FIG. 40, in the first case of “translated vertical insertion”, parallel hairpins 255-P are inserted into the first assembled crown portion 100. I (Left side) is spread outward, and finally the assembled crown part 100 F (right) at its theoretical diameter, it is inserted perfectly vertically. This requires the hairpin to be inserted at a larger diameter than it will be in its final position. In the illustration, a blade 310' is used as in the other embodiments, but any slot forming and storage system can be used. system Insertion / movement thicker than 400 system 400 II In addition, in order to simplify the illustration in the figure, system 400 II In the figure, both circumferential ends are not included, and only the central portion is illustrated in top view.

[0212] It was found from the study that taking into account the width of the crown (affected by the number of hairpins, the size of the plate and the bending dimension of the "s" shape), the hairpins inserted must be inserted to a much larger diameter than the theoretical diameter (approximately 130 mm in this particular, non-limiting case), which causes the hairpins to hit the lower wall of the clamp forming the housing, as shown in the circled portion of FIG.

[0213] Furthermore, the widening required to allow space for the insertion of hairpins means that the legs of hairpins belonging to different layers cross rather low on the stator axis, as shown in Figure 42. This means that the clamp walls are very thin (1 mm at the innermost part) and relatively low in relation to the dimensions of the product (approximately 30 mm high with the pins protruding 10 mm downwards). Due to the low walls, the hairpins tend to fall outwards and therefore need to be stowed outwards during forming. Therefore, they cannot be inserted in this way.

[0214] In the second case, with "inclined insertion", see Fig. 43, the hairpin insertion is performed at an angle γ with respect to the stator axis AS, which allows the hairpin to be inserted with a diameter close to its theoretical diameter (i.e. final position).

[0215] From tests carried out with this particular configuration, it turns out that the inclination angle γ that gives the best results is about 5° to the axis, such angle depends on the geometry of the winding and must be defined for each case, but different angles are possible, one possible range being between 0° and 30°, preferably between 3° and 7°. This inclination allows the hairpin to be inserted to be moved more inwards, and prevents the legs from hitting the clamp wall, thus solving the problem of insertion in a translated vertical manner.

[0216] The taper results in the ends of the hairpin protruding inwards, i.e. the hairpin occupies the space inside the inner storage diameter, as can be seen, for example, in Figure 40. The taper does not significantly reduce the outward expansion of the hairpin, so that the clamp wall height remains 30mm (in the particular test carried out), with a minimum thickness of 1mm and the end protrusion is 10mm below the storage.

[0217] As a result, insertion is possible but retraction is greatly reduced.

[0218] As a third case, that of "pure vertical insertion", the two methods exemplified above confirm the so-called "Model 3" above. Indeed, regardless of the presence of nulls or non-zero tilts, the hairpins are inserted on a circumference larger than the theoretical one of the layer to which they relate. Instead, the application of "Model 2" above is interesting in the presence of this type of winding, which considers the use of parallel hairpins.

[0219] Indeed, and in any case, as shown, there is the problem that in order to complete the insertion of the hairpin, a very accentuated widening of the first inserted hairpin must be provided. The necessary widening can be ensured by inserting the hairpin 255-P (or the hairpin 255 in general) directly into the "theoretical hairpin position" as shown diagrammatically in FIG. 44. The most present accentuated compression of the last inserted hairpin not only allows the insertion of the hairpin to continue unhindered, but also compensates for part of the outer widening of the first inserted hairpin, facilitating the dimensioning of the fingers of the storage clamp, and thus making them more robust and less critical.

[0220] It should be noted that applying the model shown above to this type of winding is much less problematic than windings with separate crowns, this is due to the fact that having a single crown does not present the problem of how to manage the outermost crown while compressing the hairpin towards a smaller diameter. Moreover, while keeping the shape of the fingers of the clamp the same, it was possible to verify that with this model it is possible to facilitate the insertion (without interference) and to strengthen the fingers to bring them closer to the chignon, in comparison with the previously analyzed case.

[0221] The above also applies to parallel hairpins consisting of two or more hairpins.

[0222] Further, as provided herein for all embodiments herein, and with reference to FIG. 45, the insertion of a hairpin and mobile systems Each time, it is necessary to ensure that there is a minimum insertion area in the slot. Consider a hairpin with a line cross section a·b, pitch = α, the centroids of the cross sections of the straight parts lie on the circumferences of radii R1 and R2, respectively, and have L as the value of the straight distance.

[0223] The "theoretical position area" is defined by placing the center of gravity at the intersection of the circumference R1 and one of the two straight lines that define the angle α, and placing the center of gravity at the intersection of the circumference R2 and one of the two straight lines that define the angle α (as in the image of Figure 45(a)), so that one and the other of the two areas a and b are positioned at an angle according to the cross-section of the hairpin itself.

[0224] The "minimum insertion area" is defined as one and the other of two areas a·b that are a rigid translation (with a constant length L) along the axis y, where the rigid translation is equal to a·b / cos(α / 2) (as in the image in Figure 45(b)). The hairpin needs to insert its legs into these areas and approach the areas of its theoretical position. In order to insert the hairpin, the cross section of the hairpin legs must be within the minimum insertion area, otherwise the hairpin cannot be approached and the insertion cannot be completed.

[0225] Consideration of the system with explanations for the presence of overlapping hairpins

[0226] It is interesting to evaluate how the concepts herein can be applied to windings that provide for the use of overlapping hairpins such as those in Figures 4G and 4H.

