Apparatus and method for deforming conductors of at least one winding assembly protruding from the side of a stator or rotor of an electrical machine.
The radial backing member apparatus addresses misalignment and stress issues in conductor deformation by guiding and supporting conductors during twisting, enhancing precision and insulation integrity in electrical machines.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- TECNOMATIC
- Filing Date
- 2021-10-29
- Publication Date
- 2026-07-07
Smart Images
Figure 0007886028000001 
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Abstract
Description
Technical Field
[0001] The present invention relates to an apparatus and a method for deforming a conductor protruding from a side surface of a stator or a rotor of an electric machine. In particular, the present invention relates to a method of twisting an end portion of a conductor on a welding side.
Background Art
[0002] It is known to form a winding set of electrical rod-shaped conductors for a stator or a rotor of an electric machine such as a generator or a motor.
[0003] In this type of winding, the electrical rod-shaped conductors form the elements of the winding. These winding elements are shaped in a series of steps and inserted into the stator or rotor so that, together with other winding elements, the ends of such elements are welded together to form a predetermined winding pattern. Also, these winding elements are referred to as electrical rod-shaped windings.
[0004] Certain types of electrical rod-shaped conductors are often referred to in the jargon as "hairpins" because of their initial shape. Hereinafter, for simplicity, the term "hairpin" will be used.
[0005] A hairpin comprises two legs or ends, denoted by the following terminal terms. The hairpins are assembled to the stator or rotor of the electric machine to form a circular set. This circular set is generally defined by the term "winding set". Thus, the rod-shaped windings may comprise one or more concentric sets with respect to each other. In these one or more concentric sets with respect to each other, the hairpins are electrically connected to each other according to a predetermined pattern depending on the type of operation required.
[0006] The core of a stator or rotor of an electromachine with radial magnetic flux is substantially a ring having two planes and two cylindrical surfaces, with generators perpendicular to the two planes parallel to the axis of rotation of the rotor of the electromachine. Hereinafter, radial, circumferential, and axial directions refer to the latter axis unless otherwise specified. One of the two cylindrical surfaces is at least partially adjacent to the air gap of the electromachine to which the stator or rotor belongs, and forms a group of grooves that accommodate the linear components of the windings. The two planes are divided into an insertion surface or insertion side and a surface or side opposite the insertion side, which is called the torsion side. Components of the windings protruding from the core are called headers. The ends of the free portions of the conductors belong to headers protruding from the side opposite the insertion headers. Many headers are twisted after insertion and welding. If there are bridge-connected protrusions in the windings, the protrusions belong to headers protruding from the insertion side. In the following, any portion that protrudes from the insertion side, is free, or is connected in a bridge-like manner will be referred to as the portion from the insertion side.
[0007] The core area of the stator or rotor between a groove and an adjacent groove is called a tooth. The number of teeth is equal to the number of grooves. The connecting components of the core teeth, which form a portion of each groove and are located on the opposite side of the groove that is open in the machine's cavity, are called yokes.
[0008] The groove can be divided into a matrix of positions where the legs of a rod-shaped conductor can be placed. Conductors housed in the same radial position within the groove form a so-called winding layer.
[0009] In other words, the term "layer" refers to the annular arrangement of terminals on the legs. Each set consists of two layers: an inner layer and an outer layer.
[0010] The cross-section of a hairpin may be, for example, circular, rectangular, or square. In particular, a rectangular or square cross-section means a substantially rectangular or square cross-section with rounded ends. There are also other types of cross-sections, such as a trapezoidal cross-section with rounded ends, like the rectangular cross-section mentioned above. The cross-sections of hairpins are known to those skilled in the art. This is why no further explanation is given.
[0011] Known hairpin forming processes involve three main steps: preforming, insertion-side twisting (or pre-insertion twisting), and welding-side twisting (post-insertion twisting).
[0012] Preforming involves the initial bending of a straight rod. This initial bending yields a "U" shape or a "P" shape. Examples of forming methods and respective apparatuses are described in U.S. Patent No. 7,480,987.
[0013] In this initial step, the hairpin comprises two legs connected at one end and arranged in parallel. These two legs may be of the same length ("U" shape) or of different lengths ("P" shape). In fact, this pre-forming yields a winding element resembling a hairpin. This hairpin-like winding element is later extended to a conductor with non-adjacent legs. Thus, each leg of the hairpin has a free end opposite to the connecting end. Each free end has an end face, which results from the cut of the conductor used to form the hairpin and is substantially perpendicular to the conductor itself.
[0014] Figure 1 shows an example of a pre-formed hairpin. Figure 1 shows a flat U-shaped hairpin 102 having two legs 104, 106 and a connecting part 112.
[0015] The pre-formed hairpin undergoes a so-called twisting from the insertion side, that is, a step in which the legs of the hairpin are spread substantially relative to each other. In this regard, a twisting device from the insertion side is used. This twisting device provides concentric rollers that can rotate relative to each other. Each guide roller is provided with a pocket or cavity extending substantially parallel to the axis of rotation of the roller into which the legs of the hairpin can be inserted. The hairpin is inserted with one leg into the cavity of the first roller and the other leg into the cavity of a radially adjacent second roller.
[0016] The relative rotation between the two concentric rollers results in a widening of the connection. This widening of the connection is substantially equal to the angular distance between the grooves in the stator or rotor that house the hairpin when the hairpin is mounted to the stator or rotor of an electromachine.
[0017] Figure 2 shows an example of the configuration of a hairpin after it has been twisted from the insertion side. Note that in Figure 2, the connector 112 has a region at the top where the cross-section of the conductor is rotated 180 degrees relative to the central plane of the hairpin (the plane that passes inside the hairpin and includes the two legs).
