Magnet loading device, apparatus for inserting magnets into a laminate stack, and corresponding method

Abstract

The device (10, 10') for loading magnets (M, M1, M2), included in the apparatus (100, 100') for inserting magnets (M, M1, M2) into the rotor lamination stack (L, L'), comprises a housing (20, 20') rotatable around a rotation axis (R1) and at least one member (30, 30') for loading the magnets (M, M1, M2), which partially overlaps the peripheral edge of the housing (20, 20').

Description

[Technical Field]

[0001] The present invention relates to a magnet loading device, an apparatus for inserting magnets into a lamination stack for a rotor, a method for loading magnets into a housing, and a method for inserting magnets into a lamination stack, particularly a rotor lamination stack for an electric motor. [Background technology]

[0002] Electric motors are known that typically consist of a rotor and a corresponding stator, the rotor being formed by a series of lamination stacks, each of which is made up of overlapping disc-shaped laminations.

[0003] In particular, each lamination stack is provided with a plurality of sheetings (also called slots) evenly distributed around the periphery of the lamination stack, each slot adapted to receive a respective magnet. The sheetings have two different orientations symmetrical to each other with respect to the radial direction of the lamination stack, and are alternately arranged such that two consecutive sheetings form a substantially "V" shape. The sheetings, taken together, form a substantially star shape.

[0004] Apparatus for inserting magnets into a lamination stack is also known, which comprises a device for loading magnets into a lamination stack model, also called a hopper, which replicates the sheeting of the magnets. Once the lamination stack model is fully loaded with magnets, the magnets are transferred to the lamination stack to be loaded, which is then used in the manufacture of a rotor.

[0005] U.S. Patent Application Publication No. 2021 / 242757 describes a device for inserting magnets into a laminated stack, the device including a loading device with multiple magnet supply channels configured in a twisted shape to orient each magnet toward a corresponding sheeting of a laminated stack model below the loading device, and a laminated stack below the laminated stack model into which the magnets are inserted when all sheets of the laminated stack model are loaded with magnets.

[0006] A drawback of this device is that a minimum height is required in the channel to allow the magnets to fall correctly towards the sheeting of the laminate stack model, making the device bulky, especially in terms of height.

[0007] Therefore, there is a need to develop a magnet loading device and an apparatus for inserting magnets into a rotor lamination stack that overcomes at least one of the shortcomings of the prior art.

[0008] To achieve this, the technical problem of creating an effective, fast and versatile operating magnet loading device must be solved.

[0009] In particular, it is an object of the present invention to provide a magnet loading device that can automatically load and orient a magnet directly from its supply zone.

[0010] Another object of the present invention is to provide a magnet loading device that can easily accommodate any distribution and orientation of magnet seating in a laminate stack model.

[0011] Another object of the present invention is to provide a magnetic loading device that has limited overall size.

[0012] Another object is to provide a magnet loading device and apparatus for inserting magnets into a laminate stack that allows different types of magnets to be loaded and inserted into different sheeting groups of the same laminate stack.

[0013] Another object of the present invention is to develop a method for loading magnets into a container, which allows for automatic loading and orientation of the magnet directly from its supply zone.

[0014] Another objective is to develop a method for inserting magnets into a laminate stack that allows for easy, fast, and versatile loading and insertion of magnets into the laminate stack.

[0015] Applicant has invented, tested and embodied the present invention to overcome the shortcomings of the prior art and to achieve these and other objects and advantages. Summary of the Invention

[0016] The invention is set forth and characterized in the independent claims. The dependent claims describe further features of the invention or variants of the main inventive idea.

[0017] In order to achieve the above object and solve the above disclosed technical problem in a new and original way, while also achieving significant advantages over the prior art, the magnetic loading device according to the present invention comprises a housing rotatable about a first rotation axis, the housing comprising a plurality of magnet housing seats distributed along the periphery of the housing, and at least one magnetic loading member, in particular the housing seats are perforated, i.e. open correspondingly on the upper and lower sides of the housing.

[0018] The term "receptacle" refers to a stack model that faithfully replicates the layout of the stack to be loaded. That is, it is a model that replicates the shape, size, number, and relative positions of the layout. By loading magnets into the receptacle, the magnets to be inserted into the stack are pre-positioned.

[0019] Laminated stacks refer to the type of ferromagnetic core most commonly used today in the manufacture of rotors for permanent magnet electric machines. However, new technologies have emerged in the prior art, such as solid or monoblock ferromagnetic cores obtained by alternative techniques, such as pressing and sintering soft magnetic composite (SMC) powders. Because the geometries of these alternatives are similar to those of laminated stacks, they should be considered technically equivalent, and therefore the present invention, in all its various embodiments, is also applicable to other types of ferromagnetic cores. According to one aspect of the present invention, the magnet loading member is rotatable about a second axis of rotation parallel to the axis of rotation of the housing and includes at least one loading seating constructed and arranged to at least partially accommodate magnets supplied substantially radially to the magnet loading member.

[0020] The second axis of rotation is spaced from the first axis of rotation, and the at least one loading member partially overlaps a portion of the periphery of the housing. The at least one loading member is further configured to rotate the at least one loading seating between an entrance position for receiving a magnet and a loading position for axially releasing a magnet loaded in one of the plurality of magnet receiving seats. When in the entrance position, the loading seating is spaced apart from the plurality of magnet receiving seats and overlaps one of the receiving seats when in the loading position.

[0021] Preferably, the loading member is a loading wheel. The loading seating is preferably oriented so as to be disposed along the radial direction, and advantageously has openings corresponding to the sides of the loading member to facilitate feeding the magnets into the loading seating.