[0227] Recall that windings using overlapping hairpins have the following characteristics: - the minimum number of different hairpins per crown is equal to 2, including: standard hairpins and overlapping hairpins; - An overlap hairpin is always located above a standard or reverse hairpin; The two hairpins have different divergence angles, in particular the overlap hairpin has an divergence angle (angle β) that is two stator slot pitches or more compared to the standard hairpin (angle α).

[0228] The relationship between the two opening angles is as follows: β=α+2δ, where δ=(360°) / N c is the stator slot pitch, N c indicates the number of stator slots.

[0229] The following general assumptions are made: - The spatial arrangement of standard hairpins for various crowns is the arrangement described in Model 3; - The braided windings are obtained from the construction of the innermost crown, gradually moving towards larger diameters; - The standard hairpin is at the bottom and must always be inserted before the overlap hairpin; - That is, it is not possible to insert only the standard hairpin first and then insert the remaining overlapping hairpins in a second step; - Standard hairpin-overlap hairpin sequential insertion allows hairpins to be treated individually or simultaneously; - providing an insertion system that can be set for each group and therefore for each layer and layer section; - The insertion of the last standard hairpin / overlap hairpin is possible thanks to the radial spread of the first inserted hairpin.

[0230] Consideration of the system according to the present invention in the presence of I-pins

[0231] With reference to Figures 46 and 47, practical considerations were made for a particular winding having the following types of hairpins: 12 I pins 255-IP on the innermost layer, 36 regular pins 255 on layer 5-6, 12 reverse pins 255-R on layer 4-5, 36 regular pins on layer 3-4, 12 reverse pins 255-R on layer 2-3, 36 regular pins 255 on layer 1-2 and 6 inverted pins 255-IVP on layer 1.

[0232] The purpose of these studies was to verify the feasibility of the assembly in the presence of the aforementioned pins, particularly I-pins and inverted pins.

[0233] Crown Modeling

[0234] First, the model required for the study was created from Crown 5-6, i.e., the innermost one with 12 I-pins and 36 standard hairpins. The crown was represented by inserting all the hairpins individually and constraining them according to the reference diagram, as shown in the previous section.

[0235] While a standard hairpin is constrained to the isolation-free part of the right leg, the isolation-free part of the left leg, and the "S" bend, the I-pin is only constrained to its only leg and the start of the bend on the terminal.

[0236] From the Crown 5-6 model, it is possible to evaluate the width required for standard hairpin insertion and the insertion sequence of the I-pins.

[0237] The model allowed us to see what would happen once the crown was assembled: some of the I-pins, for example, are left free to move because they are not "embraced" by standard hairpins.

[0238] Additionally, it is possible to determine the expansion required to form the crown, and therefore the dimensions of the housing structure.

[0239] The final insertion of the I-pin into the winding can be carried out using special devices, e.g. as per the prior art.

[0240] Consideration of systems according to this specification when inverted pins are present

[0241] It was possible to analyze the management of the inversion pin 255-IVP with the same stator as used in the above example.

[0242] Referring to FIG. 48, it can be seen that a robotic arm or clamp can be used to insert directly into the slot by inserting vertically from above, but on a larger diameter circumference relative to the final position.

[0243] The insertion location of the radially outermost inversion pin determines the minimum thickness and radial length of the housing wall (such parameters are usually determined by the outermost crown widening, in which case two cases are compared to see which is most critical).

[0244] Referring to FIG. 49, one pit 465 IV 400 similar to that designed for standard hairpins, IV It is also possible to use

[0245] As an example, the inversion pin can be inserted at the end, with the advantage that the insertion location is at a tight angle (ie, the robot does not follow the storage rotation).

[0246] Further embodiments

[0247] After some experimental checks, the insertion and mobile systems It has been found to be possible and advantageous to divide the machine into two different bodies, since it has been found that by moving these bodies it is possible to insert different types of hairpins and form the same winding; in other words, by doing so, it is possible to change the insertion position of the machine when changing the type of hairpin. and movementIt is possible to avoid having to redesign and replace the system.

[0248] However, insertion and movement system It is also possible for the two to be a single body. In the following, both cases are considered, with particular emphasis on the embodiment in two different separate parts.

[0249] With reference to the figures, and in particular to Figures 56-68B, the present specification relates to a system for assembling a stator or rotor winding 100, the winding including one or more sectors 100-CI, 100-CIN extending circumferentially about a winding axis 50, each sector including one or more layers, each layer including a circumferential array of hairpins 255, 255-R, 255-IP, 255-IVP, the hairpins including a head end and two legs having respective free insertion ends. Hairpins are not typically part of the system according to the invention, but may be included. In any event, hairpins are defined herein for purposes of describing the components of the system in use.

[0250] The assembly system comprises first and foremost a circumferential storage means 300, 300', 300" of the hairpin, which defines a set of spaces or slots 350, 350', 350" adapted to receive the legs of the hairpin, the angular distance between two slots being called the slot pitch according to the prior art. However, it must be noted that in this document the storage means is a single circumferential block and cannot be separated and opened in the circumferential direction as in the prior art document WO2018 / 039806. The separation elements forming the slots are movable, but the periphery of the body of the storage means is inseparable (a single circumferential block, possibly formed via retractable blades, movable only in the radial direction, but without groups of blades at different angles to each other and therefore not along the radial direction with respect to the axis of rotation). The system further comprises a removable insertion and movement means. and Mobile System 4 00, 400 II , 400 IV of The inserting and moving means includes a circumferential receiving means. Step 3 00, 300', 300 "and are separate (not integrated) and include two openings (665A, 665B) for inserting the two legs of the hairpin. Again, such means are generally known per se. To complete the general part, relative rotation means are also constructed, which are adapted to allow the circumferential storage means to permit the aforementioned removable insertion and movement. system Removable insertion and movement to advance in an approaching direction toward system and the circumferential storage means, said relative rotation means being configured to perform a rotation of one or more slot pitches about a rotation axis 50 coinciding with the axis of the circumferential storage means.