[0018] The method of twisting on the insertion side is known to those skilled in the art (for example, from U.S. Patent No. 7,805,825) and is not for the specific purposes of this disclosure, so no further explanation is provided.
[0019] A twist from the insertion side is applied to form the winding assembly before it is inserted into the stator.
[0020] Hairpins can also be obtained by molding, that is, from a straight conductor pressed against a contrasting "punch-die" type system. The cross-section of the molded hairpin does not rotate substantially with respect to the central plane of the hairpin.
[0021] Other types of hairpins in prior art include the so-called "I-pin," a conductor with a W-shape ("W-shaped conductor"), and stranded hairpins ("stranded wire").
[0022] I-pin type hairpins are "I" shaped because they are hairpins obtained without U-bending, or, as can be inferred from the name, are substantially "I" shaped. Therefore, this type of conductor has two legs protruding from different sides of the rotor or stator of an electromachine.
[0023] Hereinafter, in this disclosure, a base conductor is a conductor that can be inserted into a rotor or stator.
[0024] The winding assembly may comprise, for example, a group of base conductors whose connectors on one side and legs on the other side, particularly the free end, are parallel to each other, so that they can be inserted into corresponding grooves in the core of the stator. In other configurations, for example in the case of an I-pin, there may be windings without connectors, and windings where the connector and the free end are on the same side.
[0025] Generally, for example, the free ends of the legs of the base conductors protruding from the stator core are subjected to a different type of torsion than that described above, which is referred to as "torsion from the weld side" or "torsion after insertion" in the corresponding device. Figure 3 shows an example of a base conductor after torsion from the weld side.
[0026] The primary purpose of torsion is to combine two free ends of two radially spaced legs, which are initially on different circumferences but separated from each other.
[0027] The approach between the ends is achieved, for example, by inserting each layer of the free end of the base element's leg into the respective seat or groove of the torsion ring for that layer. The torsion rings, which are concentric with each other, determine this approach between the ends by rotating one relative to the other.
[0028] For example, as a unit of the distance between portions accommodated in grooves of two end portions that can be approximated, by using the number of grooves between the portions, assuming a distance of six grooves, three grooves of one ring are rotated in one direction and three grooves of the other ring are rotated in the opposite direction, thereby achieving approximation.
[0029] Therefore, the base conductor includes, for example, a first leg portion that stays in a corresponding groove of the stator, a portion inclined in the rotation direction of each ring with respect to the main axis of the core of the stator, and an end portion that is substantially parallel to the main axis of the core of the stator and is in a different radial direction with respect to the first leg portion.
[0030] Examples of the welding side method and the twisting device are described, for example, in U.S. Patent No. 8,215,000. In particular, a twisting device is described that enables obtaining differentiated twisting of end portions inserted into the same ring. The differentiated twisting is obtained, for example, by providing that a ring portion provided with grooves is movable along the circumference of the ring itself. This mobility means that when the ring rotates, the end portion of the base conductor inserted into the groove of the movable ring has a twist delay until the movable portion is adjacent to the remaining portion of the ring structure.
[0031] On the other hand, the method of welding the end portions of the base conductor is a very delicate step in the process of obtaining a rod-shaped winding because the end portions are very close to each other.
[0032] In fact, the approximation of the end portions of the base element is a desirable feature while complicating the welding process. For example, if the welding has to be performed only between two end portions, this step has to be very precise to prevent involving immediately adjacent end portions.
[0033] Furthermore, due to the approximation of the end portions, although a rare case, there is a possibility of an electrical phenomenon such as an electric arc occurring between a pair of terminals.
[0034] Furthermore, when using the torsion device described in the prior art, if there are many conductors housed in the grooves of each stator (or rotor), misalignment occurs between the conductors that are close to each other and the cavities of the torsion device that are separated by radially spaced walls.
[0035] Furthermore, the radial proximity between the legs prevents the insertion of insulating rings between layers of the same set.
[0036] To overcome these drawbacks, it is known to use a torsion ring having at least one pocket element that is movable radially toward or away from the axis of the torsion ring itself. This type of device is shown in International Publication No. 2020058842.
[0037] In this type of device, pocket elements are arranged that are related to conductors of the same layer that are movable in the radial direction.
[0038] In other words, the general operation of this apparatus provides a step of spreading the conductor layer before and / or during the actual twisting step.
[0039] For such a method to be effective, it is necessary to ensure that not only the conductor portion inserted into the pocket is guided accurately, but also the conductor portion that is not inserted into the pocket and is immediately outside of it.
[0040] Therefore, while conventional technologies are widely used and highly regarded, they are not without their drawbacks.
[0041] In fact, it lacks a guiding system that would allow the conductor outside the pocket to maintain its position during deformation. [Overview of the project]
[0042] Therefore, it is considered necessary to refer to prior art to at least partially resolve the aforementioned shortcomings and limitations.
[0043] Therefore, it is considered necessary to provide an apparatus and method that more accurately guides the free end of a conductor during the bending steps.
[0044] Furthermore, it is considered necessary to provide apparatus and methods that can reduce stress located at the ends of conductors, which can adversely affect the integrity of the surface coating of the conductor.
[0045] Furthermore, when viewed from the stator axis, it is considered necessary to have a device that can hold part or all of the torsion-stricken conductor outside a predetermined circle during and after deformation. For example, in certain cases, this circle is identified as being in a plane perpendicular to the axis of the device or the stator axis and substantially in contact with the inner surface of the torsion-stricken conductor at its position within the groove. This is to avoid the risk of a bent conductor hindering the completion of insertion of conductors in adjacent layers, and / or to reduce the stress on the insulator between torsion-stricken conductors belonging to adjacent layers.