[0022] This provides at least the advantage of having a loading member that can load the magnets one by one, orient them individually in any direction, and change their orientation relative to their original feed direction.

[0023] During use, the overlap of the loading seating of the loading member with the receiving seating of the housing occurs corresponding to a loading position unique to each loading member, in which the magnet is released from the loading member toward the seating of the housing, and in such a loading position, one loading seating of the rotatable loading member overlaps with a corresponding receiving seat of the housing, regardless of the radial orientation or position of the housing.

[0024] According to some embodiments, the loading member is configured and sized so that when one loading seating is positioned corresponding to the loading position, the other loading seating is positioned at the magnet entry position to radially receive another magnet to be loaded into the housing. For example, at least two adjacent loading seats are oriented to form an angle therebetween equal to the angle between the central axis of the magnet receiving seating positioned corresponding to the loading position and the central axis of the loading seating positioned at the entry position, with these central axes being positioned perpendicular to and passing through the same second rotation axis of the loading member bearing the loading seating. This feature speeds up the step of loading a magnet into the housing and reduces the time required to properly orient the loading member to feed the next magnet.

[0025] According to some embodiments, the loading member has loading seats corresponding to the number of seats of the container into which magnets are loaded. For example, the number of loading seats can be equal to or half the number of magnet-receiving seats to be loaded. This allows all or half of the seats to be loaded during a 360° rotation of the loading member and the container. This further speeds up the step of loading magnets into the seats. Preferably, the angle between two consecutive loading seats is equal to the angle between the loading seat in the entrance position and the loading position.

[0026] According to some embodiments, at least one loading sheeting is configured as a pocket having an entrance opening through which the magnet enters, an abutting bottom opposite the entrance opening against which the magnet strikes as it is fed radially, and two opposite side walls spaced at a distance substantially equal to the thickness of the magnet.

[0027] According to some embodiments, the housing sheeting is divided into a first series of sheetings oriented according to a first angle relative to the radial direction of the housing and a second series of sheetings oriented according to a second angle relative to the radial direction of the housing. In particular, the sheetings are arranged in pairs, each pair including one sheeting of the first series and one sheeting of the second series. Preferably, the loading device comprises two loading members, the first loading member for loading the magnets into the first series of sheetings and the second loading member for loading the magnets into the second series of sheetings. The two loading members may be arranged symmetrically with respect to the diameter of the housing.

[0028] According to some embodiments, the plurality of storage sheets of the storage body include a first series of sheets of the same size and a second series of sheets of the same size but different in size from the first series of sheets, and the magnet loading device includes a first loading member for loading magnets of the first series of sheets and a second loading member for loading magnets of the second series of sheets.

[0029] According to some embodiments, the housing includes a blocking device configured to temporarily and selectively block the magnets in the storage seating. This blocking is achieved by preventing the magnets from slipping out of the seating. The blocking device preferably includes a plurality of blocking members integrated into the housing corresponding to the bottom wall of the housing. Each blocking member is preferably configured to at least partially close a corresponding seating. The blocking members may be configured as diaphragms, each of which is movable between an engaged position in which at least one of the plurality of storage seats is at least partially closed at the bottom and a disengaged position in which at least one of the plurality of storage seats is fully permitted to pass through the housing corresponding to the bottom wall.

[0030] If the overall size allows, blocking can also be achieved by installing a sliding partition at the bottom of the stack model that does not interfere with the rotational movement of the stack model and has two positions, one engaged during the loading step and one disengaged.

[0031] According to another aspect of the present invention, an apparatus for inserting magnets into a lamination stack for a rotor according to the present invention comprises at least one magnet loading device as described above and a station for inserting magnets into the lamination stack, the insertion station being located at a distance from the at least one magnet loading device.

[0032] According to the present invention, the apparatus comprises a magnet transfer device movable between at least one magnet loading device and an insertion station. In particular, the transfer device is configured to transfer magnets from the at least one magnet loading device to the insertion station. Preferably, the transfer device comprises a fixed stack model formed as a cylindrical body with a plurality of transfer seats arranged in the same manner as the arrangement of the plurality of magnet receiving seats of the rotatable housing. The expression "arranged in the same manner" means that there are the same number of seats, they have the same shape and size, and are arranged in the same position relative to the receiving seats of the rotatable housing. In fact, the fixed stack model is identical to the rotatable housing (and therefore also to the loaded stack), but does not rotate. Preferably, the seats of the fixed stack model also penetrate. The fixed stack model is integrated into the transfer device and moves together with it. Holding of the magnets during transportation is ensured by a dedicated holding system.

[0033] According to some embodiments, the insertion station is positioned above the lamination stack and comprises a magnet pushing member movably mounted thereon and configured to push magnets from a fixed lamination stack model of the transfer device into a seating of the lamination stack.

[0034] Preferably, the pushing member comprises pushing elements configured to be inserted into respective seatings of the fixed lamination stack model, each pushing element pushing a respective magnet into a corresponding seating of the lamination stack.

[0035] According to some embodiments, the apparatus comprises a first magnet loading device configured to load a first type of magnet and a second magnet loading device configured to load a second type of magnet. In this case, the apparatus comprises in each case a single transport device and a single insertion station. The two magnet loading devices are arranged at a distance from each other and from the insertion station. The loaded stack thus comprises a first seating group for receiving the first type of magnet and a second seating group for receiving the second type of magnet. At least a fixed stack model of the transport device comprises a first seating group for receiving the first type of magnet and a second seating group for receiving the second type of magnet.