[0251] The two openings 665A, 665B are configured such that, in use, the first leg of the inserted hairpin is located in front relative to the approach direction and the second leg is located in the rear relative to said approach direction. Again, the location of the openings is generally known. Of course, the openings extend axially (parallel to the axis 50 in use). It should be noted that in FIG. 50, the two openings include, for example, elements 661A and 661B, which are understood to be present but are not shown in the following figures for ease of reading the figures. Such elements are just one example of how the two openings can be configured.

[0252] According to this specification, removable insertion and movement system (In the above embodiment, 400, 400 II , 400 IV, 600 from FIG. 50 onwards, which applies to all the following documents), comprises a first part 400A, 600A and a second part 400B, 600B, respectively, having a first and second circumferential extension direction and a first and second axial extension direction, the first part 400A, 600A and the second part 400B, 600B being configured such that the axial extension direction is parallel to the axis of rotation 50 and the first part 400A, 600A and the second part 400B, 600B can be arranged outside the aforementioned circumferential storage means 300, 300', 300" at a radial distance from the axis of rotation 50 greater than the radial distance of the aforementioned sectors 100-CI, 100-CIN. This is one difference with respect to document US2020 / 0336054, in which the movement means of the hairpin (for example, reference number 15 in FIG. 8) is inside the storage means.

[0253] More specifically, the first portion 400A, 600A has a first circumferential end 410, 610A, a second circumferential end and a first connection body for connecting between said first circumferential end and said second circumferential end, said first circumferential end 410, 610A increasing in thickness radially outward in a direction towards the second circumferential end in a cross section perpendicular to said axis of rotation 50. As can be seen, the first end, common to all embodiments, comprises a wedge, the face 610A1 or 410S towards the axis 50 preferably does not have a taper, the end having a taper radially outward (away from 50). This non-tapered surface allows the accommodation of already inserted hairpins (previous layers).

[0254] In all embodiments, the first portion 400A, 600A has, at said first connecting body, a distal taper 430, 680A1 to said first circumferential end, which increases in thickness radially inward in a cross section perpendicular to said rotation axis 50 in a direction toward said second circumferential end. This distal taper allows the axially inserted hairpin to move towards the sector to be assembled. Thanks to such a taper, such an approach allows the rotation of the hairpin to an axis passing through the center of the bridge-like connector, which is parallel to the legs (at least the part just attached to the head).

[0255] The second portion 400B, 600B has a first circumferential end 420, 610B and a second circumferential end, and further has a second connecting body between said first circumferential end and said second circumferential end, said connecting body having a proximal taper 421, 650B1 to said first circumferential end, the thickness of which increases radially inward in a direction towards said first circumferential end in a cross section perpendicular to said axis of rotation (50). This proximal taper Department By means of the tapering, the axially inserted hairpin can be moved to be brought towards the sector to be assembled, and by means of such tapering, such approach can include a rotation of the hairpin about an axis passing through the centre of the bridge-like connector, which is parallel to the legs (at least the part just attached to the head).

[0256] It is clear that in the embodiment 600 the circumferential second ends of each part are spaced apart from one another, whereas in the previous embodiment the two second ends coincide at the centre of the single connector body 480. If the two groups of the embodiments 400, 600 are used only in one approach direction and a mirror image configuration for the other approach direction, the functionality is equivalent and it is entirely optional to make the two second ends coincident. On the other hand, if the same means are used instead for the two approach directions and also for different crowns, the two parts 600A, 600B will have to be repositioned from time to time, so their second ends must be separate, as in the embodiment 600, and the first ends must be equal, even if circumferentially opposite (symmetrical configuration).

[0257] At this point, some further details about the construction of the two portions are necessary. First, the first circumferential end 410, 610A of said first portion 400A, 600A is aligned with said sector hairpin that corresponds to said approach direction. or hairpin group 2551, 100 I , 100-CI-2 (not shown) The first portion 400A, 600A and the second portion 400B, 600B may be configured and positioned, in use, to radially outwardly displace the hairpins. Furthermore, the positions of the first portion 400A, 600A and the second portion 400B, 600B, as well as the positions of the distal tapers 430, 680A1 of the first portion 400A, 600A and the proximal tapers 421, 650B1 of the second portion 400B, 600B, are predetermined such that, in use, upon activation of the relative rotation means, a hairpin inserted in the two aforementioned insertion openings 665A, 665B is radially inserted into the aforementioned sector. Obviously, a person skilled in the art, once he understands the concept underlying this specification, can easily dimension the elements to work with the particular hairpin to be inserted. The two aforementioned tapers act such that the hairpins are displaced upon rotation and guided radially towards the sector where they meet and are assembled. Although guides are provided in US2020 / 0336054, they are inside the containment means and therefore cannot be the same for all windings. Instead, the findings of this specification allow for the insertion and mobile systemsis separated from the storage means while maintaining the radial guidance of the hairpin and, above all, the same insertion and mobile systems This allows the sector to be widened automatically, rather than manually, to insert the hairpin at the end of the sector, and still uses the same insertion and movement system This is because the widening is done manually and the remaining hairpins are automatically placed in the correct position. and mobile systems "The situation is, moreover, very different from that of the system in document PCT / CA2017 / 051041, in which the storage is divided into parts that open without symmetry with respect to the axis of rotation. Such an opening without symmetry requires both complex and expensive means of movement and the use of special storage means, which are also expensive and, in any case, must be replaced by simpler and more commonly used ones."