[0046] Such requirements are at least partially satisfied by the apparatus for deforming a conductor protruding from one side of the stator or rotor of an electric machine as described in claim 1, and by the method for deforming a conductor protruding from one side of the stator or rotor of an electric machine as described in claim 14. [Brief explanation of the drawing]
[0047] Further features and advantages of the present invention will be better understood from the following description of preferred embodiments given by non-limiting examples. [Figure 1] Figure 1 schematically shows a perspective view of a pre-formed, flat, U-shaped hairpin as described in the prior art. [Figure 2] Figure 2 schematically shows a perspective view of a hairpin as described in the prior art. [Figure 3] Figure 3 schematically shows a perspective view of the hairpin in Figure 2 after the torsion on the weld side as described in the prior art. [Figure 4] Figure 4 schematically shows some embodiments of the mechanism for a possible embodiment in the first operating state. [Figure 5] Figure 5 schematically illustrates the mechanism shown in Figure 4 under different operating conditions. [Figure 6] Figure 6 schematically shows a perspective view of a possible alternative embodiment of the components described in the present invention. [Figure 7] Figure 7 shows a bottom perspective view of a possible embodiment of the components described in the present invention. [Figure 8] Figure 8 schematically shows a perspective view of a possible alternative embodiment of the components described in the present invention. [Figure 9] Figure 9 schematically shows a bottom perspective view of a possible embodiment of the components described in the present invention. [Figure 10] Figure 10 schematically shows an oblique view of an alternative embodiment of the components of the apparatus described in the present invention. [Figure 11] Figure 11 schematically shows a front view of some possible embodiments of the apparatus described in the present invention. [Figure 12] Figure 12 schematically shows a portion of the apparatus of Figure 11 positioned relative to the stator / rotor of an electromachine in a step of the method described in an embodiment of the present invention. [Figure 13] Figure 13 schematically shows a perspective view of a magnified portion of a part of the apparatus described in a possible embodiment of the present invention. [Figure 14] Figure 14 schematically shows a perspective view of a possible alternative embodiment of the apparatus described in the present invention. [Figure 15] Figure 15 schematically shows cross-sectional views of possible embodiments of the apparatus described in the present invention in various operating configurations. [Figure 16] Figure 16 schematically shows cross-sectional views of possible embodiments of the apparatus described in the present invention in various operating configurations. [Figure 17] Figure 17 schematically shows cross-sectional views of possible embodiments of the apparatus described in the present invention in various operating configurations. [Figure 18]Figure 18 schematically shows cross-sectional views of possible embodiments of the apparatus described in the present invention in various operating configurations. [Figure 19] Figure 19 schematically shows an enlarged portion of a possible embodiment of the apparatus described in the present invention. [Figure 20] Figure 20 schematically shows a perspective front view of a part of the apparatus described in an embodiment of the present invention. [Figure 21] Figure 21 schematically shows a cross-sectional view of a part of the apparatus described in the embodiment of the present invention in a possible mode of use. [Figure 22] Figure 22 schematically shows a cross-sectional view of a part of the apparatus described in the embodiment of the present invention in a possible mode of use. [Figure 23] Figure 23 schematically shows a plan view of the components of the apparatus described in the embodiment of the present invention.
[0048] Elements or components common to the embodiments described above are indicated by the same reference numerals below. [Modes for carrying out the invention]
[0049] Figure 15 shows a device 200 for deforming a conductor 102 of at least one winding assembly 100 that protrudes from the side of the stator or rotor 114 of an electric machine.
[0050] At least one winding assembly 100 comprises a plurality of base conductors 102, each having at least one leg 104, 106, inserted into a cavity 115 of a stator or rotor 114. Each base conductor 102 has at least one free end 108, 110.
[0051] The device 200 comprises at least one torsion matrix 201 configured to rotate around axis X. The torsion matrix 201 comprises at least one pocket 204 configured to insert free ends 108,110.
[0052] Furthermore, the device 200 includes a radial backing member 300 located near at least one torsion matrix 201, particularly near at least one pocket 204, on the insertion side of the free ends 108, 110. The radial backing member 300 has an inner radial backing surface 302 for a portion of the legs 104, 106 protruding from the side surface of the stator or rotor 114 of the electromachine.
[0053] In particular, the inner radial backing surface 302 may be positioned between the axis X of the torsion matrix 201 and the legs 104, 106 on which the inner radial backing surface 302 operates.
[0054] During the twisting step, the protruding conductors 102 on the same side are bent toward each other to form a winding coil. In this step, the radial backing member 300 acts as an inner backing surface for the portions of the conductor legs 104, 106 that remain outside the twisted pocket, particularly for the portions of the conductor between the pocket and the stator or rotor.
[0055] For example, if the torsion simultaneously wraps around two concentric, adjacent layers and bends them in opposite tangential directions, it is desirable that, with respect to axis X, the torsion-bearing conductor be arranged along a circumference or spiral that expands from an occupied groove position toward a position occupied by the free end 108 or 110, without causing undesirable bending toward, for example, the inside of the winding, according to a plane perpendicular to axis X.
[0056] Therefore, the conductors of the same layer, in their remaining portions outside the torsion pocket 204, find a response within the radial backing member 300 to the deformation acted upon by the pocket 204 itself. This contrasting effect allows for plastic deformation of the conductor at the bending point, for example, as will be described later, thereby reducing the head height accordingly.
[0057] According to a possible embodiment, the radial backing member 300 may rotate about axis X. Advantageously, the radial backing member 300 may rotate synchronously with respect to the torsion matrix 201.
[0058] As a result, the radial backing member 300 can follow the legs 104 and 106 when twisted without sliding between the surface of the conductor 102 and the surface of the radial backing member 300.
[0059] According to a possible alternative embodiment, the radial backing member 300 may rotate at a different speed from at least one torsion matrix 201.