[0036] According to another aspect of the present invention, a method for loading magnets into a housing rotatable about a first axis of rotation and having a plurality of magnet receiving seats distributed along a periphery of the rotatable housing comprises the steps of: supplying a plurality of magnets sequentially in a substantially radial direction toward at least one magnet loading member, the at least one magnet loading member being rotatable about a second axis of rotation parallel to the first axis of rotation and having at least one loading seat constructed and arranged to at least partially receive the magnets supplied to the loading member; inserting a magnet into the at least one loading seat corresponding to an entrance position away from the plurality of magnet receiving seats; and rotating the loading member about the second axis of rotation to displace the at least one loading seat containing the magnet toward a loading position where the at least one loading seat overlaps one of the magnet receiving seats of the rotatable housing, thereby releasing the magnet axially downward within the magnet receiving seat.

[0037] Preferably, the method is performed by the magnetic loading device disclosed above.

[0038] According to another aspect of the present invention, a method of inserting magnets into a lamination stack includes the steps of: corresponding to the magnet loading device, the method steps for loading a magnet into a rotatable housing as described above; Discharging the magnet loaded in the rotatable housing towards a transfer device having a fixed stack model with a plurality of transfer sheets arranged in the same manner as the arrangement of the plurality of magnet housing sheets; transferring the magnet by displacing the transfer device from the magnet loading device towards a station for inserting the magnet into the stack; inserting a magnet into the lamination stack in response to an insertion station; Includes:

[0039] Preferably, the magnetic loading device is as disclosed above.

[0040] Preferably, the magnet insertion method is performed by the apparatus disclosed above.

[0041] According to some embodiments, before the step of releasing the magnets towards the transfer device, the steps of the method of loading the magnets into the rotatable housing are repeated until all magnet housing seatings are loaded with corresponding magnets.

[0042] These and other aspects, features and advantages of the present invention will become apparent from the following description of some embodiments thereof, given by way of non-limiting example with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0043] [Figure 1] FIG. 1 is a schematic plan view of a magnetic loading device according to the present invention. [Figure 2] FIG. 2 is a schematic side view of an apparatus for inserting magnets into a rotor lamination stack according to the present invention. [Figure 2A] 2A is a plan view of the transfer device of the apparatus of FIG. 2. FIG. [Figure 3] FIG. 3 is a schematic plan view showing further details of the magnetic loading device of FIG. [Figure 4] FIG. 4 is a cross-sectional view along a vertical plane of the magnet loading device of FIG. 3, detailing the temporary magnet blocking device. [Figure 5A-C] 5A-C are plan views of the magnet loading device of FIG. 1 illustrating a series of magnet loading steps. [Figure 6A-C] 6A-C are schematic side views of an apparatus for inserting magnets into the lamination stack of the rotor of FIG. 2, illustrating a series of steps for inserting magnets into the lamination stack. [Figure 6D] FIG. 6D is a schematic side view of an apparatus for inserting magnets into the lamination stack of the rotor of FIG. 2, illustrating a series of steps for inserting magnets into the lamination stack. [Figure 7A-B] 7A-B are schematic plan views of a variation of the magnetic loading device, illustrating two different steps of operation. [Figure 8] FIG. 8 is a schematic plan view of two magnet loading devices of a variation of the apparatus for inserting magnets into the lamination stack of a rotor. [Figure 9] FIG. 9 is a schematic side view of a variation of the apparatus for inserting magnets into the lamination stack of a rotor, comprising two magnet loading devices of FIG. [Figure 9A] 9A is a plan view of the transfer device of the apparatus of FIG. 9. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0044] It must be made clear that the phraseology and terminology used in this specification, as well as the figures of the accompanying drawings, however described, have the sole function of better illustrating and explaining the invention, the scope of protection being defined by the claims, and their purpose is to provide a non-limiting example of the invention itself.

[0045] To facilitate understanding, the figures use the same reference numerals to indicate identical common elements whenever possible, and it will be understood that elements and features of one embodiment may be combined or incorporated into other embodiments as appropriate without further description.

[0046] 1, a device 10 for loading a magnet M into a corresponding apparatus 100 for inserting a laminate stack L according to the present invention comprises a housing 20 for temporarily housing the magnet M and rotatable about a first rotation axis Y1, and a pair of loading members 30, 30' rotatable about second rotation axes Y2, Y3, respectively. The first rotation axis Y1 is parallel to the rotation axes Y2, Y3 of the pair of loading members 30, 30'.

[0047] In particular, the temporary container 20 comprises a plurality of pairs 21 of sheeting, each pair of sheeting forming a substantially "V" shape, with a first sheeting 21a oriented at a first angle α1 relative to the radius R of the container 20, and a second sheeting 21b oriented at a second angle α2 relative to the same radius R, symmetrical to the first angle. In particular, the container 20 having a circular cross section has six pairs 21 of sheeting 21a, 21b regularly distributed along the periphery of the container 20, collectively forming a substantially star-shaped pattern. It will be apparent that in other embodiments, a different number of pairs of sheeting may be provided without departing from the scope of the present invention.

[0048] The sheetings 21a, 21b have a substantially rectangular cross section, with their respective central axes 210a, 210b forming a first angle α1 and a second angle α2, respectively, with the radius R of the housing 20 (FIG. 1).

[0049] In the example shown, each loading member comprises a loading wheel 30 having a plurality of radial loading seats 31, each of which is substantially rectangular in shape. Each radial loading seat 31 is arranged such that the long side of the rectangle (i.e., the central axis 310 parallel to the long side) is radially aligned with respect to the loading wheel 30.

[0050] Each loading seating 31 is configured to accommodate only one magnet M at a time.

