A removable device for loading and handling basic conductors for assembling stator or rotor windings

Abstract

The present invention relates to a removable device (500) configured to load, handle, and insert basic conductors (255, 255-R, 255-IP, 255-IVP) into circumferential storage means (300, 600), each basic conductor including a head end and one or more legs each having a respective free insertion end, and the removable loading and handling device (500) being configured to assemble a stator or rotor winding (100) consisting of one or more sectors (100-CI) extending circumferentially around a winding shaft (50), each sector including one or more layers, each layer consisting of a circumferential arrangement of basic conductors, the device including: first (521) and second (522) counter-molds configured to define a storage volume (520l1, 520l2, 521, 522) for the basic conductors, the first and second counter-molds each having a portion extending along an axial direction parallel to the aforementioned winding shaft (50) in use, the device also including loading means (530, 540) for the basic conductors into the aforementioned storage volume, the aforementioned storage volume including a terminal volume (500F) of the basic conductors with respect to the first and second counter-molds, the aforementioned terminal volume (500F) being configured to slide the basic conductors along the aforementioned axial direction (z) until inserted into circumferential storage means (300, 600) within a sector (100-CIN) of the one or more sectors (100-CI) being assembled.

Description

Technical Field

[0001] The present invention relates to a removable device for loading and handling basic conductors for assembling stator windings or rotor windings.

Background Art

[0002] Generally, in applications such as generators and motors for hybrid electric vehicles (HEVs), for example, stator and rotor windings are composed of a plurality of bar-shaped conductors that are bent and interconnected in various ways to obtain electrical windings, also called "bar windings". It is known to provide stators and rotors of electrical machines. The aforementioned bent bar-shaped conductors are also called "hairpin conductors" or simply "hairpins". Bar windings may be composed of one or more groups of concentric windings, sometimes called "crowns", and each group of windings is itself already a winding ("winding set").

[0003] In particular, windings having hairpins with a circular cross-section (also called "round wire conductors"), or windings having hairpins with a rectangular cross-section, or even conductors whose cross-sectional shape changes along the length (for example, round conductors that are made rectangular in the portion stored in the slots of the stator or rotor) are known in the prior art. In this regard, a "rectangular" or "square" conductor wire means herein a wire having four substantially flat sides, each side being joined to an adjacent side typically by a rounded edge. Bar-shaped conductors having a trapezoidal cross-section are known.

[0004] The aforementioned bar conductor is usually preformed by starting with a straight bar conductor and bending it into a "U" shape or a "P" shape. U.S. Patent No. 7,480,987 describes an example of a method for preforming a straight bar conductor to form a hairpin. The preformed conductor in a "U" or "P" shape is often referred to as a "preformed basic conductor" in the art, and typically has two adjacent legs of equal or different lengths, each leg having a free end portion and an opposite end portion connected to the other of the two legs by a bridge-like connection portion. Since the ends protrude when inserted into the rotor or stator, they will hereinafter be referred to as the "free protruding portion" and the "opposite side connecting protruding portion". The protruding portion can also be referred to as the "head portion" or the "bridge-like connecting portion". The "head portions" of the legs of the same hairpin are combined to form a so-called "bridge-like connecting portion".

[0005] Referring to FIG. 1(a), the hairpin 255 is preformed from a straight hairpin (not shown) by bending it to form a first leg 255a having respective free protruding end portions 255aE and a second leg 255b having respective free protruding end portions 255bE. The bending operation simultaneously forms a bridge-like connection portion 255c between the two legs 255a, 255b. In this example, the preformed hairpin is in a flattened "U" shape. For example, in order to form the stator of an electromechanical machine, it is known to apply two different types of twisting to a preformed hairpin in a "U" or "P" shape.

[0006] The stator or rotor core of a radial magnetic flux electric machine is substantially a ring having two flat surfaces and two cylindrical surfaces 、2 perpendicular to one flat surface and parallel to the rotation axis of the rotor of the electromechanical device and having a straight generatrix. Hereinafter, the radial direction, the circumferential direction, and the axial direction are, unless otherwise specified, Rotation of the rotor of the electromechanical deviceRefer to the shaft. One of the two cylindrical surfaces at least partially delimits a set of slots adjacent to the air gap of the electromechanical machine to which the aforementioned stator or rotor belongs and in which the straight portions of the windings are stored. These two flat surfaces are divided into an insertion surface or side surface and a surface or side opposite the insertion surface. The portion of the winding protruding from the aforementioned core is called a header. The ends of the free portions of the conductors belong to the headers protruding from the surface opposite the insertion side, and most of them are the targets for welding. If there are protrusions bridged to the legs inserted into the stator slots in the winding, they belong to the headers protruding from the insertion side. Hereinafter, the portions protruding from the insertion side are called protruding portions from the insertion side regardless of whether they are bridged or free ends.

[0007] The stator or rotor core region between a slot and an adjacent slot is called a tooth. The number of teeth is equal to the number of slots. The connection part of the core teeth that constitutes part of each slot and is located on the opposite side of the slot opening (if any) on the air gap of the machine is called a yoke.

[0008] The slots can be divided into an array of positions where the legs of the basic conductors can be arranged. The conductors stored at the same radial position as the slots define a so-called winding layer.

[0009] In the first type of twist, also called "twist at the insertion side", the preformed basic conductors are properly inserted into the corresponding pockets or "slots" aligned radially provided in a twisting device adapted to deform such conductors after insertion. The twisting device is used to substantially spread the legs in a "U" or "P" shape, and after removing the conductors from the device, the two legs of each conductor can be inserted into a corresponding pair of slots in the stator core. These slots are angularly offset from each other by a predetermined distance substantially equal to the angular distance between the slots into which the legs are to be inserted next, and are radially separated by a radial distance between the slot positions occupied by the legs.

[0010] Although not limited thereto, for example, starting from a preformed hairpin as shown in FIG. 1(a), by spreading the legs 255a, 255b and forming the bridge-shaped connection part 255c, a hairpin having a shape suitable for insertion into a stator (or rotor) is formed so as to have the shape shown in FIG. 1(b), for example. The reference numeral 255p indicates the pitch of the hairpin, that is, the linear distance or angular distance between the legs, or the distance converted to the slot pitch. Also in this case, it is worth noting that the central top 255c2 of the formed hairpin is a zone where the cross-section of the conductor rotates 180° with respect to the median surface of the hairpin (the surface passing through the inside of the hairpin and including the two legs). This rotation is effective for the layer replacement (slot position exchange) in the laminated hairpin defined later, so that compared with the case where the same layer extends in parallel without exchanging the slot position when shifting from one leg to the other leg, the eddy current circulating at the end of the layer when the layers are welded can be reduced.

[0011] The patent application published as US2009 / 0178270 describes an example of a twisting method on the insertion side for twisting with a uniform pitch after inserting a preformed bar-shaped pin into the pocket of a twisting device. In this case, the hairpin has a rectangular cross-section.

[0012] According to the prior art, referring to FIG. 2, the hairpin can also be obtained by molding. In this process, in a system of the punch and die type, a straight conductor is pressed against the contrast. FIG. 2(a) shows such a molded conductor, which does not have a cross-section that rotates with respect to the central plane of the hairpin.

[0013] It is possible to apply a so-called "welding side twist" to this formed hairpin or, alternatively, to the preformed and expanded hairpin obtained as described above. In this case, it is possible to introduce a "step-shaped" shape to the protruding portions of the legs 255a and 255b. For example, as shown in Fig. 2(b), the leg 255a has a first straight portion 255a1, a stepped portion 255a2, and a second straight portion 255a3 (substantially corresponding to the portion 255aE in Fig. 1).

[0014] Referring to Fig. 3, the shape of the insertion-side protrusion for the formed hairpin, i.e., the bridge-shaped connection portion 255c, may include three portions 255c1, 255c3, and 255c2 that start from the connection portion with the second leg 255b and end at the connection portion with the first leg 255a (hidden in Fig. 3). The portion 255c1 has a main extension direction B and a radius of curvature RB, the portion 255c3 has a main extension direction A and a radius of curvature RA, and the portion 255c2 has a main extension direction C (and in some cases, a curvature not shown). Hereinafter, the portion 255c2 is called the "layer change bending portion". In fact, thereby, the head and legs of the hairpin are on different layers when inserted into the respective slots of the stator pack. The reference number α1 indicates the angle between the direction A and the direction C, the reference number α2 indicates the angle between the direction A and the direction B, the reference number α3 indicates the angle between the direction B and the direction C, and is equal to the sum of the angles α1 and α2. This is only one of the final possible shapes of the hairpin, and all other shapes having different portions and shapes of both the bridge-shaped portion and the legs are usable by the apparatus and method according to this specification.