[0258] According to any embodiment herein, the first circumferential end 410, 610A of the first portion 400A, 600A and the first circumferential end 420, 610B of the second portion 400A, 600B have surfaces 410S, 610A1 facing the aforementioned axis 50 and are positioned at a predetermined distance from the axis of rotation 50 so as to "guide" and accommodate, in use, a hairpin already inserted in the previous sector.

[0259] According to any aspect herein, the first portion 600A and the second portion 600B are identical in shape but have a mirror image configuration (with respect to the aforementioned direction of approach, in use), and the first portion and the second portion are separate and maintained by support means and adjustment means for the positions of the first portion and the second portion.

[0260] According to any aspect of the present specification that is related only to the embodiment 600, the first portion 600A has a proximal taper 650A1 at said first radially inner connection body relative to said first circumferential end 610A, which in a cross section perpendicular to said rotation axis 50, decreases in thickness radially inward in a direction toward the second circumferential end. Furthermore, the second portion 400B, 600B has a distal taper 680B1 at said connection body relative to said first circumferential end 610B, which in a cross section perpendicular to said rotation axis 50, decreases in thickness radially inward in a direction toward the first circumferential end. Finally, the proximal taper of the first portion 600A is Department 650A1 and the proximal taper of the second portion 600B Department 650B1 terminates in respective radial and circumferential storage elements 660A, 660B, 661A, 661B of the hairpin forming two openings 665A and 665B, each circumferential storage element 660A, 660B, 661A, 661B having an inner radial extension and integrally provided along the circumferential extension of said first and second parts in front of their respective first circumferential ends 610A, 610B and at a height along said axial extension further than the height of their respective first circumferential ends 610A, 610B relative to said storage means.

[0261] According to any embodiment herein, the second circumferential end 680A of the first portion 600A and the second circumferential end 680B of the second portion 600B have respective chamfers 680A3, 680B3 in the axial direction 50 configured to guide the hairpin during insertion and insertion into the radial movement device.

[0262] According to any aspect of the present invention, the first end elements of the first and second portions are configured such that the hairpin inserted at the end of the sector is displaced inwards. This allows for the insertion and movement of the hairpin relative to the housing. system Alternatively, as shown in FIG. 9A, the rotations can be alternated to move the first and last inserted hairpins radially outward and inward, respectively.

[0263] According to an optional aspect herein, the aforementioned means for supporting and adjusting the position of the first and second portions is configured to position the first and second portions between each other so as to insert both hairpins and reverse hairpins on different layers and crowns.

[0264] Referring again to Figures 50-64B, the following individual optional features are provided (although it is understood and used explicitly to mean that "inside" always faces the axis 50 and "outside" faces in the opposite direction): system Even when not in use, system It is always possible to define inner and outer surfaces with respect to a direction perpendicular to the axial extension of: - inner surface 650A2 emerges first (from the second end) of tapered surface 650A1 and contributes to the formation of opening 665A, as does surface 650B2. - Surface 650A3 is the outer surface of end 610A of taper 610A2 and correspondingly surface 650B3 is the outer surface of end 610B of taper 610B2. Surfaces 650A3 and 650B3 extend beyond and surround the entire outer surfaces of the first and second parts, as can be clearly seen in Figures 53 and 55. 650A and 650B denote the axial extensions of the first and second parts underlying two openings 665A and 665B. - 680A and 680B show two elements attached to 650A and 650B (particularly attached to the inner surfaces 650A2 and 650B2, such elements providing the distal tapers 680A1 and 680B1 as described above, and the adjacent surfaces 680A2 and 680B2 as well, which may serve to guide and accommodate the hairpin during assembly and ensure its final positioning). Elements 680A and 680B also have rounded or axial tapers 680A3 and 680B3 as described above. Elements 680A and 680B serve to guide the hairpin both during axial insertion (particularly in the case of overlapping hairpins as in Figs. 60A-60C) and during its radial approximation. In particular, they provide the axial abutments of the bridge-like connector.

[0265] In accordance with one aspect of the present disclosure, a specific insertion and movement We will try to follow the steps that make it possible to specify a recipe for assembling a winding with overlapping hairpins when a system is used. Such an insertion system is shown in Figures 66A-66C.

[0266] First step: Positioning the standard hairpin

[0267] With reference to Fig. 60A, the first thing to do is to position the standard hairpin 255 in the openings 665A and 665B, as shown in full in Fig. 50. The two parts 600A and 600B can be moved by known moving means (not shown) to insert any hairpin (standard, reverse and inverted) of any size and therefore of any layer / crown. This also applies to the overlap of hairpins with different pitches. In this case, after the insertion of the first hairpin (e.g. with a smaller pitch), the two parts 600A and 600B can be moved (apart and / or rotated relative to each other) to accommodate the other hairpin (with a larger pitch).