[0051] The loading seating 31 is open corresponding to the side wall 32 of the corresponding loading wheel 30, and the magnets M are inserted radially therein. In particular, the magnets are supplied from a supply zone 11 located in the same horizontal plane as the loading wheel 30. The supply zone 11 can be configured, for example, as a rack with a magnet supply belt.

[0052] The magnets M are fed horizontally, i.e. with their thinner side down, so that they can be easily inserted into the loading seat 31 by the corresponding feeding movement of the belt. The magnets M are inserted into the loading seat 31 corresponding to the inlet position PI (FIG. 1).

[0053] The loading wheel 30 and the container 20 are arranged horizontally. The loading wheel 30 is arranged above the container 20 (FIGS. 1 and 2) and is arranged so as to partially overlap its peripheral edge. This allows the loading sheet 31 to be aligned vertically with the sheets 21a and 21b, and two loading positions PCa and PCb are defined for the sheets 21a and 21b, respectively. Magnets M are loaded individually by dropping them from the loading sheet 31 onto the corresponding sheets 21a and 21b below. For this reason, the loading sheet 31 has an opening corresponding to the bottom wall 33 of the loading wheel 30. Similarly, the sheets 21a and 21b also have openings corresponding to the top wall 22 of the container 20.

[0054] Each loading wheel 30 loads a respective set of sheets 21a, 21b. In particular, as shown in FIG. 1, the left loading wheel 30 is positioned such that when its loading sheet 31 reaches its respective loading position PCb, it is aligned with the second sheet 21b. Meanwhile, when the loading sheet 31 of the right loading wheel 30 reaches its corresponding loading position PCa, it is aligned with the first sheet 21a.

[0055] In the example shown here, each loading wheel 30 has six loading sheets 31 corresponding to the number of first sheetings 21 a and second sheetings 21 b of the container 20. In this way, all of the sheets 21 a, 21 b can be loaded by rotating each loading wheel 30 and the container 20 once.

[0056] Furthermore, in order to optimize the loading time of the magnets M, the angle β formed between the central axis 310 of the loading seat 31 of one loading wheel 30 and the central axis 310 of the next loading seat 31 is equal to the angle δ between the axes 210a, 210b of the seats 21a, 21b at the loading positions PCa, PCb and the direction of the central axis 310 of the loading seat 31 when it is in the above-defined entry position PI. At this time, as will be explained in more detail below, when one magnet M is loaded into the housing 20 corresponding to the loading positions PCa, PCb, the following magnet M is simultaneously inserted radially into the following loading seat 31 depending on the direction of rotation of the loading wheel 30 (FIG. 1).

[0057] It should be noted that in the example shown here, all six loading seats 31 form an angle β with one another, except for the angle between the first loading seat 31a and the last loading seat 31b (FIG. 1). Thus, the loading seats 31 are regularly arranged only along an arc within the loading wheel 30, the angle of which corresponds to five times the angle β. This arrangement has the advantage that, while loading magnets M into the loading seats 21a, 21b at loading positions PCa, PCb, other magnets M can be loaded into the loading seats 31, and also that the container 20 can be completely loaded with magnets M during one rotation of the container 20 and the loading wheel 30.

[0058] The magnet loading device 10 is adapted to be included in an apparatus 100 for inserting magnets M into a lamination stack L, which is then integrated into the rotor of an electric motor.

[0059] In addition to the magnet loading device 10, the apparatus 100 comprises a transfer device 40 and an insertion station 50 by means of which the magnets M are inserted into the lamination stack L (FIGS. 2 and 2A).

[0060] The transport device 40 is configured to transport the magnet M from the magnet loading device 10 to the insertion station 50 and is therefore displaceable, in particular translatable, between a position located adjacent to the device 10 and the insertion station 50 (Figure 2).

[0061] The transfer device 40 includes a cylindrical laminated stack model 41, in which a plurality of sheets 41a, 41b are arranged in the same manner as the arrangement of the storage sheets 21a, 21b of the storage body 20 (FIG. 2A). The laminated stack model 41 is fixed within the transfer device 40, and in particular, does not rotate by itself.

[0062] The transfer device 40 is arranged below the housing 20 of the magnet loading device 10, and the magnets M can pass from the housing 20 to the fixed laminated stack model 41 by dropping. This means that the seatings 21a, 21b of the housing 20 are open corresponding to the bottom wall 23 and the top wall 22 of the housing 20. The dropping of the magnets M from the housing 20 is selectively prevented by a blocking device 24 arranged below the housing 20. The blocking device 24 will be described in detail later.

[0063] An insertion station 50, in which a laminate stack L loaded with magnets M is disposed, is adjacent to the magnet loading device 10 (FIG. 2). The insertion station 50 includes a pusher member 51 configured to be disposed above the laminate stack L, the pusher member 51 being vertically displaceable between a raised rest position (FIGS. 6A-6C) relative to the laminate stack L and a lowered insertion position (FIG. 6D). In the insertion position, the pusher member 51 applies a pushing force to the magnets M, inserting them into the laminate stack L below.

[0064] In order to push the magnets M through the laminated stack model 41 of the transfer device 40, the pushing member 51 comprises a plurality of pushing elements 52 configured / arranged to push the magnets M in the seats 41 a, 41 b of the fixed laminated stack model 41. In particular, the pushing elements 52 are identical in number, shape, size and position to the seats 42 a, 42 b of the fixed laminated stack model 41 (and therefore also to the seatings of the laminated stack L).