[0060] On the other hand, the surface of the radial backing member 300 intended to contact the conductor may have a surface treatment that minimizes stress on the insulating coating of the conductor that is in contact with the surface of the radial backing member 300. More specifically, possible embodiments of the surface treatment may include full polishing, anti-friction treatment, and treatments having special surface finishes.
[0061] According to a possible embodiment, the inner radial backing surface 302 may have a cylindrical extension relative to the axis X. That is, the inner radial backing surface 302 that contacts a portion of the legs 104, 106 protruding from the side surface of the stator or rotor 114 of the electromachine during use may be substantially parallel to the axis X.
[0062] In a possible alternative embodiment, the inner radial backing surface 302 may have a conical extension. That is, in this case, the inner radial backing surface 302, which is intended to contact a portion of the legs 104, 106 during use, is inclined to widen toward the torsion matrix 201 and narrow toward the stator or rotor.
[0063] In a further possible embodiment, the inner radial backing surface may have a conical extension. That is, the cross-sectional trace of such a surface obtained by the longitudinal plane may have a predetermined external curvature.
[0064] In this disclosure, the "extension" of the inner radial backing surface 302 means the trace of a cross section following a plane having the axis X of the backing surface that acts on the leg portions 104 and 106.
[0065] The inner radial backing surface 302 may have a continuous extension along the entire circumference of the radial backing member 300.
[0066] Alternatively, as shown in the embodiment of Figure 23, the radial backing member 300 may comprise a body 304 and a plurality of teeth 306 protruding from the body 304, such that the radial backing surface 302 is positioned on the teeth 306.
[0067] A groove may be provided between each tooth. In this case, each tooth 306 protrudes between the two grooves 308.
[0068] In a possible embodiment, the teeth 306 may be fixed to the body, for example, to form the whole.
[0069] According to a possible alternative embodiment, the radial backing member 300 may have at least one tooth 306 that can be moved radially with respect to the axis X by a moving means 310. The radial backing surface 302 is provided on at least one of the teeth 306.
[0070] In this case, at least one tooth 306 can move between a retracted position that defines the minimum radial dimension and an extended position that defines the maximum radial dimension.
[0071] According to a possible embodiment, at least one tooth 306 moves within each radial seat 312 obtained in the body 304.
[0072] According to possible embodiments, the moving means 310 may be of the cam type. In particular, the moving means 310 can utilize the rotation or movement of the control sleeve 314 along axis X.
[0073] According to a possible embodiment, the moving means 310 is A first plate 316 extending perpendicular to axis X, having at least one radial seat portion 312 for a tooth 306 that can move in at least one radial direction, and configured to at least partially suppress axial and circumferential movement of the first plate 316 itself, The first plate 316 may also have a second plate 318 that extends perpendicularly to the axis X and moves relative to the first plate 316 to cause radial movement of at least one tooth 306.
[0074] In this disclosure, the term “flat” used to describe an element means an element extending by two main dimensions to a third dimension, and preferably includes a circular equipment contact surface which may consist of multiple elements.
[0075] Figure 11 shows a possible embodiment of a moving means 310 having a first plate 316 and a second plate 318.
[0076] According to a possible embodiment, the moving means 310 may have a horizontal cam system.
[0077] For example, embodiments are shown in Figures 6 to 10.
[0078] The horizontal cam-driven moving means 310 is A first plate 316 extending perpendicular to axis X, having at least one radial seat portion 312 for a tooth 306 that can move in at least one radial direction, and configured to at least partially suppress axial and circumferential movement of the first plate 316 itself, A second plate 318 extending perpendicularly to axis X, which moves relative to the first plate 316 to cause radial movement of at least one tooth 306, A slot 320 extending in a plane perpendicular to the axis X for each tooth 306, located in the second plate 318, and The device may also have at least one pin 322, which includes an extension substantially parallel to axis X, provided at one end of each tooth 306, and configured to slide and be guided by each horizontal slot 320, facing the second plate 318 when in use. Pin 322 has a direction parallel to the axis X of the device.
[0079] As shown in Figure 10, each slot 320 may have a curved extension for advantage.
[0080] In this embodiment, the first plate 316 and the second plate 318 are connected to the first sleeve 324 and the second control sleeve 314, respectively.
[0081] According to a possible embodiment, the horizontal cam moving means 310 may have a limit stop 315. The limit stop 315 may have at least one radial projection 319 provided on the side surface of the first plate 316 and at least one corresponding sliding seat portion 321 located on the second plate 318.
[0082] Figure 7 shows an embodiment of this type.
[0083] According to a possible embodiment, the limit stop 315 may have eight radial projections 319 and eight corresponding sliding seat portions 321.
[0084] The radial projection 319 may be substantially trapezoidal in cross-section, similar to the corresponding sliding seat portion 321. Thus, there is engagement of each hypotenuse at the limit stop.
[0085] Since at least one tooth 306 is located in each radial seat (not shown in the accompanying drawings) on the first plate 316, relative rotation between the first sleeve 324 and the control sleeve 314 causes at least one pin 322 located on at least one tooth 306 to slide. Thus, the tooth 306 can move radially outward or inward in accordance with the direction of rotation.
[0086] According to a possible alternative embodiment, the moving means 310 may have a vertical cam system.
[0087] For example, this type of embodiment is shown in Figures 11-13. It is also shown schematically in Figures 4-5.
[0088] The vertical cam moving means 310 is A first plate 316 extending perpendicular to axis X, having at least one radial seat portion 312 for a tooth 306 that can move in at least one radial direction, and configured to at least partially suppress axial and circumferential movement of the first plate 316 itself, A second plate 318 extends perpendicular to axis X and, by moving relative to the first plate 316, defines the radial movement of at least one tooth 306, and includes a radial groove 328 corresponding to each tooth 306, and each tooth 306 is partially inserted into the radial groove 328 together with a support portion 307, the second plate 318 and A vertical slot 326 is provided in each support portion 307 of each tooth 306, and the vertical slot 326 is inclined with respect to the axis X, The device includes at least one horizontal pin 330 extending substantially perpendicular to the axis X, provided within a corresponding radial groove 328 and configured to slide within a vertical slot 326 perpendicular to the radial direction.