[0268] Overlapping hairpins can also consist of a population of hairpins of increasing pitch, where there are two or more hairpins, i.e., a hairpin with a larger pitch and one or more hairpins with gradually smaller pitches, which also overlap with each other, i.e., have pitches that allow for overlap.

[0269] Second step: Inserting a standard hairpin

[0270] In this step, the two parts 600A, 600B are moved after inserting the hairpin 255. It is also possible to provide a stop element at the head of the hairpin with a small pitch.

[0271] Third step: Positioning the overlapping hairpins

[0272] After inserting the standard hairpin and displacing the two portions 600A, 600B, it is possible to position the overlap hairpin 255A.

[0273] Fourth step: Inserting overlapping hairpins

[0274] Next, insertion of overlapping hairpin 255A is performed.

[0275] Fifth step: Simultaneous accommodation of fiducials and overlapping hairpins

[0276] Referring to FIG. 60C, rotation by the slot pitch (clockwise or counterclockwise depending on the "S" shape) allows insertion and movement. system The shape of the sector allows the hairpins to be accommodated in the sector, with the legs of each hairpin sliding on the working surface as shown above and according to the arrows in the figure (which, for clarity, are only provided for the overlapping hairpins).

[0277] Additionally, in Figures 52-55, the surfaces along which the hairpin slides are highlighted. In particular, the surface highlighted in Figure 52 is the working surface during insertion and take-up assembly of the hairpin in a relatively counterclockwise rotational direction, whereas the surface highlighted in Figure 54 is the working surface during insertion and take-up assembly of the hairpin in a relatively clockwise rotational direction. Similarly, Figures 53 and 55 also show the working surface of the first inserted hairpin, displaced radially to make room for the last hairpin in the sector.

[0278] In the diagram of embodiment 600, the arrows indicate the displacement of the hairpin on the work surface. Figures 62A and 62B show the insertion and movement of a reverse hairpin 255R.

[0279] According to any aspect of this specification referring to an embodiment other than 600, removable insertion and removal system 400, 400 II , 400 IV are made integrally. As seen above, said connecting body of said first part, said second circumferential end of said first part, said connecting body of said second part and said second circumferential end of said second part form a fixed bridge 480. said first end of said second part has, in use, an axial surface 422 facing said axis of rotation 50 and located at a distance therefrom corresponding to the thickness of the crown, said first end of said second part having no increase in thickness radially outwardly in the direction towards said second circumferential end of said second part. Here, insertion and displacement system In the embodiment in which the two portions 400A and 400B are integral with each other, the two portions 400A and 400B are connected at their second ends along their circumferential extensions. System It should be remembered that it is mounted approximately in the center.

[0280] According to any aspect of the present specification, An embodiment of the system 400In this regard, the aforementioned opening is part of a bifurcated pit having a common portion 440U configured for one leg of a standard hairpin or a reverse hairpin, a contiguous first portion 440S for the other leg of the standard hairpin, and a second portion 440R for the other leg of the reverse hairpin.

[0281] According to any aspect of the present specification, but also in relation to all embodiments, the subset of hairpins may include a group of one or more overlapping hairpins 255, 255A having respective pitches between two legs, each group including a hairpin having a larger pitch 255A and one or more hairpins having respective progressively smaller pitches 255, and may be inserted and moved. system is displaced to insert and guide the overlap hairpin into place. An example of the method is described below.

[0282] According to any aspect of the present specification for all embodiments , take Removable insertion and movement system are configured to rotate about the aforementioned axis of rotation 50, while the circumferential storage means 300, 300', 300" are fixed.

[0283] According to an alternative optional aspect of the present specification for all embodiments, the circumferential storage means 300, 300', 300" are configured to rotate about the aforementioned axis of rotation 50, while the removable insertion and movement system is fixed. Obviously, both blocks could be counter-rotated, but this complicates the structure of the system.

[0284] As seen above, the present specification with respect to all embodiments is also directed to a method for assembling a stator or rotor winding 100 including one or more sectors 100-CI, 100-CIN extending circumferentially about a winding axis 50, each sector including one or more layers, each layer including a circumferential array of hairpins 255, 255-R, 255-IP, 255-IVP, the hairpins including a head end and one or more legs having respective free insertion ends. The method comprises the following steps carried out: A. Providing a system according to one or more of the preceding claims; B. The aforementioned insertion and movement means 400, 400 II , 400 IV , 600 into respective regions of the circumferential containment means 300, 300′, 300″; C. actuating said rotating means of said circumferential storage means through one or more slot pitches; D. Repeat steps B and C, inserting and moving, until the sector is complete, and then the entire winding 100 is completed. system 400, 400 II , 400 IV ,600 is the step used for the insertion of the last hairpin in each sector; Now, in step D, when the last hairpin of the sector is inserted, the insertion and movement system 400, 400 II , 400 IV , 600 are removed and inserted into the respective areas of the new sector.

[0285] According to an alternative optional aspect of the present specification for all embodiments: - The windings are assembled starting from the innermost sector and gradually moving to sectors with larger diameters; - one or more reverse-type hairpins are inserted during construction of the outermost sector between each pair of consecutive sectors at the start of assembly of the outermost sector of the pair; - Before inserting the reverse type hairpin 255-R, insert and move the circumferential storage means 300, 300', 300" system 400, 400 II , 400 IV , 600 are aligned relative to one another to define a minimum area for inserting a reverse-type hairpin into said slot; - as soon as the reverse hairpin is inserted, a relative rotation of the circumferential storage means 300, 300', 300" occurs according to the slot pitch; and As soon as one or more reverse hairpins are inserted between two consecutive sectors, steps F and G are executed in which the hairpins are not reverse.