[0065] In order to prevent the magnet M from free falling from the fixed laminated stack model 41, the transfer device 40 is provided with a blocking member 42 (in particular a plate hingedly attached to the underside 43 of the laminated stack model 41), which rotates between a blocking position (Figure 2) in which the plate blocks all of the seats 41a, 41b of the fixed laminated stack model 41, and a disengaged position (Figure 6D) in which the plate moves so that all of the seats 41a, 41b of the fixed laminated stack model 41 are not covered and the magnet M can fall towards the laminated stack L.

[0066] It should be noted that the blocking device 42 of the transfer device 40 is structurally simpler than the lower blocking device 24 of the container 20. This will be explained in more detail with particular reference to Figures 3 and 4.

[0067] The lower blocking device 24 is integrated into the housing 20 and comprises six diaphragms 25, each configured to cover one of the seats 21a, 21b (FIG. 3) of a pair 21. Each diaphragm 25 is shown schematically by dashed lines in FIG. 3 and is more clearly visible in FIG. 4. As shown in FIG. 4, the diaphragms 25 have the shape of a generally trapezoidal member with a pair of openings 26 formed therein, which reproduce the imprint of the seats 21a, 21b of each of the pairs 21 of the housing 20. Each diaphragm 25 is supported by a common fixing plate 23a (FIG. 4). This fixing plate 23a constitutes the bottom wall 23 of the temporary container 20, which is provided with openings corresponding to the magnet-receiving seats, and is displaceable between an engaged position (FIGS. 3 and 4) in which the openings 26 are offset relative to the corresponding seats 21a, 21b and partially cover them, and a disengaged position in which the openings 26 are aligned with the seats 21a, 21b and allow the magnets M to fall through. In particular, in the engaged position, each diaphragm 25 partially shields the corresponding seats 21a, 21b of one pair 21 with an edge 26a of the opening 26, which edge 26a is offset relative to the seats 21a, 21b and projects inward from their outer peripheries.

[0068] In the engaged position, the diaphragm 25 is held in a state in which it is elastically pressed toward the first rotation axis Y1 by a spring 27 disposed between the outer surface 25a of the diaphragm 25 and the peripheral wall 28 of the housing 20 (FIG. 4).

[0069] Each diaphragm 25 has an inclined surface 25b on the side closest to the first rotation axis R1, and the blocking device 24 also includes a pusher member 29 with an end wheel 29a that contacts each inclined surface 25b.

[0070] The pusher members 29 are vertically positioned with their end wheels 29a facing downward and are displaceable between a rest position (FIG. 4) and a lowered, pushed-in position. In the rest position, no pressure is applied to the inclined surfaces 25b, maintaining the diaphragms 25 in a position that closes the seatings 21a, 21b. In the lowered, pushed-in position, the pressure of each pusher member 29 and the presence of the corresponding end wheel 29a pressing against the inclined surface 25b of the corresponding diaphragm 25 cause the diaphragms 25 to move radially outward from the housing 20. This outward radial displacement determines the alignment of the openings 26 with the seatings 21a, 21b.

[0071] It should be noted that the displacement of diaphragm 25 may be achieved by other than the devices described above or by other technically equivalent devices, such as cam devices of the type known in the art.

[0072] The operation of the magnet loading device 10 and the apparatus 100 for inserting magnets into a rotor lamination stack as described thus far includes the following steps.

[0073] The magnets M are arranged in two rows, preferably transverse to the transport direction (FIG. 1). The magnets M are advanced so that one magnet M enters the first loading seating 31a of each loading wheel 30 (FIG. 5A). The container 20 is already in a position with two seats 21a, 21b (either one of the first or second series) corresponding to the two loading positions PCa, PCb defined above.

[0074] A rotation angle β of both loading wheels 30 is determined. The left loading wheel 30 rotates counterclockwise, and the right loading wheel 30 rotates clockwise, moving each first loading sheet 31a to its corresponding loading position PCa, PCb (FIG. 5B). At this point, the loading sheet 31 following the first loading sheet 31a is aligned with the inlet position PI and receives a new magnet from the supply zone 11 (FIG. 5B). Meanwhile, the magnet M corresponding to the loading position PCa, PCb falls into the lower sheeting 21a, 21b of the container 20.

[0075] Next, the container 20 is rotated clockwise by an angle equal to the number of pairs 21 of sheets 21a, 21b present in the container 20 divided by 360° (e.g., 60° in the example described herein where six pairs of sheets 21 are provided), and the corresponding sheets 21a, 21b are moved to the loading positions PCa, PCb (FIG. 5C). Next, the loading wheel 30 is rotated again as described above, and the second magnet M supplied to the loading wheel 30 is moved to the corresponding loading position PCa, PCb (FIG. 5C), and the second magnet M is dropped onto the corresponding sheet 21a, 21b. At the same time, a new magnet M is supplied to the next loading sheet 31 on the loading wheel 30.

[0076] This series of steps is performed a total of six times to fill the seatings 21a, 21b of the six pairs 21 of the housing 20. During these steps, the blocking device 24 remains in the engaged position, preventing the magnet M from falling out of the housing 20.

[0077] Once the sheets 21a, 21b of the six pairs 21 are loaded, the transfer device 40 is placed under the magnet loading device 10 (Figure 6A) with the stacked stack model 41 perfectly aligned with the housing 20, and in particular, the sheets 41a, 41b of the stacked stack model 41 perfectly aligned with the sheets 21a, 21b of the housing 20.

[0078] Next, the drive of the lower blocking device 24 is controlled to move the diaphragm 25 to the outside of the container 20. As a result, the opening 26 of the diaphragm 25 is aligned with the sheets 21 a and 21 b, and the magnet M falls onto the sheets 41 a and 41 b of the laminated stack model 41 ( FIG. 6B ). At this stage, the blocking device 42 of the transfer device 40 is in the blocking position, preventing the magnet M from falling.