[0089] In this embodiment, the first plate 316 and the second plate 318 are connected to the first sleeve 324 and the control sleeve 314, respectively.
[0090] Since at least one tooth 306 is located in each radial seat 312 on the first plate 316, relative rotation between the first sleeve 324 and the control sleeve 314 causes at least one pin 330 located in at least one radial groove 328 to slide. Thus, the tooth 306 can move radially outward or inward according to the relative direction of movement.
[0091] For example, as shown in Figure 11, the vertical slot 326 may be inclined with respect to axis X such that the distance from axis X closer to the first plate 316 is greater, and the distance from axis X closer to the second plate 318 is smaller. This type of embodiment is schematically shown in Figures 4 and 5.
[0092] In this case, moving the first plate 316 toward the second plate 318 causes at least one tooth to be contained within the first plate 316. Alternatively, moving the first plate 316 away from the second plate 318 causes at least one tooth to emerge toward the deployed position.
[0093] This embodiment is illustrative only, as the vertical cam may have other configurations. For example, the vertical slot 326 may be reversed. That is, the vertical slot 326 may be inclined with respect to the axis X such that it is closer to the first plate 316 and further away from the axis X closer to the second plate 318.
[0094] In this case, by moving the first plate 316 away from the second plate 318, at least one tooth will be contained within the first plate 316. Alternatively, by moving the first plate 316 toward the second plate 318, at least one tooth will emerge toward the deployed position.
[0095] According to a possible alternative embodiment, although not shown in the accompanying drawings, the second plate 318 or tappet support element may consist of a plurality of identical parts arranged radially, each supporting one or more pins that drive the teeth 306. For example, the parts may be connected / supported by a specific structure (plate, sleeve, etc.).
[0096] According to a possible embodiment, the annular surfaces of the sleeves 314, 324 may have teeth for driving the circular motion of the sleeves.
[0097] Figure 12 shows an apparatus according to the present invention. In this apparatus, the radial backing member 300 is positioned near the winding assembly 100 on which the radial backing member 300 will act. In the drawing, the winding set 100 is partially inserted into the cavity 115 of the stator 114 and does not fully emerge from the torsion side of the stator core. In this case, the teeth 306 of the radial backing member 300 need to be in a stowed position or at an angle offset from the groove 115 to leave space for the full insertion of at least one winding set 100.
[0098] Figures 13-17 show an embodiment in which the device 200 comprises a torsion matrix 201 with at least one pocket 204 located on a radially movable element 203. In the particular embodiment shown, all pockets 204 are located on the radially movable element 203.
[0099] Referring to the embodiment shown in Figure 15, the first plate 316 may be integrated with the stator 114 by the support structure 333 of the stator 114.
[0100] In an alternative embodiment, although not shown in the accompanying drawings, the first plate can be moved in the direction of axis X, thereby enabling movement of the radial backing member 300 along axis X.
[0101] In Figure 15, it should be noted that the outer set 100 is inserted into the pockets 204 of the torsion matrix 201 until the free ends 108 and 110 are inserted, and that the teeth 306 of the radial backing member 300 are brought closer to the protrusions of the conductor 102.
[0102] Figure 16 shows a later point in time than shown in Figure 15. In this case, torsion has begun, and tooth 306 is acting in response to the force applied by the conductor in contact with the tooth. More specifically, compared to the previous situation, tooth 306 is shifted outward because the pocket element 204 of the torsion matrix 201 has shifted outward.
[0103] Figure 17 shows a detail of how tooth 306 further follows the outward movement of the conductor.
[0104] It should be noted that the innermost set of conductors is prevented from sliding vertically by the teeth themselves.
[0105] Figure 22 also shows the same operating mode.
[0106] In other words, according to a conceivable embodiment, the radial backing member 300 may be used to prevent a predetermined set of conductors from moving vertically.
[0107] According to a possible embodiment, the radial backing member 300 can be used as a guide while inserting the conductor into the pockets of the torsion matrix.
[0108] In fact, Figure 22 shows the position of the radial backing member at the end of inserting the multiple conductors of the outermost layer into their respective pockets in the torsion matrix. Essentially, the entry of the conductors into the pockets is facilitated by the radial backing member guiding the conductors so that they cannot move radially inward.
[0109] According to a possible embodiment, pushing the conductors ensures they fully exit from the torsion side, allowing them to be re-entered from the insertion side. The pocket can follow such movement, while the radial backing member may remain stationary to prevent frictional drag of the innermost set of conductors. That is, the radial backing member can also act as axial backing for the innermost set of conductors when exiting from the torsion side of the stator or rotor of an electromachine.
[0110] Figure 18 shows the moment after the torsion of the outermost set 100 is complete and the sets adjacent to set 100 have been inserted into the pocket elements of the torsion matrix.
[0111] According to a possible alternative embodiment, the radial backing member 300 may have a plurality of radially movable teeth 306, each having circumferential ends 362,364 that overlap with the corresponding circumferential ends 362,364 of adjacent teeth 306 in a direction parallel to the axis X.
[0112] In other words, each tooth 306 has circumferential ends 362, 364 that protrude from the tooth 306 at positions spaced apart along axis X. Furthermore, the thickness of each circumferential end 362, 364 may be substantially half the thickness of the tooth 306. This allows two consecutive teeth to connect to each other, as the circumferential ends face each other and form substantially the same tooth thickness.