[0286] According to an alternative optional aspect of the present specification for all embodiments, the hairpins include two pairs of reverse hairpins 255-R and a number of non-reverse hairpins 255, 255-IVP, the two pairs of reverse hairpins 255-R are inserted into the winding 100 at a predetermined mutual angular distance, all sectors of the winding are first assembled with the non-reverse hairpins 255, 255-IVP leaving the necessary space for the reverse hairpins 255-R, then the reverse hairpins are inserted between the pairs of sectors by the following steps: The radially outermost sector of the sector pair is removable for insertion and movement. system (400, 400 II , 400 IV , 600) by a radial amount equal to the radial dimension of the horizontal cross section of the leg of the reverse hairpin (255-R) in the insertion position; and the radially innermost sector of said pair of sectors is displaced towards said winding axis 50 by a radial amount equal to the radial dimension of the horizontal cross section of the leg of the reverse hairpin 255-R in the insertion position.

[0287] According to an alternative optional aspect herein for all embodiments, said predetermined mutual angular distance is 180°.

[0288] According to an alternative optional aspect of the present specification for all embodiments, steps B and C are performed for parallel hairpin 255-P, step D is repeated until no insertions of the last parallel hairpin are missing, and then the following steps are performed: - Removable insert and move system 400, 400 II , 400IV, , 600, ,expanding the first sector portion outwardly, starting with the first hairpin inserted and ending with one of the next hairpins inserted; - maintaining a second sector portion at a final theoretical diameter, the second portion being complementary to said first sector portion; - inserting said last parallel hairpin with its legs at a predetermined angle relative to the winding axis 50; - bringing the first sector portion back into contact with the second sector portion.

[0289] According to an alternative optional aspect herein for all embodiments, in the case of parallel hairpins 255-P, each of which is made up of two hairpins, the aforementioned predetermined angle is between 3 degrees and 7 degrees.

[0290] According to alternative optional aspects of the present specification relating to embodiment 400, the system for overlapping hairpins described above is used: - one or more hairpins 255 of progressively smaller pitch are inserted into the circumferential containment means 300, 300', 300", starting with the hairpin with the smaller pitch, always before the hairpin 255A with the larger pitch; and - said further movable storage means 470 are actuated to position one or more hairpins of progressively smaller pitch and are then immediately removed;

[0291] According to an alternative optional aspect of the present specification for all embodiments 400, the system is used for overlap hairpins, and the assembly of the overlap hairpins 255, 255A in the winding 100 is performed with a relative rotation of at least one slot pitch of the circumferential storage means 300, 300', 300", as a function of the bending of the bridge-like hairpin connectors of the overlap hairpins 255, 255A, either clockwise or counterclockwise as viewed from the insertion side of the circumferential storage means.

[0292] A further object of the present specification is to provide a removable insertion and movement device configured to insert and move the hairpins 255, 255-R, 255-IVP into the circumferential storage means 300, 300', 300" during the process of assembling a stator or rotor winding 100 including one or more sectors 100-CI, 100-CIN extending circumferentially about a winding axis 50. system 400, 400 II , 400 IV , 600, each sector including one or more layers, each layer being comprised of a circumferential array of hairpins, each hairpin including a head end and one or more legs having respective free insertion ends. , take Removable insertion and movement means is as above .

[0293] All of the above also applies to hairpins with more than two legs, but there is a limit to the total pitch; beyond 90°, radial insertion quickly becomes jammed and vertical insertion is required.

[0294] Two or more of the above mentioned parts (elements, devices, systems) may be freely associated and considered as a kit of parts in accordance with this specification.

[0295] Although preferred embodiments have been described and variations of the present invention have been proposed, it is understood that those skilled in the art can make modifications and variations without departing from the relevant scope of protection, as defined by the appended claims.