[0015] There are also conductors defined as "reverse" conductors (not shown), which are hairpins having a bending direction at the bridge-shaped connection portion opposite to that of most of the hairpins forming the same winding. These are used to go from the last layer of one crown to the first layer of the next crown.

[0016] Furthermore, referring to FIG. 4A, there is a layered (“stranded”) hairpin where the cross-section is inverted at the bend point (FIG. 4A(a)) and the positions occupied by the layers are exchanged. As can be seen from the type of hatching of the cross-section in FIG. 4A(a), due to the aforementioned inversion, i.e., the exchange of positions, the upper layer of the pair of layers in the left slot is below the other layer in the right slot. In another form of the hairpin, the transposition can be continuous along the portion of the hairpin housed within the slot (FIG. 4A(b); US 3837072). The variant shown in FIG. 4B is a layered hairpin without inversion as shown in US8552611B2 (layered hairpin 4 having a plurality of hairpins 42 each having a leg 41 and a head end 42a with a bend). FIG. 4C (obtained from FIG. 6 of patent US6,894,417B2) shows a variant of the arrangement of the legs of a double-crown-wound layered hairpin at different positions within the slot. The reference letters A and B indicate the crowns to which the legs shown within the slot belong (belonging to different hairpins).

[0017] Here too, there are pins called “I-pins”, i.e., pins that are stored in a single slot and have a portion where the free end protrudes from both flat surfaces of the stator core when stored in the slot. FIG. 4D shows an example of an I-pin. The I-pin does not necessarily have all the direction changes shown in the figure and can have none 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 conductors protruding from the slot or to a third element (bus bar, eyelet, etc.) or can function as a phase terminal. This portion can undergo a “weld side” type of bend. Examples of I-pins can be found in the hairpins shown by reference numbers 81-83 in document US7622843B2. The “W-shaped conductor” is also known. For example, see again patent US7,622,843B2 and FIG. 4E where the distance between the legs is N slots. The W-shaped conductor can be formed by welding a shaped hairpin to one I-pin or by welding a fourth conductor to three I-pins. Repeating, the W-pin does not necessarily have all the direction changes shown in the figure and can have none and can also be bent at the output side of the hairpin winding assembly drum.

[0018] Referring exemplarily to FIG. 4F (obtained from US10749399B2), there are also so-called "inverted hairpins" 255-IVP, i.e., hairpins that can be formed by spreading the legs (rather than by the above-described insertion-side twisting method) or formed by a "press & die" system, characterized in that the legs in each slot occupy the same radial position, i.e., belong to the same layer. Accordingly, the ends on the twisting side are bent in the same direction. In practice, the protrusions on the side of the bridge-shaped connection can be bent in the same tangential direction or take a V-shape. At least two layers of variable bending may be required at the connection part.

[0019] Finally, there are hairpin pairs of homologous legs belonging to different layers (FIG. 4G) or the same layer (FIG. 4H), which are configured to be nested and dimensioned.

[0020] Hereinafter, all "hairpin" types, I-pins, and W-pins are included in the definition of "basic conductor".

[0021] After the first type of twisting or after being formed, the basic conductor is generally pre-assembled in a winding set as described above. The pre-assembly device generally has a set of slots equal in number to the slots of the stator associated with the winding for inserting the legs of each hairpin, and generally differs from the twisting device.

[0022] Next, the winding set is inserted en masse into the slots of the stator core from the first side of the stator core (the so-called "insertion side" or "insertion surface"), and the free portions of each protrude from the second side of the core opposite the first side (the so-called "welding side" or "connection side" or "welding surface" or "relief surface").

[0023] Based on the specific winding pattern to be obtained, the free part of the basic conductor protruding from the side opposite to the insertion side can, for example, after being inserted into a pocket made in a suitable twisting device, undergo a second type of twisting, also called "twisting on the welding side". Here, the twisting device aims to bend or twist the free part of the conductor to properly form the free part, so that an appropriate electrical connection between the conductors can be obtained to complete the winding. A patent application published as US2009 / 0302705 describes an example of the twisting method on the welding side of the above type.

[0024] Electrical winding assembly systems for stators and / or rotors are known. Systems for transferring windings and inserting them into stator packs are also known.

[0025] For example, International Patent Application WO2019207448A1 describes an apparatus for pre-assembling a stator winding of an electrical machine including a plurality of basic conductors (see FIG. 5 of this specification). However, such an apparatus is configured to process and insert only one type of hairpin into the stator pack at a time. Therefore, the insertion system has to be manually changed according to the type of hairpin to be inserted, which significantly increases the cycle time of the apparatus, and as a result, there is a problem that the efficiency of the entire system decreases.

[0026] Patent document US2020336054 describes an alignment device that aligns winding segments to form aligned windings, including a cylindrical containment for hairpins provided with slots. The containment has radial teeth rotatable with respect to the cylinder body. The cylindrical containment further has an internal inlet provided in the internal cylinder, an external inlet provided in the external cylinder, and several guide walls provided between these openings. Such guide walls are below the plane of the rotatable radial teeth. A device for inserting hairpins into slots above the plane of the rotatable teeth is described, and this device is configured to insert hairpins one by one into predetermined slots at a predetermined timing and to enable rotation of the teeth between one insertion and another. The morphological configuration of such an insertion device is not described. This device includes the same problems as described above, that is, this device is configured to process and insert only one type of hairpin into the stator pack at a time. Therefore, the insertion system has to be manually changed according to the type of hairpin to be inserted, which significantly increases the cycle time of the device, and as a result, there is a problem that the efficiency of the entire system decreases.

[0027] Patent document EP3700071A1 describes a system for simultaneously pre-assembling hairpins in a stator winding. This system includes a containment having hairpin slots formed by radially retractable teeth. The hairpins are first inserted into positions corresponding to all necessary slots, and then the radial teeth are rotated about the axis of the containment so that the same hairpins are simultaneously positioned in the assembled crown as they rotate. Again, the insertion means is not described in detail, and the simultaneous assembly of hairpins does not allow different types of hairpins to be inserted and included in the same pre-assembly process.

[0028] Patent Document JP2004072839 describes a system provided with a slot storage container in which all the crown hairpins are inserted before performing the rotation that brings the crown hairpins to the crown position. However, in this case, no radial teeth are provided, and this system is subject to the same limitations as those of the other documents described above.

[0029] Patent Document WO2018039806A2 describes a method and a system for assembling hairpins to a stator core. The slot storage container is divided into three parts, and hinges are provided to enable relative rotation of the three parts. The hairpins are inserted independently into the three storage parts, and then the storage parts are closed to form a complete winding. It is obvious that this arrangement is very complicated and has a long cycle time for the insertion into the three separate container parts and the rotation of such parts. Although it is theoretically possible to use different types of hairpins, the efficiency of the system is low and the cost is high. Furthermore, due to the complexity of the system, the wear is severe.

[0030] US2020 / 343797 discloses an alignment device that aligns coil segments in a ring to form an aligned coil. Each of the coil segments has a pair of first and second legs. The alignment device includes an outer jig and an inner jig. The outer jig has radially arranged partition members. The partition members are arranged at intervals such that each first leg of the coil segment can be inserted between a pair of circumferentially adjacent partition members. The inner jig has a hole-forming member arranged radially inside the partition members of the outer jig. Each of the hole-forming members has a hole into which one of the second legs of the coil segment is inserted. Further, the hole-forming member is configured to be rotatable relative to the outer jig in the circumferential direction and movable in the radial direction.

[0031] Japanese Patent Application Laid-Open No. 2012-151996 discloses a method for annularly arranging coil segments, including a step of sequentially guiding a plurality of coil segments each formed in a substantially U shape and having a pair of legs and a connecting portion connecting the legs, and arranging them annularly while overlapping the coil segments. In the annular arrangement step (annular arrangement tool), insulating paper is inserted into a portion corresponding to the connection portion between the pair of legs of the coil segment.

[0032] As the time cycle, accuracy specifications, and further specifications regarding cost and ease of maintenance are becoming increasingly stringent, there is a felt need to assemble all the windings in one system to facilitate inserting the windings into the stator pack.

SUMMARY OF THE INVENTION

[0033] An object of the present invention is to provide an apparatus for loading and handling basic conductors that solves and overcomes all or some of the drawbacks of the prior art.

[0034] The present invention relates to an apparatus for loading and handling basic conductors for the assembly of stator windings or rotor windings, in accordance with the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Next, the present invention will be described non-limitingly with particular reference to the figures of the accompanying drawings.

[0036]

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Embodiments for Carrying Out the Invention

[0037] In this specification, it is specified that, without limitation, those of ordinary skill in the art can combine the elements of different embodiments to provide further embodiments by respecting the technical idea of the present invention so as to be easily understood from this specification.

[0038] Furthermore, this specification also refers to the prior art regarding the implementation of detailed features not described, such as elements of low importance that are commonly used in the prior art in the same type of solution.