[0079] The transfer device 40 is then commanded to move towards the insertion station 50 (FIG. 6C) so that the lamination stack model 41 is aligned with the lamination stack L to be loaded and the pusher member 51 .

[0080] The blocking device 42 is then placed in the disengaged position, allowing the magnet M to fall towards the lamination stack L, and the pushing element 51 is lowered so that its pushing element 52 is inserted into the seating 41 a, 41 b of the lamination stack model 41, pushing the magnet M into the seating of the lamination stack L. It can now be used to create a rotor or stator for an electric motor (FIG. 6D).

[0081] 7A and 7B, a variation of the magnetic loading device 10 includes a single loading wheel 30 with two loading seats 31. Two diametrically opposed rows of magnets M are fed into the loading wheel 30, forming two entry positions PI in the loading seats 31.

[0082] The loading wheel 30 is configured to load magnets M into both the first and second series of seats 21 a, 21 b at two loading positions PCa, PCb that are substantially symmetrical to one another. The two loading seats 31 of the loading wheel 30 form an angle β between them that corresponds to the angle between the axes 210 a, 210 b of the first and second seats 21 a, 21 b at loading positions PCa, PCb, respectively, and the axis of the loading seat 31 at the entrance position PI for the magnets M of the opposite row.

[0083] In this way, while one magnet M is being loaded from a first loading seat 31 corresponding to its loading position PCa, PCb, the next magnet M enters the other loading seat 31. This makes it possible to optimize the loading time even with a single loading wheel 30. The loading of the magnets M into the loading seats 31 is carried out by two push-in members 12 each located in front of a corresponding inlet position PI (FIGS. 7A and 7B).

[0084] In this example, a minimum rotation of the container 20, e.g., 5°, is required to position the sheets 21a, 21b at the corresponding loading positions PCa, PCb, but this minimum rotation can be eliminated by adjusting the angle β between the loading sheets 31 and / or the position of the loading wheel 30 relative to the container 20.

[0085] The operation of the device 10 in this modified example is similar to that of the first modified example already described, with the major difference being that the loading wheel 30 moves back and forth between the position shown in Fig. 7A and the position shown in Fig. 7B. In the position shown in Fig. 7A, the loading wheel 30 loads a magnet M into the seating 21a at the loading position PCa, and simultaneously causes the corresponding pushing member 12 to advance the magnet M into the second loading seating 31. In the position shown in Fig. 7B, the magnet M previously advanced into the second loading seating is loaded into the seating 21b corresponding to the loading position PCb, and simultaneously causes the corresponding pushing member 12 to advance the magnet M into the first loading seating 31.

[0086] In the example shown, there are six pairs of seatings, and the housing 20 is rotated by 60° at each step, and the above steps are repeated until all seatings 21a, 21b are loaded with their respective magnets M.

[0087] 8 and 9, a second embodiment of an apparatus 100′ for inserting magnets into a laminate stack L′ is shown. In this second embodiment, the apparatus 100 is configured to insert two different types of magnets M1 and M2 into the same laminate stack L′. To this end, the laminate stack L and the laminate stack model 41′ comprise a plurality of identical sheets 41′ a, 41′ b, 41′ c, and 41′ d, which are divided into a first pair of sheets 41′ a, 41′ b configured to accommodate a first type of magnet M1 and a second pair of sheets 41′ c, 41′ d configured to accommodate a second type of magnet M2 ( FIGS. 9 and 9A ).

[0088] The first and second sheeting pairs 41'a, 41'b, 41'c, 41'd are distributed on two respective circumferences along the periphery of the laminate stack L and the corresponding model.

[0089] In this case, two different magnet loading devices 10, 10' are provided. The first device 10 (left side of FIG. 8) loads a first type magnet M1 into a plurality of first seating pairs 21'a, 21'b corresponding to the aforementioned first seating pairs 41'a, 41'b of the stack model 41. The second device 10' (right side of FIG. 8) loads a second type magnet M2 into a plurality of second seating pairs 21'c, 21'd corresponding to the aforementioned second seating pairs 41'c, 41'd of the stack model 41. Two loading positions PCc, PCd are defined in the second device 10' for loading the sheets 21'c, 21'd, which overlap and are coaxial with the corresponding loading sheets 31' of the loading wheel 30'.

[0090] The two devices 10, 10' differ in their housings 20', 20'', each of which only has one pair of seatings loaded. More precisely, the housing 20' of the first magnetic loading device 10 only has first seatings 21'a, 21'b, while the housing 20'' of the second magnetic loading device 10' only has second seatings 21'c, 21'd.

[0091] Furthermore, the two devices 10, 10' differ in the size of the loading seats 31, 31' of the loading wheels 30, 30' and in their positions relative to the containers 20', 20" so that the loading seats 31, 31' overlap the corresponding seats 21'a, 21'b, 21'c, 21'd at the loading positions PCa, PCb, PCc, PCd.

[0092] The operation of the two magnetic loading devices 10, 10' is similar to that described above with reference to Figures 6a to 6d.

[0093] As an alternative to the two magnetic loading devices 10, 10′ shown in FIG. 9, the apparatus 100′ can be configured with only one magnetic loading device configured to load both types of magnets. For example, the device can have two loading members, each loading a different type of magnet. A single magnetic loading device can also be configured with a single loading member having two different types of loading seatings, each loading a different type of magnet. For example, the device can be of the type shown in FIGS. 7A-7B, with a single loading member having two loading seatings, one configured to accommodate a first type of magnet and the other configured to accommodate a second type of magnet.