Claims

1. A system for assembling a stator or rotor winding (100), comprising: the winding includes one or more sectors (100-CI, 100-CIN) extending circumferentially about a winding axis (50), each sector including one or more layers, each layer including a circumferential array of hairpins (255, 255-R, 255-IP, 255-IVP), each hairpin including a head end and two legs having respective free insertion ends; The assembly system is - comprising circumferential storage means (300, 300', 300") for the hairpins (255, 255-R, 255-IP, 255-IVP), The circumferential storage means extends circumferentially as a single block and defines a set of spaces or slots (350, 350', 350") configured to receive the legs of the hairpins, the angular distance between two slots being called the slot pitch according to the prior art; The assembly system also - removable insertion and displacement means (400, 400 ＩＩ , 400 ＩＶ ), the insertion and movement means being separate from the circumferential storage means (300, 300', 300") and including two openings (665A, 665B) for inserting the two legs of the hairpin; The assembly system also - the removable inserting and moving means (400, 400) is moved in such a way that the circumferential storage means advances in the approaching direction towards the removable inserting and moving means; ＩＩ , 400 ＩＶ Relative rotation means configured to rotate the circumferential storage means (300, 300', 300") relative to one another, the relative rotation means are adapted to effect a rotation of one or more slot pitches about a rotation axis (50) coinciding with the axis of the circumferential containment means (300, 300', 300"), The two openings (665A, 665B) are configured such that, in use, a first leg of an inserted hairpin is located forward relative to the approach direction and a second leg is located backward relative to the approach direction; - removable insertion and displacement means (400, 400 ＩＩ , 400 ＩＶ , 600) includes a first portion (400A, 600A) and a second portion (400B, 600B) having first and second circumferential extension directions and first and second axial extension directions, respectively; the first portion (400A, 600A) and the second portion (400B, 600B) are configured such that their axial extension direction is parallel to the axis of rotation (50) and they can be positioned outside the circumferential storage means (300, 300', 300") at a radial distance from the axis of rotation (50) that is greater than the radial distance of the sectors (100-CI, 100-CIN); the first portion (400A, 600A) has a first circumferential end (410, 610A), a second circumferential end and a first connector for connecting the first circumferential end and the second circumferential end, the first circumferential end (410, 610A) increasing in thickness radially outward in a direction towards the second circumferential end in a cross section perpendicular to the axis of rotation (50); the first portion (400A, 600A) has, at the first connecting body, radially inwardly, a distal taper (430, 680A1) towards the first circumferential end, the thickness of which increases radially inwardly in a direction towards the second circumferential end, in a cross section perpendicular to the axis of rotation (50); the second portion (400B, 600B) has a first circumferential end (420, 610B) and a second circumferential end, and further has a second connecting body between the first and second circumferential ends, the connecting body having, radially inwardly, a proximal taper (421, 650B1) to the second circumferential end, the thickness of which increases radially inwardly in a direction towards the first circumferential end, in a cross section perpendicular to the axis of rotation (50); The first circumferential end (410, 610A) of the first portion (400A, 600A) is aligned with the hairpin (255) of the sector to which it corresponds in the approach direction. １ , 100 Ｉ , 100-CI-2) radially outwardly, and may be positioned, in use, to the positions of the first (400A, 600A) and second (400B, 600B) parts, as well as the positions of the distal taper (430, 680A1) of the first (400A, 600A) and the proximal taper (421, 650B1) of the second (400B, 600B) parts, are predetermined such that, in use, upon activation of the relative rotation means, a hairpin inserted in the two insertion openings (665A, 665B) is inserted radially into the sector; system.

2. The first circumferential end (410, 610A) of the first portion (400A, 600A) and the first circumferential end (420, 610B) of the second portion (400A, 600B) have a surface (410S, 610A1) facing the rotation axis (50), and are arranged at a predetermined distance from the rotation axis (50) so as to guide and store, in use, a hairpin of a previous sector that has already been inserted, and are removable insertion and movement means (400, 400′, 400″) as the circumferential storage means (300, 300′, 300″) rotate relative to each other. ＩＩ , 400 ＩＶ , 600) The system of claim 1 .

3. The first part (600A) and the second part (600B) are identical in shape but have a mirror image configuration, the first part and the second part are separate and the position of the first part and the second part are maintained by support means and adjustment means.

3. A system according to claim 1 or 2.

4. the first portion (600A) has, in the first connecting body, a radially inward proximal taper (650A1) relative to the first circumferential end (610A) which, in a cross section perpendicular to the axis of rotation (50), decreases in thickness radially inward in a direction towards the second circumferential end, the second part (400B, 600B) has, in the connecting body, radially inwardly, a distal taper (680B1) relative to the first circumferential end (610B) which, in a cross section perpendicular to the axis of rotation (50), decreases in thickness radially inwardly in a direction towards the first circumferential end; the proximal taper (650A1) of the first portion (600A) and the proximal taper (650B1) of the second portion (600B) end in respective radial and circumferential storage elements (660A, 660B, 661A, 661B) of the hairpin forming two openings (665A, 665B), each circumferential storage element (660A, 660B, 661A, 661B) having an inner radial extension and being integrally provided along the circumferential extension of the first and second portions before the respective first circumferential ends (610A, 610B) and at a height along their axial extension which is further than the height of the respective first circumferential ends (610A, 610B) relative to the storage means; The system of claim 3.

5. the second circumferential end (680A) of the first portion (600A) and the second circumferential end (680B) of the second portion (600B) have respective chamfers (680A3, 680B3) in the axial direction (50) configured to radially guide the hairpin during use until it is located within the sector; 5. A system according to claim 3 or 4.

6. The means for supporting and adjusting the position of the first and second portions is configured to position the first and second portions relative to one another to insert both hairpins and reverse hairpins on different layers and crowns. A system according to any one of claims 3 to 5.

7. Removable insertion and movement means (400, 400 ＩＩ , 400 ＩＶ ) are made integrally, the connecting body of the first portion, the second circumferential end of the first portion, the connecting body of the second portion, and the second circumferential end of the second portion form a shaped bridge (480); the first end of the second portion has an axial surface (422) that, in use, faces the axis of rotation (50) and is located a distance therefrom corresponding to a thickness of the crown, and the first end of the second portion does not increase in thickness radially outwardly in a direction toward the second circumferential end of the second portion; A system according to any one of claims 1 to 6.

8. the opening is part of a bifurcating pit having a common portion (440U) configured for one leg of a standard hairpin or a reverse hairpin, and in a contiguous manner a first portion (440S) for the other leg of the standard hairpin and a second portion (440R) for the other leg of the reverse hairpin; The system of claim 7.

9. the insertion means and the removable insertion and movement means are adapted to rotate about a rotation axis (50), while the circumferential storage means (300, 300', 300") are fixed; A system according to any one of claims 1 to 8.