[0039] When an element is introduced, it is always understood that there can be "at least one" or "one or more".

[0040] When a list of elements or characteristics is shown in this specification, the findings according to the present invention are understood to be "including such elements" or alternatively "consisting of such elements".

[0041] When listing characteristics within the same sentence or bulleted list, one or more of the individual characteristics can be included in the present invention without associating them with other characteristics on the list.

[0042] Two or more parts (components, devices, systems) described below can be freely associated and regarded as a component kit according to the present invention.

[0043] Insertion and handling system According to the definition of the present invention, the stator or rotor winding 100 can be composed of one or more sectors 100-CI, 100-CIN extending circumferentially around the winding axis 50, each sector including one or more layers, and each layer consisting of a circumferential arrangement (which may be partial) of basic conductors (see FIGS. 7 to 10b).

[0044] The first embodiment of the present invention includes a wedge-shaped (circumferential) guide and storage end 410, an opposite circumferential storage end 420, and a wedge-shaped inner circumferential end (or "bevel" or "taper") 430 that functions as a guide for a basic conductor inserted into a winding, a removable insertion and handling device 400 (for example, as shown in FIGS. 6, 7 to 10, 29, 30). The removable insertion and handling device 400 can be configured to insert all types of hairpins except I-pins. In the case of basic conductors such as W-pins and parallel hairpins, the removable insertion and handling device 400 can be adapted with appropriate shapes and excavations for their insertion. After being inserted into the insertion region, the basic conductor is moved to the target region within the winding.

[0045] The wedge-shaped circumferential guide and storage end 410 is an example of one or more components provided in the removable insertion and handling device 400, and the one or more components are configured to cause a cam movement of the basic conductor in the radial direction toward the inside and / or outside of the sector when the associated rotating means operates. The guide and storage end is narrowed in a plane perpendicular to the winding axis 50 in a direction opposite to the relative rotation direction of the circumferential storage means 300. The wedge-shaped guide and storage end 410 is arranged at a predetermined distance from the rotation axis 50 of the circumferential storage means 300 so as to guide and store the basic conductor that has already been inserted into the sector in the winding 100-CI and is supplied toward the removable insertion and handling device 400 during the relative rotation of the circumferential storage means 300.

[0046] The removable insertion and handling means 400 for the basic conductor is, in all embodiments, means for insertion, displacement, and / or orientation (generally, movement), not means for elastic bending: It is impossible to utilize the elasticity of the basic conductor because problems of friction with other basic conductors occur. The removable insertion and handling device 400 can further be made different for each sector or can be made unique with variable dimensions because the dimensions of the basic conductors belonging to each sector are different.

[0047] In fact, although the removable insertion and handling device 400 is illustrated as consisting of a single block in some figures, it will be understood that it can also be made up of several independently movable blocks in order to process basic conductors of different dimensions. In this case, the various blocks are moved and then blocked so that the overall shape of the removable insertion and handling device 400 is fixed during the operation of the device itself. As can be seen, the mutual fixation can be carried out in different ways, either via mutual fixation elements or via different elements that hold the different blocks in their mutual fixation positions. The dimensional configurability of the removable insertion and handling device does not change its functionality, as will be explained below.

[0048] The removable insertion and handling means can be configured to insert the basic conductor along the slot of the storage device and displace the basic conductor inserted into the sector during assembly radially inwards and / or outwards with respect to the radius of the aforementioned sector.

[0049] The removable insertion and handling device 400 is configured such that the basic conductor, which has been gradually inserted previously, is moved radially from a first angular position with respect to the winding axis, at which the basic conductor already inserted into the winding does not yet interfere with the basic conductor to be inserted, to a second angular position with respect to the winding axis corresponding to each of the aforementioned target regions (wedge-shaped inner circumferential end portion 430, described below).

[0050] According to one aspect of the invention, when the last basic conductor is inserted into the sector, the removable insertion and handling device 400 is removed. If the size is changed, the basic conductor can be inserted into each region of the new sector, or else, if not, another removable insertion and handling device of a different size is used for such regions.

[0051] In this step, it is advantageous to arrange the intermediate crown such that the free reverse space SLR required to store the reverse hairpin is aligned with the axis of the reverse hairpin. See the so-called "initial crown alignment". In other words, the circumferential storage means and the removable insertion and handling device are positioned relative to each other so as to define the minimum insertion region of the reverse basic conductor in the aforementioned slot.

[0052] If the device 400 is manufactured only as a single piece, the wedge-shaped inner circumferential end 430 is part of a formed bridge 480 that joins the two circumferential ends of the removable insertion and handling device 400 and is between two recesses or through-holes for insertion in the case of a hairpin (see FIG. 7, which is a view on a plane perpendicular to the axis 50). According to one aspect of the invention, the wedge-shaped inner circumferential end 430 is positioned on the leg of the rear basic conductor relative to the relative rotational direction of the circumferential storage means, and the wedge-shaped inner circumferential end 430 extends in the relative rotational direction. This positioning of the tapered portion can also be maintained in embodiments where the device 400 is not integral.

[0053] Normally, after initially placing the reverse basic conductor (optional), it is possible to start inserting the basic conductor of the standard type 255 into the inner crown 100-CI, for example using the same device as in FIGS. 6 and 27. The first thing to do is to correctly position the hairpin in the through-opening 440U + 440S of the insertion and handling device. This through-opening can be branched as shown to have the possibility of inserting both the standard conductor (inserted into the through-opening 400S) and the reverse conductor (inserted into the through-opening 400R). There is an initial single through-opening portion 440U from which two dedicated through-openings 440S and 440R for the standard conductor and the reverse conductor respectively originate. Note that 440S and 440R are in both cases along the bending direction of the bridge-like connection of the basic conductor.

[0054] As can be seen in FIGS. 8 - 10, once the reverse basic conductor is inserted, the first conductor inserted into the crown continues to be inserted in a standard manner while gradually rotating the circumferential storage container until it contacts the wedge-shaped guide and storage end 410, which extends the crown to be assembled and stores the bridge-like portion 255RT of the reverse basic conductor 255-R. FIG. 10a shows this more clearly with an alternative variant of a different circumferential storage container system 600 that includes a retractable radial element 610, also known from patent application PCT / IB2023 / 052123. FIG. 10b shows a similar situation, but with the insertion and handling device 400 reversed, i.e., the wedge-shaped guide and storage end 410 facing the clockwise rather than the counterclockwise direction. In practice, this process is also operable in the reverse direction.

[0055] According to a specific embodiment of the present invention for the nested hairpin according to FIGS. 11 to 13, a standard basic conductor 255 can be arranged in an insertion hole 465 (in the form of a through-opening) at the upper insertion end 460 of the removable insertion and handling device 400'. Such an upper insertion end can have a (flattened) sleeve shape.

[0056] It should be noted that the through-opening of the insertion and handling device is sized to accommodate a basic conductor (which is a nested conductor in the case of a nested example, but similar recesses are provided for other conductors, see above) having a larger opening angle. To make the process repeatable and safe, it is advantageous to provide a movable storage element (or means) 470 having a unique function of storing a standard basic conductor 255 (with a small pitch) passing through the insertion end 460 (in the form of a sleeve) during the insertion step. In some cases, without these, the basic conductor may be inserted into the wrong "equivalent stator slot". The movable storage container system can include different elements other than 470, although not shown here. A person of ordinary skill in the art can understand from what has been described so far that it can have any shape useful for laterally storing a basic conductor with a small insertion pitch.

[0057] The nested basic conductor may also include two or more hairpins, that is, a group of hairpins with an increasing pitch, and one or more basic conductors with a gradually decreasing pitch, and these also have a pitch that allows a nested structure, that is, a nested structure.

[0058] Referring to FIG. 12(a), in this step, the basic conductor 255 (with a small pitch) is inserted, and then the movable storage element 470 is moved backward, that is, in front of the basic conductor with a large pitch. It is also possible to provide a stop element 466 at the head of the hairpin with a small pitch.

[0059] Referring to FIGS. 12(b) and (c), once the standard basic conductor is inserted and the movable storage container is retracted, it is possible to arrange the nested basic conductor 255A.

[0060] Referring to FIG. 13, the nested basic conductor 255A is inserted, and this basic conductor stops above (head-on) the basic conductor with a small pitch in the insertion and handling device.

[0061] Loading and Insertion Device The removable insertion and handling device 400 described above is part of a larger composite system, which in this specification is referred to as a device for the loading and handling of base conductors.

[0062] The loading and insertion device 500 (or "inserter" or "charger"), shown in Figure 14, is a system that can load, position, and then move a single base conductor in the removable insertion and handling device 400 or 400' (hereinafter, always referring to device 400 to show both embodiments in combination with the loading and insertion device). The loading and insertion device 500 may also include the removable insertion and handling device 400 (401, 402) described herein, which is involved in the actual insertion and handling of the wound base conductor.