[0094] The apparatus 100' for inserting magnets into a lamination stack L' comprises, in addition to the two magnet loading devices 10, 10' described above, a single transfer device 40' and a single insertion station 50'. The transfer device 40' and the insertion station 50' are identical to those of the first variant of the apparatus, except for the corresponding lamination stack model 41', which reproduces the seating positions of the lamination stack L' to be loaded, and the push-in elements 52', which correspond to the lamination stack model 41' and the seats 41'a, 41'b, 41'c, 41'd of the lamination stack L', as shown in Figure 9A.

[0095] The two magnetic loading devices 10, 10' are spaced apart from each other and from the insertion station 50' (Fig. 9). The transfer device 40' is displaceable, in particular translatable, between the first magnetic loading device 10, the second magnetic loading device 10' and the insertion station 50'.

[0096] The operation of the apparatus 100' is to load different types of magnets M1, M2 into the rotatable housings 20', 20", respectively. Once the housings 20', 20" are loaded, the transfer device 40' moves below the first magnet loading device 10' and removes the first magnet M1 stored therein. Subsequently, the transfer device 40' moves below the second magnet loading device 10' and removes the second magnet M2 stored therein.

[0097] At this point, sheets 41'a, 41'b, 41'c, 41'd of the laminated stack model 41' are loaded with magnets M1, M2 of both types. The transfer device 40' moves to a corresponding insertion station 50', where the magnets M1, M2 are inserted into the laminated stack L' by means of a pusher member 51'. The pusher member 51' is suitably provided with pusher elements 52' that reproduce the number, shape, size, and arrangement of all first sheeting pairs and all second sheeting pairs of the laminated stack L'.

[0098] It will be apparent that modifications and / or additions of components or steps may be made to the magnet loading device 10, the apparatus 100 for inserting magnets into a rotor lamination stack, and the corresponding method of operation described above, without departing from the field and scope of the present invention as defined in the claims.

[0099] Although the present invention has been described with reference to some specific examples, it will be clear to those skilled in the art that other equivalent forms of magnet loading devices and apparatuses for inserting magnets into a rotor lamination stack, and corresponding methods of operation, can also be realised which have the features set out in the claims and which are therefore all included in the field of protection defined by the claims.

[0100] In the following claims, references in parentheses are for the purpose of readability only and should not be considered as limiting factors with regard to the field of protection defined by the claims.

Claims

1. a housing (20, 20') rotatable about a first rotation axis (Y1), the housing (20, 20') comprising a plurality of magnet housing seats (21a, 21b, 21'a, 21'b, 21'c, 21'd) distributed along the periphery of the housing (20, 20'); at least one magnet loading member (30, 30') rotatable about a second rotation axis (Y2, Y3) parallel to the first rotation axis (Y1), the at least one magnet loading member (30, 30') comprising at least one loading seating (31, 31') constructed and arranged to at least partially accommodate magnets (M, M1, M2) supplied substantially radially to the magnet loading member (30, 30'); A magnetic loading device (10, 10') comprising: the second rotation axis (Y2, Y3) is spaced from the first rotation axis (Y1), and the at least one loading member (30, 30') partially overlaps with a portion of the peripheral edge of the container (20, 20'); the at least one loading member (30, 30') is configured to rotate the at least one loading seating (31, 31') between an entrance position (PI) for receiving a magnet and a loading position (PCa, PCb) for axially releasing a magnet loaded in one of the plurality of magnet receiving seats (21a, 21b, 21'a, 21'b, 21'c, 21'd); the loading sheeting (31, 31') is positioned away from the plurality of magnet storage sheets (21a, 21b, 21'a, 21'b, 21'c, 21'd) when in the entrance position (PI), and overlaps with one of the storage sheets (21a, 21b, 21'a, 21'b, 21'c, 21'd) when in the loading position (PCa, PCb); A magnetic loading device (10, 10').

2. the at least one loading member (30, 30') is configured and sized such that when one loading seating (31, 31') is positioned corresponding to the loading position (PCa, PCb, PCc, PCd), another loading seating (31, 31') of the same loading member (30, 30') is at the magnet inlet position (PI) to radially accommodate magnets (M, M1, M2) subsequently loaded into the housing (20, 20'); A magnetic loading device (10, 10') according to claim 1.

3. at least two adjacent loading seats (31, 31') of the loading member (30, 30') are oriented to form an angle (β) therebetween equal to the angle formed between the central axes (210a, 210b) of the magnet containing seats (21a, 21b, 21'a, 21'b, 21'c, 21'd) located at the loading positions (PCa, PCb, PCc, PCd) and the central axis of the loading seat (31, 31') located at the entrance position (PI); the central axis is arranged perpendicular to and passes through the second rotation axis (Y2, Y3) of the loading member (30, 30') having the loading seating; A magnetic loading device (10, 10') according to claim 2.

4. the at least one loading sheeting (31, 31') is configured as a pocket having an inlet opening through which the magnets (M, M1, M2) enter, an abutment bottom opposite the inlet opening against which the magnets collide as they are fed radially, and two opposite side walls arranged at a distance substantially equal to the thickness of the magnets; A magnetic loading device (10, 10') according to any one of claims 1 to 3.

5. The loading member (30, 30') is configured as a wheel having a plurality of loading seats (31, 31') arranged along a radial direction. A magnetic loading device (10, 10') according to any one of claims 1 to 4.