10. The circumferential storage means (300, 300', 300") is configured to rotate about an axis of rotation (50), while the removable insertion and movement means is fixed. A system according to any one of claims 1 to 9.

11. A method for assembling a stator or rotor winding (100), comprising the steps of: The winding includes one or more sectors (100-CI, 100-CIN) extending circumferentially about a winding axis (50); Each sector includes one or more layers; Each layer contains a circumferential array of hairpins (255, 255-R, 255-IP, 255-IVP), The hairpin includes a head end and one or more legs having respective free insertion ends; The method comprises the following steps: A. Providing a system according to one or more of claims 1 to 10; B. Insertion and Transfer Means (400, 400 ＩＩ , 400 ＩＶ 600) into respective regions of the circumferential containment means (300, 300', 300''); C. actuating a rotating means of the circumferential storage means through one or more slot pitches; D. Repeat steps B and C until the sector is completed, and then the entire winding (100) is completed, inserting and moving means (400, 400 ＩＩ , 400 ＩＶ , 600) is used for inserting the last hairpin of each sector; Including, In step D, when the last hairpin of the sector is inserted, the inserting and moving means (400, 400 ＩＩ , 400 ＩＶ , 600) are removed and inserted into the respective areas of the new sectors. method.

12. - the windings are assembled starting from the innermost sector and moving gradually to sectors of larger diameter; - one or more reverse type hairpins are inserted during the construction of the outermost sector between each pair of consecutive sectors at the start of the assembly of the outermost sector of the pair; Before inserting the reverse type hairpin (255-R), the circumferential storage means (300, 300', 300") and the inserting and moving means (400, 400) are ＩＩ , 400 ＩＶ , 600) are aligned relative to one another to define a minimum area for inserting a reverse-type hairpin into the slot; - as soon as the reverse hairpin is inserted, a relative rotation of the circumferential storage means (300, 300', 300") according to the slot pitch takes place; and As soon as one or more hairpins of reverse type are inserted between two consecutive sectors, steps F and G are carried out in which the hairpins are not of reverse type; The method of claim 11.

13. The hairpins include two pairs of reverse hairpins (255-R) and multiple non-reverse hairpins (255, 255-IVP), Two pairs of reverse hairpins (255-R) are inserted into the winding (100) at a predetermined mutual angular distance; All sectors of the winding are first assembled with the non-reverse hairpins (255, 255-IVP), leaving the necessary space for the reverse hairpins (255-R), Next, the reverse hairpin is performed in two steps: The radially outermost sector of the sector pair is provided with removable insertion and displacement means (400, 400 ＩＩ , 400 ＩＶ , 600) by a radial amount equal to the radial dimension of the horizontal cross section of the leg of the reverse hairpin (255-R) in the insertion position; - the radially innermost sector of the sector pair is displaced towards the winding axis (50) by a radial amount equal to the radial dimension of the horizontal cross section of the leg of the reverse hairpin (255-R) in the insertion position; between pairs of sectors by The method of claim 12.

14. The predetermined mutual angular distance is 180°. The method of claim 13.

15. Steps B and C are performed for the parallel hairpin (255-P), and repetitions of step D are performed until the last parallel hairpin insertion is not missing, after which the following steps are performed: - removable insertion and displacement means (400, 400 ＩＩ , 400IV, 600) starting with the first hairpin inserted and ending with one of the next hairpins inserted; - maintaining a second sector portion at a final theoretical diameter, the second portion being complementary to the first sector portion; - inserting the last parallel hairpin with its legs at a given angle to the winding axis (50); - bringing the first sector portion back into contact with the second sector portion; is executed, The method according to any one of claims 11 to 14.

16. For parallel hairpins (255-P), the predetermined angle, each of which consists of two hairpins, is between 3 and 7 degrees. The method of claim 15.

17. The system according to any one of claims 3 to 5 is used, one or more hairpins (255) of progressively smaller pitch are inserted into the circumferential storage means (300, 300', 300"), starting with the hairpin with the smaller pitch, always before the hairpin with the larger pitch (255A); for each hairpin of the one or more hairpins (255) with progressively smaller pitch, the first and second portions (610A, 610B) are displaced from one another to accommodate each hairpin; The method according to any one of claims 11 to 16.

18. The system according to claim 10 is used, assembly of the overlap hairpins (255, 255A) in the overlap winding (100) with a relative rotation of at least one slot pitch in the circumferential storage means (300, 300', 300"), said relative rotation being either clockwise or counterclockwise as viewed from the insertion side in the circumferential storage means as a function of the bending of the bridge-like hairpin connectors of the overlap hairpins (255, 255A); 20. The method of claim 17.

19. The first and second portions are positioned and / or displaced to widen outwardly and / or the first sector portion is pushed radially inward starting from the first inserted hairpin and / or the second sector portion is pushed radially inward starting from one of the next inserted hairpins and / or the second sector portion is pushed last. The method according to any one of claims 11 to 18.

20. configured to insert and move hairpins (255, 255-R, 255-IVP) in circumferential containment means (300, 300', 300") during a process of assembling a stator or rotor winding (100) including one or more sectors (100-CI, 100-CIN) extending circumferentially about a winding axis (50); Each sector includes one or more layers; Each layer is composed of a circumferential array of hairpins, Each hairpin includes a head end and one or more legs having respective free insertion ends; A removable insertion and movement means according to any one of claims 1 to 10, Removable insertion and movement device (400, 400 ＩＩ , 400 ＩＶ , 600).

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