[0113] More specifically, the number of teeth 306 may be less than the number of grooves in the stator being machined. This embodiment applies, for example, when each tooth 306 can be used to compare the simultaneous deformation of multiple protruding conductors in the same layer.
[0114] Compared to the previously described embodiment, this embodiment has the advantage of being smaller in size due to the smaller number of teeth 306 to be moved, and therefore the advantage that the moving means 310 is relatively simple and the number of grooves in the stator to be machined is the same.
[0115] As shown in Figures 6-10, the radial backing member 300 has a substantial overlap at its circumferential ends 362 and 364 in the radial dimension to maintain a predetermined continuity. The overlap can, in some cases, maintain a symmetrical action on the conductor between one tooth and the next, and can also eliminate rotational motion of the tooth 306. In fact, without such overlap, as the teeth expand, a groove is created between one tooth and the other, which in the same case causes undesirable deformation of the corresponding conductor. Therefore, without such overlap, the radial backing member needs to rotate to prevent the twisted conductor from occupying the space between the elements.
[0116] The operation of the device is evident from the description of the device provided.
[0117] Possible operating modes are described below. However, other operating modes are clearly conceivable, and such operating modes should not be considered as limiting the present invention.
[0118] The insertion of the outermost layer set is completed when the conductors are screwed into the stator core. Therefore, the protrusions of the conductors in the winding set have an appropriate length so that their free ends can be welded together. In this step, the conductors of the winding set occupy the grooves formed by the projections / teeth of the radial backing member by axial movement.
[0119] The ends of the conductors are inserted into their respective pockets in the torsion matrix so as to collectively form a conical surface, and are then bent radially by the torsion matrix.
[0120] In this step, the conductive portion occupying the groove of the radial backing member emerges from the groove. When the conductive portion emerges from the groove, the radial backing member rotates freely.
[0121] At the end of the process in which the conductor portion is fully exposed radially from the grooves of the radial backing member, the radial backing member rotates with respect to the axis X of the device, preferably by half the groove pitch, without contacting the conductor of the winding set. Thus, the conductor portion is at an angular position that coincides with the teeth of the radial backing member.
[0122] The function of the teeth is to provide a contrasting effect during the subsequent steps of twisting, which are performed on a circumference with a larger diameter than when the same conductor is placed in a groove. The function of the groove is to prevent obstruction by the backing device when the conductor emerges on the welded side of the stator pack while the axial insertion of the conductor into the groove is completed.
[0123] The free ends of the conductors in the winding set are brought closer to the axis X of the device through the torsion matrix. As a result, a portion of the conductor comes into contact with the teeth of the radial backing member.
[0124] If the radial backing member has radially movable teeth, this step is replaced by a step of repositioning the teeth so that they contact the conductor portion.
[0125] At this point, the rotation step of the pocket elements of the torsion matrix begins, along with the deformation of the conductors of the winding set involved by the grip. During this step, the radial backing member rotates at an appropriate angular velocity so as to prevent the conductors from partially entering the grooves of the radial backing member.
[0126] In this disclosure, “gripping” by the pocket elements of the torsion matrix means inserting the end of a conductor into the pocket or groove, without necessarily intending to actually clamp the conductor within the pocket or groove of the torsion matrix.
[0127] Therefore, the rotation of the backing device is related to the presence of grooves in the radial backing member, and is necessary to prevent the conductor from returning to occupy at least part of the groove area of the radial backing member, i.e., to prevent excessive stress on the insulating coating.
[0128] The rotation can be stopped when the conductor is sufficiently inclined with respect to the insertion surface of the stator core and does not enter the groove of the radial backing member.
[0129] After bending the conductors of a winding set, if the winding is composed of multiple sets, the radial backing member needs to change shape or be replaced with another similar one of appropriate size to accommodate the inward twist of the next winding set, i.e., the adjacent set.
[0130] The surface of the radial backing member connecting multiple contact / pair regions with each conductor subjected to torsional action does not need to have radially movable parts (teeth) and grooves, unless radial expansion of the conductor itself is required.
[0131] The radial backing member can perform any function to prevent untwisted conductors from emerging from the stator pack on the weld side. If the radial backing member has various shapes so that it can be used with multiple winding sets subjected to non-simultaneous torsional action, the function of preventing the inner set from emerging can be performed by plates of various shapes that are axially coupled to the radial backing member and rotate freely relative to the radial backing member.
[0132] Figure 21 schematically illustrates a further embodiment using the radial backing member described in the present invention. In practice, depending on the conceivable modes of operation, the radial backing member may be used to shape and deform the conductive portion between the stator or rotor of an electromachine and the torsion matrix.
[0133] For example, after the end of the conductor has been inserted into the pocket, radial movement of the opposing teeth may occur so that the portion of the conductor between the pocket of the torsion matrix and the stator or rotor of the electromachine can be pushed outward. Preferably, the radial pushing motion by the radial backing member may be accompanied by an axial approach motion between the torsion matrix and the stator or rotor.
[0134] In other words, the backing step allows the free ends 108,110 of the circular array to be radially expanded when a portion of the free ends 108,110 is inserted into the pockets 204 of the torsion array 108,110. That is, the pockets have a substantially constant radial distance from axis X.
[0135] Such an approach may serve two purposes. For example, it can prevent the ends of the conductor from coming out of their respective pockets. Or, it can contribute to the deformation of the conductor portion.