[0063] The base conductor reaches a containment volume 500R formed as described below by a transfer system 530 (in one possible embodiment) through a 2D-3D shaping process known per se.

[0064] The loading and insertion device 500 is configured as follows: 1. Move the base conductor from a clearly defined area of the space in the end volume 500F (described below). Generally, with the help of the transfer system 530 and also a brush (not shown in Figure 14), it is possible to confirm that the base conductor reaches a reproducible position defined with a certain error. Such a storage area or volume 500R for the base conductor is shown in Figure 15. The presence of the base conductor in that area is preferably transmitted to all other system components, for example via an inductive presence sensor, to ensure the automation of the entire system. 2. As shown in FIG. 16, corresponding to the through-opening or recess of the removable insertion and handling device 400 such that the basic conductor reaches the end region or volume 500F many times, the basic conductor is positioned by a radial movement with respect to the winding in a direction perpendicular thereto. This step can be carried out by using lateral feeding and positioning rollers 540 and / or a continuous nib 535 moved from the opposite side of the countermold. The nib has the function of supporting the basic conductor along the axis 70 of the inserter (shown in FIG. 14 and actually parallel to axis 50) while the conductor is separated from the guide or chute of the transfer system 530. 3. Insert (or slide) the basic conductor into the removable insertion and handling device 400. Once the basic conductor is positioned, the blade 510 can be used as a presser and inserted using the lateral feeding and positioning rollers 540 and the countermold 520 as a storage container (see FIG. 14). The blade can also have the function of controlling the transfer of the conductor. The reason is that if the basic conductor falls due to gravity but remains blocked in some way, the blade can release it or it may remain blocked, and as a result, it can indicate a malfunction. Further, during this step, the nib 535, if present, rotates downward by 90° by the operation of a suitable gear 545 (on the right side of FIG. 18), and this gear 545 can be moved by the movement of the blade or by utilizing, for example, the rotational movement of the lateral feeding and positioning rollers. Generally, the nib can be retracted linearly in various ways.

[0065] As shown in FIG. 17, the lateral feeding and positioning rollers 540 can be arranged such that the straight line passing through their respective centers is not perpendicular to the radial direction but has an inclination α. Such an inclination corresponds to the bend of the head of the basic conductor. In this way, the rollers thrust the basic conductor uniformly during the processing step. This ensures that the rollers are identical to each other. Conversely, if the centers are arranged on a horizontal line, two different shapes will result.

[0066] In certain embodiments of the loading and insertion device, regardless of the position of the blade 510, due to the presence of vents 525 on the counter mold, the lateral feed and positioning rollers can rotate (see FIG. 26). A vent means a lateral hollow portion of the counter mold for rotatably positioning the roller. In the illustrated embodiment, the rollers have continuous fins 541 that are 180° apart from each other.

[0067] For example, by selecting rollers about 50 mm in length, the counter mold has at least the same amount of hollow portion in the perpendicular direction (in use, it is usually parallel to the axis 70 parallel to the spool 50). This solution is functional, but a problem that may occur when inserting the basic conductor is that the blade may deform after being pushed. The blade 510 functions only after the basic conductor reaches the upper end volume 500F of the removable insertion and handling device 400 and is to be stored in the winding by the rotation of the circumferential storage means.

[0068] To avoid this problem, it is useful to adopt different shapes for the roller fins. In particular, referring to FIG. 18, four fins can be provided in pairs of two at 180°, and each pair is spaced by a central empty space 542. The empty space 542 can have corresponding raised elements on the counter mold 520, thus improving the storage of the basic conductor and increasing the strength of the counter mold itself. Note that the counter mold is provided with a relief 526 in the area of the empty space between the fins of the lateral feed and positioning rollers.

[0069] Positioning of the basic conductor in the case of having a nib Referring to FIGS. 16 to 21, once the basic conductor (definable regardless of the presence or absence of a nib, described later) carried into the storage volume is conveniently guided by the through opening or recess of the removable insertion and handling device 400, the initial theoretical position 500I and the final position 500F (also called the "end volume" occupied by the basic conductor ready to slide down) can be defined inside the storage volume.

[0070] The positioning of the basic conductor from its initial theoretical position 500I to the end volume 500F in the presence of nib 535 can be carried out according to rotational and non-translational motion (by the lateral supply and positioning rollers). In fact, in this way, it is possible to increase the speed of the whole system while increasing the angular position of the supply roller fins and the positioning of the basic conductor. Different positioning modes can be devised due to the different contacts between the roller fins and the strip 255z. Generally, the term strip is used to identify the section of the leg of the basic conductor shown in FIGS. 20 and 21, and includes, for example, the connecting spokes or connecting edges 255y of the extending surface or parallel surfaces 255x.

[0071] In the first positioning mode, for example, as shown in FIG. 21(a) representing the final position of the basic conductor, the first contact or entry of the basic conductor occurs by utilizing the connecting spoke of the strip 255y, while the external storage is ensured by the physical contact between the roller fin 541 and the large surface 255x of the strip.

[0072] In the second positioning mode, the first contact or entry of the basic conductor is carried out by utilizing the maximum surface 255x of the strip, while the storage is made possible by the "point" contact of the roller fin 541 with respect to the connecting spoke 255y of the strip, as shown in FIG. 21(a) representing the final position of the basic conductor.

[0073] In the third positioning mode, the uniform contact between the roller fin 541 and the extended surface 255x of the strip is instead intermediate between the final and the initial positions, as shown in FIG. 21(c) representing the final position of the basic conductor.

[0074] There can be advantages and disadvantages in the various situations described above, but the basic advantage of the present invention is that the rollers can be positioned so that the first contact of the strip can be whatever it may be, while ensuring that the final storage position is always on either the long side or the short side of the strip.

[0075] Initial theoretical position and uncertainty region As described above, the basic conductor is conveniently positioned at a position that probably coincides with the initial theoretical position 500I before being positioned in the through openings 440U, 440S, 440R of the removable insertion and handling device 400. Positioning the basic conductor at its initial theoretical position is made possible by the presence of a transfer system 530 of appropriate size and, for example, with the help of a brush-type braking system.

[0076] In reality, the basic conductor can always occupy different positions within the volume (storage or processability) based on the maximum deviation possible defined by the transfer system. Therefore, it is possible to know and define the maximum deviation and various initial positions that the basic conductor can take in order to ensure processability in subsequent operations.

[0077] The first position that the basic conductor can take can be associated with a bundle of straight lines passing through a point equal to the midpoint of the conductor at the theoretical initial position as seen from above.

[0078] The size of the cross-section of the storage volume converted to the height h of the rectangle in Fig. 22 is related to the difference between the distance D between the centers of the legs of the strip at the theoretical initial position with respect to an amount Δ equal to the distance between the centers of the two lower guides 530b, 530c of the transfer system 530.

[0079] This formulation makes it possible to determine the size of the chute that can correctly position the basic conductor at the theoretical initial position 500I. In the details of the formulation, the size D is affected by the forming process and the length of the basic conductor and generally includes an error.

[0080] As shown in Figs. 23 - 24, there is another type of variation caused by the vibration of the basic conductor along the chute that supports the head of the conductor. However, these vibrations can be controlled by appropriately selecting the dimensions of the upper guide. Such variations can be taken into account when defining the storage volume.

[0081] Positioning of the basic conductor in the absence of nibs In a possible embodiment of the present invention, the loading and handling of the basic conductor can be performed without using the nib 535.

[0082] In the absence of nibs, it is preferable that the transfer system 530 is arranged near the countermold 520 so that the basic conductor does not fall by gravity before being placed in the removable insertion and handling device 400.

[0083] When using nibs, it is convenient to make the minimum distance Xmin between the nib and the countermold equal to the height Hpiattina of the strip 255z (i.e., the thickness smaller than the cross-section), as shown in Fig. 24. According to the following formula.

[0084]

Number

[0085] In practice, it is convenient to leave a safety factor ε such that it becomes as follows in the formula below.

[0086]

Number

[0087] Instead, since there is no nib, the basic conductor is not supported vertically but only stored horizontally over a supply section equal to X and is guided by the movement of the lateral supply and positioning rollers 540.

[0088] Regarding the evaluation of the positioning mode and storage volume of the basic conductor, the same considerations as those made above for the loading and insertion device 500 are also valid in the case where there is a nib.