6. The plurality of magnet containing sheets (21a, 21b, 21'a, 21'b, 21'c, 21'd) are divided into a first series of sheets (21a, 21'a, 21'c) oriented according to a first angle (α1) with respect to the radial direction (R) of the containing body (20), and a second series of sheets (21b, 21'b, 21'd) oriented according to a second angle (α2) with respect to the radial direction (R) of the containing body (20). A magnetic loading device (10, 10') according to any one of claims 1 to 5.

7. The plurality of magnet-containing sheetings (21a, 21b, 21'a, 21'b, 21'c, 21'd) are arranged in pairs; each pair comprises one sheeting of said first series of sheetings (21a, 21'a, 21'c) and one sheeting of said second series of sheetings (21b, 21'b, 21'd); A magnetic loading device (10, 10') according to claim 6.

8. the sheets of said first series of sheetings (21a, 21'a, 21'c) have the same or different sizes relative to the sizes of the sheets of said second series of sheetings (21b, 21'b, 21'd); A magnetic loading device (10, 10') according to claim 6 or 7.

9. the housing (20, 20') comprises a blocking device (24, 24') configured to temporarily and selectively retain the magnets (M, M1, M2) within the magnet housing seating (21a, 21b, 21'a, 21'b, 21'c, 21'd); A magnetic loading device (10, 10') according to any one of claims 1 to 8.

10. The blocking device (24, 24') comprises a plurality of diaphragms (25); Each diaphragm (25) an engagement position in which at least one of the plurality of magnet-containing seats (21a, 21b, 21'a, 21'b, 21'c, 21'd) is at least partially closed at the bottom; a release position in which the at least one sheeting among the plurality of magnet containing sheets (21a, 21b, 21'a, 21'b, 21'c, 21'd) is allowed to completely pass through in correspondence with the bottom wall (23) of the containing body (20, 20'); It is movable between A magnetic loading device (10, 10') according to claim 9.

11. 1. A device (100, 100') for inserting magnets (M, M1, M2) into a lamination stack (L, L'), comprising: At least one magnetic loading device (10, 10') according to any one of claims 1 to 10, an insertion station (50, 50') for inserting magnets (M, M1, M2) into said lamination stack (L, L'), said insertion station (50, 50') being positioned at a distance from said at least one magnet loading device (10, 10'); a transfer device (40, 40') movable between the at least one magnet loading device (10, 10') and the insertion station (50, 50') and configured to transfer the magnets (M, M1, M2) from the at least one magnet loading device (10, 10') to the insertion station (50, 50'); An apparatus (100, 100') comprising:

12. The transfer device (40, 40') comprises a stack model (41, 41') having a plurality of transfer sheets (41a, 41b, 41'a, 41'b, 41'c, 41'd) arranged in the same manner as the arrangement of the plurality of magnet-containing sheets (21a, 21b, 21'a, 21'b, 21'c, 21'd).

12. The device (100, 100') according to claim 11.

13. a first magnet loading device (10) configured to load a first type magnet (M1); a second magnet loading device (10') configured to load a second type magnet (M2); the first magnetic loading device (10) and the second magnetic loading device (10') are spaced apart from each other and from the insertion station (50'); 13. An apparatus (100') according to claim 11 or 12.

14. 1. A method for loading magnets into a housing (20, 20') rotatable about a first axis of rotation (Y1), the housing (20, 20') comprising a plurality of magnet housing seats (21a, 21b, 21'a, 21'b, 21'c, 21'd) distributed along the periphery of the rotatable housing (20, 20'), comprising: supplying a plurality of magnets (M, M1, M2) sequentially in a substantially radial direction towards at least one magnet loading member (30, 30'), the at least one magnet loading member (30, 30') being rotatable about a second rotation axis (Y2, Y3) parallel to and spaced apart from the first rotation axis (Y1), and comprising at least one loading seating (31, 31') constructed and arranged to be able to at least partially accommodate the magnets (M, M1, M2) supplied to the loading member (30, 30'); inserting a magnet (M, M1, M2) into the at least one loading seating (31, 31') corresponding to an entry position (PI) away from the plurality of magnet receiving seats (21a, 21b, 21'a, 21'b, 21'c, 21'd); rotating the loading member (30, 30') around the second rotation axis (Y2, Y3) to displace the at least one loading seating (31, 31') in which the magnets (M, M1, M2) are housed towards a loading position (PCa, PCb) where the at least one loading seating (31, 31') overlaps one of the magnet housing seats (21a, 21b, 21'a, 21'b, 21'c, 21'd) of the rotatable housing (20, 20'), thereby releasing the magnets axially downward within the magnet housing seats (21a, 21b, 21'a, 21'b, 21'c, 21'd); A method for providing the above.

15. A method for inserting magnets into a lamination stack (L, L'), comprising the steps of: The method for loading a magnet into a rotatable housing (20, 20') according to claim 14, which is associated with a magnet loading device (10, 10'), comprises the steps: a step of releasing the magnets (M, M1, M2) loaded in the rotatable housing (20, 20') toward a transfer device (40, 40'), the transfer device (40, 40') comprising a stack model (41, 41') having a plurality of transfer seats (41a, 41b, 41'a, 41'b, 41'c, 41'd) arranged in the same manner as the arrangement of the plurality of magnet housing seats (21a, 21b, 21'a, 21'b, 21'c, 21'd); transferring the magnets (M, M1, M2) by displacing the transfer device (40, 40') from the magnet loading device (10, 10') towards a magnet insertion station (50, 50'); inserting the magnets (M, M1, M2) into the lamination stack (L, L') corresponding to the insertion stations (50, 50'); A method for providing the above.

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