[0136] Some steps in which the radial backing member apparatus described in the present invention may be used are described below. A step of partially inserting a conductor into a groove in the stator core. The step is completed by inserting one or more winding sets axially into the twist pocket. The step of positioning the radial backing member in the appropriate location so as not to prevent it from being fully exposed on the weld side in order to complete the insertion of the conductor into the groove of the stator core. A step of spreading the conductor protruding towards the welding side radially and positioning it on the outside of the cone shape. A step of positioning a radial backing member near each portion of the conductor protruding toward the weld side by rotating the teeth and / or positioning the teeth in the axial direction relative to the winding. A step of recovering the distance between the radial backing member and the conductor by rotating the teeth, moving the teeth radially, and positioning the teeth axially. The same operation as before is performed until the conductor makes contact with an element of the backing material. A step in which the radial backing member is positioned until it contacts the conductor, through tooth rotation, radial movement of the teeth, and axial positioning of the teeth. A twisting step that may occur simultaneously with or in conjunction with radial expansion. A step of tracking a conductor with a radial backing member, achieved by combining radial, angular, and axial motion trajectories, in order to form the conductor's projections such that the projections of the conductors are located in the region of a frustoconical or cylindrical area, and to minimize the slippage of each conductor on the surface of each radial backing member. A step of ending the twisting, accompanied by radial expansion of the previous / simultaneous / successor winding set or group of winding sets. A step of moving the radial backing member relative to each constrained or unconstrained portion of the conductor within the pocket. A step of changing the control device or changing its shape. A step that repeats steps already performed for multiple winding sets.
[0137] The advantages of the apparatus and method described in the present invention are clear.
[0138] In particular, using the radial backing member described in the present invention is convenient because the radial backing member applies an outward radial force with respect to the axis X of the torsion device at the portion of the conductor leg that is not engaged by the gripping element.
[0139] Therefore, the legs of the conductor can be kept outside a predetermined radial distance from axis X. Furthermore, by using a radial backing member, the mechanical adaptive forces in the coating of the conductor undergoing some steps of torsion can be minimized, particularly in relation to the interaction between a pair of adjacent layers of conductors that undergo torsion simultaneously on the weld side. The contrast / contact surface with the outer layer conductor can be determined at any point in the torsion of the inner layer conductor. This contrast / contact surface with the outer layer conductor exerts the contrasting action on the outer layer conductor. This surface is maximized to minimize the pressure on the insulator resulting from these actions if the inner layer conductor remains in contact with the surface of the contrasting movable teeth.
[0140] In particular, by using a radial backing member, a portion of at least one conductor protruding from the weld side is prevented from being subjected to deformation of the conductor acting on the torsional matrix, and as a result of this deformation, from occupying the space required for the insertion of the rotor (or stator), the completion of the insertion of the rotor (or stator), or the completion of the insertion of the winding layer located at the innermost or outermost radial position relative to the axis X.
[0141] Using radial backing members is useful in minimizing stress in the insulator of a conductor protruding from the weld side, provided that before bending the conductor, at least one adjacent layer of conductors is fully inserted so that it protrudes from the weld side by the length necessary for the free end of the conductor to approach the free end of the conductor in the adjacent layer.
[0142] Furthermore, by using a radial backing member having an element that moves radially with respect to axis X, the process of bending the protruding conductor is facilitated, as described above, and because the radial backing member can accommodate sets or winding layers of different sizes that should be bent to form windings of the stator or rotor. The movable teeth allow for the use of a single symmetry matrix per winding instead of one symmetry matrix per set or winding layer.
[0143] To satisfy specific requirements, those skilled in the art can modify the embodiments described above or replace the elements described above with equivalent elements without departing from the scope of the appended claims.
Claims
1. A device (200) for deforming conductors of at least one winding assembly (100) protruding from the side of a stator or rotor (114) of an electric machine, The at least one winding assembly (100) has a plurality of base conductors (102) including at least one leg portion (104, 106) which is inserted into a cavity (115) of a stator or rotor (114) and includes at least one free end (108, 110), The device (200) comprises at least one torsion matrix (201) configured to rotate around a predetermined axis (X), The torsion matrix (201) includes at least one pocket (204) configured to insert the free ends (108, 110), The device (200) includes a radial backing member (300) provided near at least one of the torsion matrices (201), particularly near at least one of the pockets (204), on the insertion side of the free ends (108, 110). The radial backing member (300) has an inner radial backing surface (302) with respect to a portion of at least one of the legs (104, 106) protruding from the side surface of the stator or rotor (114), The apparatus (200) is characterized in that the radial backing member (300) is configured to rotate around the axis (X) synchronously or asynchronously with respect to at least one of the torsion matrices (201).
2. The apparatus (200) according to claim 1, characterized in that the radial backing member (300) has an inner radial backing surface (302) between the stator or rotor (114) and the pocket (204) and a portion of the legs (104, 106) protruding from the side surface of the stator or rotor (114).
3. The apparatus (200) according to claim 1 or 2, characterized in that the inner radial backing surface (302) is positioned between the axis (X) of the torsion matrix (201) and the legs (104, 106) on which the inner radial backing surface (302) operates.
4. The apparatus (200) according to any one of claims 1 to 3, characterized in that the radial backing member (300) is configured to move along the axis (X).
5. The apparatus (200) according to any one of claims 1 to 4, characterized in that the inner radial backing surface (302) has a substantially cylindrical extension.
6. The apparatus (200) according to any one of claims 1 to 4, characterized in that the inner radial backing surface (302) has a substantially conical extension.
7. The radial backing member (300) has a body (304) and a plurality of teeth (306) protruding from the body (304), The apparatus (200) according to any one of claims 1 to 6, characterized in that the radial backing surface (302) is provided on the tooth (306).
8. The radial backing member (300) has at least one tooth (306) that can be moved radially with respect to the axis (X) by a moving means (310), At least one of the teeth (306) is movable between a retracted position that defines the minimum radial dimension and an extended position that defines the maximum radial dimension. The apparatus (200) according to any one of claims 1 to 7, characterized in that the radial backing surface (302) is provided on at least one of the teeth (306).