[0089] Cycle time of the loading and insertion device The cycle time of the loading and insertion device 500 can vary according to different possible embodiments of the present invention: I. In a first embodiment called Case 1, the lateral supply and positioning rollers 540 capable of supplying the basic conductor perform rotational movements in opposite directions in one direction with respect to each other; in other words, the lateral rollers rotate 360° (the rotation ends after the basic conductor slides vertically); II. In a second embodiment called Case 2, the lateral supply and positioning rollers 540 capable of sending the basic conductor perform rotational movements in opposite directions alternately with respect to each other; in other words, the lateral rollers rotate within an interval of less than 180°; III. In a third embodiment called Case 3, since the blade 510 ensuring the vertical movement (insertion into the device 400) of the basic conductor presses about 2 / 3 of the upper surface of the basic conductor, the movements of the lateral rollers and the blade can always occur simultaneously without hindrance; IV. In a fourth embodiment called Case 4, the blade 510 ensuring the insertion of the basic conductor presses the entire upper surface thereof; in this case, due to the problem of mechanical interference, the movement of the lateral rollers and the movement of the blade cannot always occur simultaneously.

[0090] A preferred embodiment of the present invention provides the cycle time shown in FIG. 25, which includes basic conductor supply steps F1 and F2, basic conductor positioning step F3, blade lowering step F4, idle lateral roller rotation step F5, and blade raising step F6, under the above assumptions. Such an embodiment is a combination of case 2-4, i.e., when the roller rotates by an angle less than 180° (which occurs by sweeping the same angle φ for both roller positioning and idling), and when the blade presses only 2 / 3 of the upper surface of the basic conductor, and enables the movement of the blade and the roller to occur simultaneously. Such an embodiment is also advantageous in that the cycle time of the loading and insertion device 500 is shortened, and the surface in contact with the basic conductor during guiding and insertion is reduced, reducing the possibility of damage to the basic conductor and its coating. The following values were obtained in laboratory tests (see FIG. 25):

[0091]

Table 1

[0092] Management of reverse basic conductors As described above, the removable insertion and handling device 400 is configured to insert both a standard basic conductor 255 and a reverse basic conductor 255R. Next, an explanation will be given of the fact that the basic conductor loading and insertion device 500 is configured to guide both the standard basic conductor and the reverse basic conductor toward the removable insertion and handling device 400.

[0093] To fully accommodate both the standard and reverse basic conductors (i.e., over the entire opening angle of the basic conductor), as shown in FIG. 30, the countermold 520 may include two bodies configured to move relative to each other. The first countermold body 521 can be spatially fixed, for example (the body related to the common portion of the two standard and reverse basic conductors corresponding to the through-opening 440U of the removable insertion and handling device 400), while the second countermold body 522 is movable (the body corresponding to the through-openings 440S and 440R of the removable insertion and handling device 400, as shown again in FIG. 27) and can move forward or backward depending on whether the processed item is a standard or reverse basic conductor. Also, the first and second countermold bodies 521, 522 are both independently movable and can also form the storage volume necessary to store the basic conductor multiple times. Such a storage volume can be defined between the first and second countermold bodies 521, 522 and their side walls 520l1, 520l2, which can be the walls of the single-block countermold 520 in the corresponding embodiment. The storage volume is defined with respect to the legs of the basic conductor, and the bridge-shaped connection portion can project from this volume.

[0094] In this embodiment, the blade 510 of the loading and insertion device can be configured to push both basic conductors into their respective recesses 440U, 440S, 440R and can include a fixed blade portion 511 and a movable blade portion 512, as shown in FIG. 30. Again, the blade 510 can include both movable parts 511, 512.

[0095] Some possible embodiments of the present invention that combine different solutions for guiding and inserting both standard basic conductors and reverse basic conductors are shown below.

[0096] Solution 1 Referring again to FIGS. 26 - 29, a first embodiment for guiding and inserting standard and reverse basic conductors will be described. Such a first embodiment can include the following: - A countermold 520 made as a single body and having a shape along the shape and curvature of the basic reverse conductor (thus, for the standard one, there is a non-accommodating portion PNC); - The blade 510 has two parallel end portions 512 and 511, one for the reverse basic conductor and the other for the standard basic conductor, which do not interfere with the insertion system and do not interfere with each other. FIG. 28 shows the blade reinforcement element 515.

[0097] In this first possible embodiment, the portion of the blade that presses the reverse basic conductor has a greater length than the portion for inserting the standard basic conductor. So when the blade system is fully raised and the standard basic conductor has to be inserted, it is the blade itself that functions to store the standard basic conductor, which is about half of the opening angle of the conductor. Further, the portion of the blade common to both basic conductors has the same vertical length as the end portion of the blade related to the insertion of the standard basic conductor, and thus the insertion of the standard basic conductor is facilitated without hindrance.

[0098] It is clear that while the reverse basic conductor is stored over its entire length for the full angle of the opening angle, the standard basic conductor is fully stored only for half of the opening angle, and for the remaining half it is stored by the blade but not along the entire length of the basic conductor (for example, the first 20 - 30 mm measured from the head of the basic conductor).

[0099] As shown in FIG. 29, in this first embodiment, due to how the blade structure is selected, the reverse basic conductor is only pushed through half of the opening angle of the conductor itself and does not push the entire surface of the head so as to act instead of the standard basic conductor.

[0100] In other advantageous embodiments, the blade has a shape with a thickness such that it presses one or more points of each type of basic conductor.

[0101] Solution 2 FIGS. 30 - 32 show a second possible embodiment of the present invention for guiding and inserting the standard conductor and the reverse basic conductor. Such an embodiment can include the following: - Two separate bodies: a countermold 520 including a fixed first and second countermold body 521 and a movable countermold body 522; - A blade 510 including two separate bodies 511, 512 (see FIG. 30); or a body shaped to enter between the first and second countermold bodies 521, 522 and simultaneously press the basic conductor during the insertion step at the cusp of the head portion.

[0102] In this possible second embodiment, the movable part of the countermold, and thus also the movable part of the blade, operates to move relative to the removable insertion and handling device 400 which is fixed.

[0103] The blade can be inserted by pressing the basic conductor along a part of its head or the entire arc of the head, which applies to both standard basic conductors and reverse conductors.

[0104] Due to the two-body countermold system and the presence of two-body or one-body blades, such a solution enables the accurate and complete storage of both basic reverse conductors and standard conductors.

[0105] Solution 3 Figure 35 shows a third possible embodiment of the present invention for guiding and inserting standard and reverse basic conductors. In this embodiment, the countermold is composed of first and second countermold bodies 521 and 522 that are movable independently of each other to adapt to various basic conductors that are loaded and handled multiple times (even with different crowns). An insertion and handling device 400 is also shown.

[0106] Figure 33 shows how it is possible to process all the crowns of the winding through a single loading and insertion device with two independent bodies. This innovative solution avoids using multiple loading and insertion devices, introduces specific movements of the entire loading and insertion device, and enables it to be placed at any time on the layer of crowns formed by them. If the opening angles of the basic conductors are the same, the basic conductors located in the outermost layer tend to have larger circumferential sizes, and these are the ones that determine the dimensions of the countermold. Figure 33 shows different layers of reverse basic conductors contained inside the countermold 520. It should be noted that while the basic conductors located in the outermost layer are well laterally stored by the countermold, the basic conductors located more internally have greater lability. Therefore, there is an error ε that depends on various factors including the height of the strip, the number of strips in one slot, the height of the stator slot, and the opening angle of the basic conductor.

[0107] In such an embodiment, as shown in Figure 34, both standard and reverse basic conductors can be moved, and lateral supply and positioning rollers as described above and resumed below, which are suitable for moving the basic conductors loaded towards the countermold, can be used.

[0108] Returning to FIG. 33, according to one aspect of the present invention, the counter mold or the loading and insertion device can be divided into two independent parts. In this possible embodiment, the loading and insertion device translates radially with respect to the center of the stator pack. In other cases, it can also translate along an axis perpendicular to the axial direction through the center of the loading and insertion device 500 (also called the "loader"). Various movements will be described in detail below with reference to the nested basic conductors (see below), but it should be understood that they are individually applicable to various situations as needed.

[0109] Thus, it should be noted that the basic conductors are well stored and it is possible to process all types of basic conductors (openings of the same angle) for each crown.

[0110] Two-barrel insertion and handling device Referring to FIGS. 35, 36, and 40, the removable insertion and handling device 400 can also be composed of two independent bodies that are integral with the two bodies of the loading and insertion device, as shown in FIG. 35. The same elements as above, for example, the wedge-shaped guide and storage end 410, the opposite storage end 420, the wedge-shaped inner circumferential end 430 for moving the basic conductor when the circumferential storage container rotates, and optionally, if the device is made more symmetrically and can serve for movement in both circumferential directions, a wedge-shaped inner circumferential end 430' similar to the wedge-shaped inner circumferential end 430 is provided. In this case, the end 420 has a shape that is functionally similar to the wedge-shaped guide and storage end 410.