9. The radial backing member (300) has a plurality of teeth (306) that can move in the radial direction. The apparatus (200) according to claim 8, characterized in that the tooth (306) has circumferential ends (362, 364) that overlap with the corresponding circumferential ends of adjacent teeth (306) in a direction parallel to the axis (X).
10. The aforementioned moving means (310) is A first plate (316) extending perpendicularly to the axis (X), having at least one radial seat portion (312) for the teeth (306) that can move in at least one radial direction, and configured to at least partially suppress the axial and circumferential movement of the teeth (306) relative to the first plate (316) itself, The apparatus (200) according to claim 8 or 9, comprising: a second plate (318) extending perpendicularly to the axis (X), the second plate (318) moving relative to the first plate (316) to cause radial movement of at least one of the teeth (306).
11. The aforementioned moving means (310) is It has a horizontal cam, A first plate (316) extending perpendicularly to the axis (X), having at least one radial seat portion (312) for the teeth (306) that can move in at least one radial direction, and configured to at least partially suppress the axial and circumferential movement of the teeth (306) relative to the first plate (316) itself, A second plate (318) extending perpendicularly to the axis (X), the second plate (318) moving relative to the first plate (316) to cause radial movement of at least one of the teeth (306), A horizontal slot (320) for each of the teeth (306) provided in the second plate (318), wherein the horizontal slot (320) extends radially outward as it moves toward one side in the circumferential direction, The apparatus (200) according to claim 10, comprising: at least one pin (322) having an extension substantially parallel to the axis (X), provided at one end of each of the teeth (306), and configured to slide and be guided by each of the horizontal slots (320) while facing the second plate (318) during use.
12. The aforementioned moving means (310) is It has a vertical cam, A first plate (316) extending perpendicularly to the axis (X), having at least one radial seat portion (312) for the teeth (306) that can move in at least one radial direction, and configured to at least partially suppress the axial and circumferential movement of the teeth (306) relative to the first plate (316) itself, A second plate (318) extending perpendicular to the axis (X), which moves relative to the first plate (316) to cause radial movement of at least one of the teeth (306), and includes at least one radial groove (328) corresponding to at least one of the teeth (306), wherein each of the teeth (306) is partially inserted into the radial groove (328) together with a support portion (307) connected to the tooth (306), A vertical slot (326) extending in a plane passing through the axis (X), provided on each of the support portions (307) of each of the teeth (306), and inclined with respect to the axis (X), the vertical slot (326) The apparatus (200) according to claim 10, comprising: at least one horizontal pin (330) connected to the second plate (318) and extending substantially perpendicularly with respect to the axis (X), provided in the corresponding radial groove (328) and configured to slide within the vertical slot (326) perpendicularly to the radial direction.
13. A method for deforming conductors of at least one winding assembly (100) protruding from the side of a stator or rotor (114) of an electric machine, The at least one winding assembly (100) has a plurality of base conductors (102) including at least one leg portion (104, 106) which is inserted into a cavity (115) of a stator or rotor (114) and includes at least one free end (108, 110), The aforementioned method, A step of gripping at least one of the free ends (108, 110) with a torsion matrix (201) configured to rotate around an axis (X), wherein at least one of the free ends (108, 110) is inserted into a pocket (204) of the torsion matrix (201), The steps include: releasing at least one of the free ends (108, 110) using the torsion matrix (201); A radial backing member (300) provided near at least one of the torsion matrices (201), particularly near at least one of the pockets (204), comprises a backing step that, on the insertion side where the free ends (108, 110) are inserted into the pockets (204), serves as an inner radial backing element for a portion of at least one of the legs (104, 106) protruding from the side surface of the stator or rotor (114), The backing step may be performed before the step of gripping the free ends (108, 110), after the step of gripping the free ends (108, 110), and / or during the step of gripping the free ends (108, 110). The method is characterized in that the radial backing member (300) is configured to rotate around the axis (X) synchronously or asynchronously with respect to at least one of the torsion matrices (201).
14. The method according to claim 13, characterized in that the steps of gripping the free ends (108, 110), releasing the free ends (108, 110), and backing steps simultaneously include all of the legs (104, 106) protruding from the side surface of the circular arrangement of the stator or rotor (114) having the same radial position as determined by the pockets (204) of the torsion matrix (201) into which the free ends (108, 110) of the legs (104, 106) are inserted.
15. The radial backing member (300) has at least one tooth (306) that can be moved radially with respect to the axis (X) by a moving means (310), The inner radial backing surface (302) for a portion of the legs (104, 106) protruding from the side surface of the stator or rotor (114) is provided on at least one of the teeth (306), At least one of the teeth (306) is movable between a retracted position that defines the minimum radial dimension and an extended position that defines the maximum radial dimension. The method according to claim 13 or 14, characterized in that it comprises the step of moving at least one of the teeth (306) in the radial direction.
16. The method according to claim 15, characterized in that during the backing step, at least one of the teeth (306) of the radial backing member (300) moves radially between a retracted position and an unfolded position substantially simultaneously with the torsion step.
17. The method according to claim 16, characterized in that the torsion step includes a step in which at least one of the pockets (204) moves radially.
18. The method according to any one of claims 13 to 17, characterized in that the radial backing member (300) rotates with respect to the axis (X) and / or moves along the axis (X) during the torsional motion.
19. The method according to claim 18, characterized in that the backing step simultaneously includes all of the legs (104, 106) protruding from the side surface of the circular arrangement of the stator or rotor (114) having the same radial position determined by the pocket (204) of the torsion matrix (201) into which the free ends (108, 110) of the legs (104, 106) are inserted.
20. The method according to any one of claims 13 to 19, characterized in that the backing step expands the circularly arranged legs (104, 106) radially when the free ends (108, 110) are inserted into the pockets (204) of the torsion matrix (201).