[0111] In this case, the thruster blade 510 also includes two independent bodies (not shown) extending in the axial direction of the winding. Each blade body is configured to push the aforementioned basic conductor, at least a part of the head, and can be configured to rotate independently with respect to the aforementioned axial direction or move radially as described above.

[0112] It is clear that the shape of the part of the wedge-shaped guide and storage end 410 (towards the winding) of the removable insertion and handling device 400 is linked to the shape of the strip and the opening angle of the basic conductor. Furthermore, the shape of the removable insertion and handling device 400 can be such that it can store the basic conductor during the rotation of the hollow pitch with the simultaneous rotation of the basic conductor.

[0113] In this case, there may be interference between the basic element and the conductor, but this interference can be conveniently avoided by providing one or more appropriate bevels with respect to the cross-section of the device. In the upper right of Fig. 36(b), it can be seen how the collision with the sector that has already been inserted and moved radially is avoided by the chamfer 450.

[0114] Management of nested basic conductors Next, some possible embodiments for managing the nested basic conductor 255A will be described in the presence of a single loading and insertion device 500 including independent first and second counter-mold bodies 521 and 522.

[0115] First scenario In a first embodiment of the loading and insertion device 500, as shown in Figs. 37 and 38, for storing standard / reverse basic conductors and for storing standard / reverse basic conductors of different layers, the independent first and second counter-mold bodies 521 and 522 can rotate, and in particular, can rotate in opposite directions to each other. Such a type of operation enables the basic conductor to be stored in a safe and repeatable manner.

[0116] Second scenario In the second embodiment shown in Fig. 39, the independent first and second counter-mold bodies 521 and 522 of the loading and insertion device 500 (not shown for simplicity) form an angle equal to the central straight line 60 perpendicular to the axis 70 along the first straight line 61, and along a second straight line 62 that coincides with the radial direction with the same displacement obtained by the associated displacement means, and can move through two linear motions.

[0117] Third scenario In the third embodiment, again referring to Figs. 39 and 37, the moving straight lines 61 and 62 of the independent first and second counter-mold bodies 521 and 522 can be selected at the opening angle of the nested non-standard basic conductor. Therefore, the first and second counter-mold bodies 521 and 522 of the inserter have the possibility of moving along these two straight lines (the rotation of the two elements in Fig. 37 also has the effect of storing the internal basic conductor).

[0118] The insertion of two basic conductors according to the nested standard sequence can be performed individually, thus sequentially, or simultaneously.

[0119] Inserting two basic conductors simultaneously is advantageous because the legs of the nested basic conductor on top of the standard basic conductor are stored angularly.

[0120] Figure 40 shows an example of a removable insertion and handling device 400 that is divided into two parts for inserting nested basic conductors. Stop elements 466A, 466B are provided in two parts for the two bodies and serve to stop the head of the conductor, but have appropriate bevels that allow the basic conductor to slide radially when the circumferential storage part rotates.

[0121] Final Assembly By combining all of the above concepts, the loading and insertion device 500 can be as shown in Figures 41 - 45, 47 - 49. The loading and insertion device 500 may include the following: - A base plate 550 oriented at a right angle to the shaft 70 such that the entire loading and insertion device 500 can translate axially with respect to the stator pack. This movement is advantageous each time the formation of the winding crown is started and ended; - A transfer system 530 that does not have the above-described nib 535 but can be provided; - First and second counter-mold bodies 521, 522 of the inserter that can move radially and circumferentially by means of a radial electrical axis 551, a pneumatic cylinder 555, and a curved guide 556 and can process standard, reverse, and nested basic conductors in all crowns with a single system. Further details will be described later.

[0122] Basic Conductor Transfer System Here, it will be explained how it is possible to create a versatile basic conductor transfer system 530 that can correspond to and process standard, reverse, and nested basic conductors regardless of which crown they belong to.

[0123] The transfer system 530 of the basic conductor may include three rods, an upper guide 530a and two lower guides 530b, 530c, such that the cross-section is visible at the apex of the triangle.

[0124] The upper guide 530a is integral with the base plate and supports the basic conductor from its tip. The other two lower shoots are always integral with the base plate, but can be translated by a guide system 534 when it is necessary to process products containing nested basic conductors.

[0125] Figure 44 shows how the handling (i.e., horizontal movement on the XY plane) of the two lower guides 530b, 530c that guide the legs of the basic conductor is performed. The ball joint 534 is provided for such movement. Further, in at least the transition from a standard basic conductor to a nested basic conductor, a system can be provided that can adjust the distance between the two lower rods of the chute. In fact, it is understood that the greater the distance of the ball joint from the center of the stator pack, the greater the magnitude of the movement.

[0126] As can be seen from Figure 45, the quantity D depends on the circumference to which the joint 536 is attached. In the transition from a standard basic conductor to a nested conductor, this quantity must be calculated taking into account the circumferences of the two innermost layers, as described above with respect to Figure 45. If, for space reasons, the joint is attached to a much larger diameter, for example, it is inevitable to consider the limitation of movement by a system using abutment and springs.

[0127] In the static configuration of the system, when transitioning from one crown to another more outer crown, the transfer system 530 does not receive any movement. Thus, as is clear from Figure 46, it should be noted that the lower guides 530b, 530c store fewer legs of the basic conductor the greater the displacement from the axis towards the outermost layer (SE) towards the proximal diameter (SI).

[0128] In a specific configuration according to the invention, the transfer system 530 of the basic conductor can be integrated with the base plate, and regardless of the type of basic conductor to be processed (standard, reverse, nested), the rods of the chute can be selected to have a length that does not prevent the insertion of the outermost basic conductor of the winding (belonging to layers 1 - 2). As a result, the basic conductors belonging to the innermost layers (layers n and n - 1) will leave the chute earlier. In this situation, the basic conductors are not constrained or supported in the vertical direction and are thus free, provided that when lateral supply and positioning rollers are present, they can be prevented from falling towards the outer diameter.

[0129] An alternative embodiment for this first solution for the transfer and handling of the basic conductor can be devised as follows: - The first alternative embodiment includes compensation for the distance by the movement of the chute along the radial axis. - The second alternative embodiment includes the introduction of the nib 535 actuated by a two-position pneumatic cylinder or by an actuator that operates the blade via a suitable mechanism, and the base plate is made to move only in direction 70.

[0130] Compensation by movement of the chute Alternative embodiments regarding the transfer and handling of the basic conductors are shown in FIGS. 53 to 57.

[0131] Since the transfer system 530 of the basic conductors slides relative to the base plate, it is possible to bring each basic conductor arbitrarily and by the same amount closer to the counter mold, regardless of the crown formed, and to facilitate the loading and feeding of the basic conductors to the insertion and handling device body 400 by means of the lateral feed and positioning rollers without preventing the removable insertion of the conductors themselves and their falling into the device 400.

[0132] The pneumatic cylinder 555 for moving the plate 560 can be replaced by an electric actuator.

[0133] In this case, unlike what happened with the previous solution, the positioning of the counter mold, and thus of the loading and insertion device 500, is now done by using not only one but two movements. In the previous case, as can be seen from FIG. 42, when the opening angle of the basic conductors to be processed was fixed through two electric axes, it was possible to position them precisely on each crown, but in this new configuration, instead, as shown in FIGS. 49 to 50, this displacement can be reproduced by using translation and rotation.

[0134] In fact, to position the counter mold with respect to the basic conductor CB3-4, as shown in FIG. 50, a first translation in the direction of the axis 60 is used.

[0135] At this time, by using two pneumatic cylinders 555, the rotation indicated by the arrow can be realized and the basic conductor 3-4 can be correctly stored.

[0136] The same procedure is applied when inserting the basic conductor CB5-6.

[0137] It should be noted that, unlike the case where the counter mold moves in the radial directions 61, 62, in this alternative embodiment, a slight error ε is assumed in terms of storing the basic conductors.

[0138] In this embodiment, it is convenient to model the counter mold so as to correctly position the outermost basic conductors (the conductors belonging to the 1-2 layers) while referring to the innermost basic conductors (the conductors belonging to the nth and n-1th layers) and to always store all the basic conductors in the legs well.

[0139] By first linearly moving along the central axis 60 and then rotating, it is achieved that the basic conductors belonging to the innermost layer (in this case 5 - 6) are thus stored (see Fig. 51).

[0140] A further solution is to attach one of the two inserter bodies to a carriage (not shown) actuated by a two - position pneumatic cylinder.

[0141] A further aspect to be evaluated in this case is as follows: Each time the crown is changed, the body of the loading and insertion device is repositioned (by means of two movements as seen from above). This also applies to the two lower rods of the chute, which are integral with the base plate. Therefore, any system of abutment - springs must be "modular" according to the type of crown formed and / or the type of basic conductors to be processed (standard or nested).

[0142] Presence of auxiliary nibs for the hairpin transfer system In a second alternative embodiment (Fig. 52) for the transfer and handling of basic conductors, due to the presence of the nibs 535, the basic conductors (especially those belonging to the innermost layer) do not fall and are thus supported in the last segment before landing on the counter - mold 520.

[0143] For example, the nibs can be actuated according to two different logics: - By means of a two - position pneumatic cylinder 555. Once the basic conductor arrives, it is advanced by the lateral feed and positioning rollers 540 and is supported by the nibs 535 in this segment. Thereby, as shown in Fig. 52, when the rollers complete their stroke, the nibs 535 retract. The nibs retract by means of a cylinder (or retraction means not shown), and the basic conductor can fall freely and / or with the help of the thruster blade 510; - The nibs 535 can rotate 90° downwards (as previously explained and shown in Fig. 18 together with the handling mechanism 545) to return to a suitable seat 535S and not interfere with other elements.

[0144] A third alternative solution for managing the transfer and processing system of basic conductors is shown in Figs. 53 - 55. Such a solution provides the following: - The upper guide or rod 530a of the transfer rod is integral with the base plate 550, and the base plate 550 has freedom of movement only along the axis 70; - The lower guides or rods 530b and 530c are integral with two electric axes that move the first and second counter-mold bodies 521 and 522 of the inserter, respectively. Thus, it is possible to omit the presence of ball joints, while ensuring good guidance for both the basic conductors belonging to different crowns and the nested basic conductors.

[0145] Figure 54 shows the radial displacement of two counter-molds for handling the basic conductor CB1-2 of layer 1-2 and the basic conductor CB3-4 of layer 3-4.

[0146] The advantage of this solution is the absence of the leg storage error ε emphasized above.

[0147] It should be noted that the nested basic conductor 255A can be similarly processed because the two lower rods are integral with the electric axes that move the body of the loading and insertion device.

[0148] However, regarding the upper rod, it remains integrated with the lower plate, while, as shown in Figure 55, the nib 535 can be present.

[0149] Movement of the rod The movement of the two lower guides 530b, 530c of the basic conductor transfer system 530 can be performed, for example, via two electric axes.

[0150] By integrally arranging the two lower guides 530b, 530c of the transfer system with the two electric axes that move the two bodies of the loading and insertion device, the desired movement, i.e., the translation along axes 61, 62, can be obtained.

[0151] To process basic conductors (e.g., the nested basic conductor 255A) with different opening angles on the same crown, it is possible to introduce specific movements of the two lower guides 530b, 530c of the basic conductor transfer system 530.

[0152] For the sake of simplicity, the following description will be given for one of the two rods.

[0153] In the state where the standard basic conductor is processed, the lower rod or guide can be supplied through the two electrolytic cylinders as described above so as to be arranged in the layer related to the basic conductor at hand.

[0154] Blade The blade system can be manufactured in a different shape and configuration as shown in Figures 56 and 57. The alternative blade system includes the following: - The nib 535 for supporting the basic conductor, as described above; - The upper thruster 517 (similar to the version 510 of the blade). This thruster ensures the insertion of the basic conductor by pushing at its upper ridge when the conductor does not fall naturally.

[0155] In this configuration, the nib is synchronized with the mechanism that advances the upper thruster vertically.

[0156] The thruster allows the insertion of the basic conductor, so the nib moves without preventing its insertion. In fact, in other embodiments, the thruster replaces the blade. Generally, the thruster can be included in the term "blade".

[0157] Advantages of the present invention The basic conductor loading and insertion device 500 and the related removable insertion and handling device 400 have several advantages over the prior art techniques and methods.

[0158] First, the system according to the present invention enables different types of basic conductors, such as standard, reverse, and nested basic conductors, to be processed sequentially and automatically in a single device without relying on the intervention of an external operator. Also, since this system is compact in its configuration, the size of the prior art system can be reduced.

[0159] In this way, the cycle time for the assembly of the stator winding is shortened. On the one hand, the efficiency of the system is improved compared to the prior art, and the manufacturing cost is reduced. The time is shortened due to both the flexibility of the system to adapt to various windings and the fact that the same flexibility is quickly implemented by the structure of the means according to the present invention.

[0160] Another advantage of the system according to the present invention is that the handling and insertion of the basic conductor are highly accurate. In fact, when the basic conductor enters the system, it is guided and pushed into the winding without being deformed or changed from its initial shape. This ensures the provision of the stator winding with high accuracy and can suppress as much as possible the incompleteness and rubbing between the basic conductors that tend to cause electrical defects.

Explanation of Symbols

[0161] Electrical axis, radial direction CB1-2 - Basic conductor layer 1-2 CB3-4 - Basic conductor layer 3-4 CB5-6 - Basic conductor layer 5-6 CR2-3 - Reverse basic conductor layer 2-3 CB4-5 - Reverse basic conductor layer 4-5 T - Tangent 50 - Winding shaft 60 - Central counter mold moving axis 61 - Oblique counter mold moving axis 62 - Oblique counter mold moving axis 70 - Inserter shaft 100 - Winding 100-CI - Inner crown 100-CIN - Intermediate crown SLR - Reverse basic conductor storage space in the winding 255 - Standard basic conductor 255 1 - Inserted standard basic conductor 255A - Nested basic conductor 255R - Reverse basic conductor 255RT - Bridged portion of the reverse basic conductor 255z - Strip 255x - Extended side of the strip 255y - Connection edge or spoke of the strip 255-IVP - Inverted Hairpin 255-IP - I Pin 300 - Circumferential Storage Container for Basic Conductor 350 - Slot 400 - Insertion and Handling Device or "means" 400’ - Insertion and Handling Device or "means" for Nested Basic Conductor 401 - First (Independent) Insertion and Handling Device 402 - Second (Independent) Insertion and Handling Device 410 - Wedge-shaped (Circumferential) Guide and Storage End 420 - Circumferential Storage End 430 - Wedge-shaped Inner Circumferential End or "Bevel" 440U - Single Drilling Part 440S - Standard Basic Conductor Drilling Part 440R - Reverse Basic Conductor Drilling Part 460 - (Upper) Insertion End 465 - Hole in (Upper) Insertion End 466 - Stop Element 470 - Movable Storage Means 480 - Formed Bridge 500 - Loading and Insertion System for Basic Conductor or "Inserter" 500I - Theoretically Initial Position 500F - End Volume of Basic Conductor Before Vertical Slide 500R - Storage Volume 510 - Blade 511 - First Blade Body 512 - Second Blade Body 517 - Upper Thruster (Same as Blade Version 510) 520 - Counter Mold 520l1 - First Counter Mold Side Wall 520l2 - Second Counter Mold Side Wall 521 - First Counter Mold Body 522 - Second Counter Mold Body 530 - Basic Conductor Transfer System or "Shoot" (Generally "Loading Means") 530a - Upper Guide 530b - Lower Guide 530c - Lower Guide 534 - Ball Joint 535 - Nib 535S - Seat 540 - Lateral Feeding and Positioning Roller (Generally "Loading Means") 541 - Roller Fin 542 - Roller Vent 545 - Wheel 550 - Base Plate 551 - Electric Axis 555 - Pneumatic Cylinder 556 - Curved Guide 560 - Moving Plate 600 - Different Circumferential Storage Containers for Basic Conductor 610 - Retractable Radial Element SLR - Inverted Hairpin Connection Region PFR - Final Position of Inverted Hairpin SE - Outermost Layer SI - Innermost Layer F1, F2 - Steps of Supplying Basic Conductor F3 - Step of Positioning Basic Conductor F4 - Step of Lowering Blade F5 - Step of Idling Lateral Roller F6 - Step of Raising Blade PNC - Non-storage Part of Inverted Hairpin

[0162] The preferred embodiments have been described above, and some modifications of the present invention have been proposed. However, it is understood that those skilled in the art can make modifications and changes without departing from the relevant protection scope as defined by the appended claims.

Claims

1. A removable device (500) for loading and handling a basic conductor (255, 255-R, 255-IP, 255-IVP), configured to load, handle, and insert the basic conductor into circumferential storage means (300, 600), each basic conductor including a head end and one or more legs each having a respective free insertion end, the removable loading and handling device (500) being configured to assemble a stator or rotor winding (100) consisting of one or more sectors (100-CI) extending circumferentially around a winding shaft (50), each sector including one or more layers, each layer consisting of a circumferential arrangement of basic conductors, the device comprising: a first (521) and a second (522) countermold configured to define a storage volume (520l1, 520l2, 521, 522) for the basic conductor, the first and second countermolds each having an extension along an axial direction parallel to the winding shaft (50) during use, the device further comprising: loading means (530, 540) for the storage volume of the basic conductor, the storage volume (500R) including an end volume (500F) of the basic conductor with respect to the first and second countermolds, the end volume (500F) being configured to slide the basic conductor along the axial direction (z) until it is inserted into circumferential storage means (300, 600) within a sector (100-CIN) of one or more sectors (100-CI) being assembled, the device.

2. including one or more thrusting blades (510, 511, 512, 515, 517) of the basic conductor, configured to slide axially and push the basic conductor axially along the end volume (500F) to substantially the outside of the first and second countermolds, The device according to claim 1.

3. At one axial end of the first and second countermolds, on the side intended to face the circumferential storage means during use, corresponding first means (401) and corresponding second means (402) are provided, integral with the first and second countermolds, for inserting and handling the basic conductor into the circumferential storage container, The first insertion and handling device (401) guides and allows a basic conductor (255, 255R) to be inserted into circumferential storage means (300, 600) in an insertion area of the circumferential storage means in an axial direction parallel to a winding shaft (50) until it is inserted. It includes a first through-hole (440U) in a part of the basic conductor, a first wedge-shaped guide, and a storage end portion (410) that narrows in a direction crossing the axial direction. The guide and the storage end portion (410) are arranged at a predetermined distance from the winding shaft (50). The guide and the storage end portion (410) During use, when the circumferential storage container rotates relative to the removable insertion and handling device, it is configured to be displaced in the radial direction. For the insertion of the last basic conductor of the sector, within the insertion region, one or more layers (255 １ ) of the sector (100-CIN) are assembled such that there is a free space between the basic conductors of the sector (100-CIN), as a function of their circumferential position within the sector. The guide and the storage end (410) also During relative rotation, it is configured to guide and store the basic conductor of the sector that has already been inserted and supplied towards the first insertion and handling device (401). The device according to claim 1 or 2.

4. A second insertion and handling device (402) includes a part of the basic conductor, and second through-holes (440R, 440S) from the first guide and storage end portion (410) to a second storage end portion (420) on the circumferentially opposite side. The second guide and storage end portion (420) is configured to store the basic conductor that has already been inserted into the assembled sectors (100 - CIN) of one or more sectors (100 - CL). The device according to claim 3.

5. The first wedge-shaped guide and storage end portion (410) is configured such that, during use, the basic conductor that is gradually inserted into the assembled sectors (100 - CIN) moves the first basic conductor inserted into the sectors radially outward along a helical profile around the winding shaft (50). The device according to claim 3 or 4.

6. The first (401) and / or second (402) insertion and handling devices include stop elements (466A, 466B, 466) at the head end. The device according to any one of claims 1 to 5.

7. The first (401) and / or second (402) insertion and handling devices are fixed to each other. The device according to any one of claims 1 to 6.

8. The first (401) and / or second (402) insertion and handling devices are formed as a single piece (400, 400'). The device according to claim 7.

9. The first counter mold (521) is provided as a single counter mold (520), and the second counter mold (522) is provided movably in a direction perpendicular to the axial direction. The blade (510) includes a body shaped to fit between the first and second counter molds. The blade is simultaneously configured to push the basic conductor at the tip of the head. The device according to any one of claims 1 to 6.

10. The first (521) and second counter molds (522) are configured to rotate around the axial direction to change the storage volume and move independently of each other. The device according to any one of claims 1 to 6.

11. The thrusting blade (510) includes first and second independent bodies (511, 512) extending in the axial direction. Each of the two independent bodies is configured to push the basic conductor at at least a part of the head portion. The first and second independent bodies are each integral with the first and second counter molds. The device according to claims 2 and 10.

12. The first counter mold and the second counter mold are configured to shift radially along the winding axis during use. The device according to claim 10 or 11.

13. The first counter mold and the second counter mold are configured to rotate in opposite directions around the axial direction respectively. The device according to claim 10 or 11.

14. A corresponding first device (401) for inserting and handling the basic conductor is provided. During use, when a relative rotational movement occurs between the first removable insertion and handling device (401) and the circumferential storage means (300, 600), the first removable insertion and handling device (401) exits and until it is disposed within the assembled sector (100 - CIN), one or more first components (430) configured to cause a cam movement of one or more basic conductors (255, 255R) within the first insertion and handling device (401) in a radial direction towards the assembled sector (100 - CIN). The device according to any one of claims 1 to 13.

15. The basic conductor is a two-legged hairpin (255, 255-R, 255-IVP, 255-P), and the first through-hole (440U) and the second through-holes (440R, 440S) are such that the first leg inserted into the first through-hole is forward with respect to the relative rotational direction of the circumferential storage means (300, 600), and the second leg inserted into the second through-hole is rearward with respect to the relative rotational direction, One or more first elements include a tapered portion (430) corresponding to the second leg on a plane perpendicular to the winding axis (50), and the tapered portion (430) extends in the relative rotational direction, The device according to claims 3 and 14.

16. The first (401) and second (402) insertion and handling devices extend axially from the insertion ends (460, 465) to the end opposite the insertion ends, The insertion ends (460, 465) include a guide sleeve formed to accommodate, laterally store, and guide one or more basic conductors, The end opposite the insertion end is dimensioned to store the head end of the basic conductor and opens to the side facing the winding sector (100-CIN) during use, The device according to claim 3 and any one of claims 1 to 15.

17. A subset of the basic conductors includes one or more groups of nested basic conductors (255, 255A) each having a pitch between two legs, each group including a basic conductor (255A) having a higher pitch and one or more basic conductors (255) each having a gradually decreasing pitch, Additional movable storage means (470) are provided to store one or more basic conductors (255) having a gradually decreasing pitch, The additional movable storage means (470) is configured to operate to position one or more basic conductors having a gradually decreasing pitch and is removed immediately before inserting the basic conductor (255A) having a higher pitch, The device according to any one or more of claims 1 to 16.

18. The end opposite the insertion end includes a stop element (466) for the head of the basic conductor having a lower pitch, The device according to claim 17.

19. The first insertion and handling device (401) includes a through-hole (440U) configured for the second leg of a standard or reverse basic conductor, The corresponding second insertion and handling device (402) includes a first through-hole (440S) for the first leg in the case of a standard basic conductor and a second through-hole (440R) for the first leg in the case of a reverse hairpin. The device according to claim 3 or any one or more of claims 3 and 4 to 18.

20. The loading means (530, 540) includes a transfer system (530) configured to slide the head end of the basic conductor from the loading station to the storage volume. The device according to claims 1 to 19.

21. The loading means includes one or more lateral supply and positioning rollers (540) arranged rotatably about the axial direction in a laterally axial direction at the end of the storage volume and including fins (541) perpendicular to the axial direction. By the rotation of the one or more lateral supply and positioning rollers, the basic conductor is tightly packed against the first (521) and second (522) counter-molds in the storage volume by pushing each time. The device according to claim 20.

22. The first and second counter-molds have lateral recesses configured to allow the fins (541) to continue rotating after the thrust of the basic conductor. The device according to claim 21.

23. The one or more lateral supply and positioning rollers (540) are the same on both sides of the counter-mold, and the straight line passing through the respective rotation centers is not perpendicular to the radial direction with respect to the winding shaft (50) during use, but has an inclination α proportional to the bending of the head of the basic conductor. The device according to claim 21 or 22.

24. The basic conductor has a rectangular strip-shaped portion (255z) with two long sides (255x) and two short sides (255y). One or more lateral supply and positioning rollers (540) are arranged such that the fins (541) contact the entire long side (255x) at one position of the lateral supply and positioning rollers corresponding to the position of the basic conductor in the end volume (500F). The device according to any one of claims 21 to 23.

25. The basic conductor has a rectangular strip-shaped portion (255z) with two long sides (255x) and two short sides (255y). One or more lateral feed and positioning rollers (540) are arranged such that the fins (541) contact over the entire short side (255y) at one position of the lateral feed and positioning roller corresponding to the position of the basic conductor within the end volume (500F). The apparatus according to any one of claims 21 to 24.

26. One or more lateral feed and positioning rollers (540) are configured to rotate over an angle less than 180 degrees during use. The blade (510) has a shape such that it presses only about two-thirds of the head surface of the basic conductor, and the operations of the blade and the roller are simultaneous. The apparatus according to any one of claims 21 to 25.

27. The transfer system (530) comprises a first upper guide (530a, 535) configured to support the head end of the basic conductor, and two lower guides (530b, 530c) configured to slide within the legs of the basic conductor being supplied. The apparatus according to any one of claims 21 to 26.

28. The upper guide continuously terminates at a removable support (535) of the head end of the basic conductor that can be retracted to slide the basic conductor axially along. The apparatus according to claim 27.

29. For loading and moving telescopic basic conductors, the upper guide (530a) is fixed and the two lower guides (530b, 530c) are configured to move away from each other or towards each other by the transfer means (534) of the lower guide. The apparatus according to claim 27 or 28.

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