Device and method for preparing a stator and a pre-formed insulator

Abstract

The present invention relates to a stator (1) that can be used in an electric rotating machine, an apparatus for preparing a pre-formed insulator, and a method for preparing a pre-formed insulator. The stator (1) comprises a stator core (10), which has a plurality of axially extended slots (11) arranged in the circumferential direction (C) of the stator core (10) and at least two conductors (20, 21) arranged along the radial direction (R) of the same slot (11). Each conductor (20, 21) is surrounded by an individual insulator (30) extending around the outer circumference (22) of the conductor (20, 21), so that the insulator (30) in the circumferential direction comprises a single layer section (37) and an overlapping section (31) extending along the full axial length (29) of the insulator (30).

Description

Technology Field

[0001] The present invention relates to a stator that can be used in an electric rotating machine, an apparatus for preparing a pre-formed insulator, and a method for preparing a pre-formed insulator. Background Technology

[0002] Generally, multiple slots are formed within the stator core. These slots extend along the axial direction of the stator. The stator includes stator windings made of conductors having in-slot portions placed in the slots.

[0003] In a stator assembly, an insulating sheet is used to line the walls of the slots of the stator core. In the case of a stator assembly in which two or more conductors are inserted within a single slot, an insulating sheet may be used to provide insulation between adjacent conductors. Generally, conductors are connected together at their ends, but care must be taken to ensure that adjacent conductors do not come into contact with each other and short-circuit the designed winding arrangement. For this purpose, it is known to provide a sheet of insulating material bent into an S shape, for example, as disclosed in EP 3 427 920 A1.

[0004] The S-shaped design generally does not provide complete closure, so that a gap exists between the slot liner and the inner surface of the stator slot, or even between two adjacent conductors. Such a gap may also exist when a sheet of insulating material is bent into a B-shape, for example, as disclosed in US 8,456,056 B2.

[0005] US 8,446,061 B1 and US 2015 / 0188379 disclose an insulating unit for a stator core. The insulator surrounds two or more adjacent conductors and provides an overlapping section.

[0006] Before an insulator sheet is inserted into a slot, it must typically be pre-formed from a flat continuous sheet initially. Pre-formed insulators providing one or more overlapping sections require multiple folding steps, making manufacturing complex, time-consuming, and costly. The problem to be solved

[0007] Therefore, the object of the present invention is to overcome the drawbacks of the prior art, particularly

[0008] The invention provides a stator, device, and method capable of providing a configuration with sufficient insulation and increasing the accuracy of the forming operation. Preferably, the device and method should be capable of fine adjustment or adjustment of the shape. means of solving the problem

[0009] These and other objectives according to the present invention are solved by the apparatus and method according to the independent claim.

[0010] According to the present invention, a stator for a rotary electric machine comprises a stator core, which has a plurality of axially extended slots arranged in the circumferential direction.

[0011] In this application, the terms axial, circumferential, and radial refer to the geometric shape of the stator.

[0012] At least two conductors are arranged adjacent to each other along at least one slot, preferably along each slot.

[0013] Each of at least two conductors is surrounded by individual insulators extending around the outer circumference of the conductor, and thus the insulators in the circumferential direction include a single-layer section and an overlapping section.

[0014] There may be additional conductors within the same slot that are not individually surrounded by an insulator and / or are not insulated toward the stator core and / or other conductors.

[0015] The single-layer section and the overlapping section of each insulator extend along the full axial length of the insulator.

[0016] The axial length of each insulator is equal to or greater than the axial dimension of the slot. Typically, the axial length of each insulator depends on the axial length of the corresponding conductor; in particular, the conductor does not include an insulated in-slot portion, and the insulated axial end of the conductor protrudes from the insulator on the outside of the stator core.

[0017] Since the circumference of the insulator is greater than the circumference of the conductor, an overlapping section is formed.

[0018] The overlapping section provides complete closure, and gaps are avoided.

[0019] Therefore, each conductor is insulated around its circumference with respect to the walls of the slot and to adjacent conductors.

[0020] In one embodiment of the stator, the insulator overlaps the side of the conductor facing in the circumferential direction.

[0021] Since each conductor includes an individual insulator, there are at least two insulating layers between two adjacent conductors.

[0022] The overlapping insulator on the side of the conductor also provides a two-layer section between the conductor and the circumferential wall of the slot. The gap is avoided.

[0023] Preferably, all insulators of the conductors placed within a single slot overlap on the same side. Thus, the conductors are arranged in a line, and the slot can be formed to provide sufficient space for the overlapping sections of the conductors and insulators.

[0024] Since the distance between the conductor and the first sidewall of the slot (i.e., the wall that substantially extends radially and faces the circumferential direction) may be slightly smaller than the distance between the conductor and the second sidewall of the slot, this configuration may be slightly asymmetric in a plane perpendicular to the axis of the stator core.

[0025] Advantageously, each slot is open toward the axis of the stator core.

[0026] Each slot may include a constriction at the radially inner end of the slot having a radially extended centerline. This opening facing the axis may include a circumferential width smaller than the maximum circumferential width of the slot. This opening may be positioned circumferentially symmetrically or asymmetrically with respect to the maximum circumferential width of the slot.

[0027] The circumferential distance between the first sidewall of the slot and the radially extended centerline of the opening may be smaller than the circumferential distance between the second sidewall of the slot and the centerline. The difference between the circumferential distances is preferably equal to or greater than the thickness of the insulator. Thus, an overlapping section may be placed between the conductor and the second sidewall.

[0028] A conductor having the same cross-sectional area can be surrounded by a conductor of the same type of pre-formed insulator. Since only one or a few types of these insulators need to be provided, manufacturing can be made easier.

[0029] The conductor can be formed from various conductive components such as strands or wires. Apart from the pre-formed insulator placed within the slot, one conductor basically fills the slot circumferentially.

[0030] This conductor may have a rectangular cross-section having a radial length of 1.5 mm to 11 mm, preferably 4 mm to 10 mm, and a circumferential width of 1.5 mm to 6 mm, preferably 3.9 mm to 4.1 mm.

[0031] The outer diameter of the stator core may be 200 mm to 250 mm, preferably 220 mm to 225 mm. The inner diameter of the stator core may be 150 mm to 160 mm, preferably 155 mm to 156 mm. The axial length of the stator core may be 50 mm to 200 mm, preferably 125 mm to 130 mm. The stator core may include 40 to 100 slots, preferably 45 to 50 slots.

[0032] According to another aspect of the present invention, an apparatus is provided for preparing a pre-formed insulator from an insulating sheet for use in a stator as described above.

[0033] This device includes a bending station.

[0034] The bending station has a base station, which includes a recess having a contact surface that forms a first part of the outer circumference of the pre-formed insulator.

[0035] Preferably, the base station includes a central floor portion and two opposing wall portions. The wall portions may be positioned perpendicular to the floor portion. Preferably, the width of the central floor portion corresponds to the radial width of the pre-formed insulator to be formed, and the height of the wall portions corresponds to the circumferential width of the pre-formed insulator to be formed.

[0036] The insulator may have a rectangular cross-section, and the width of the central bottom portion and the height of the opposing wall may correspond to the dimensions of the pre-formed insulator to be formed as a cross-section in a plane perpendicular to the axial direction.

[0037] Typically, since at least two conductors and accordingly at least two pre-formed insulators must be inserted into a single slot, the width of the center bottom portion of the contact surface is smaller than the radial width of the slot of the stator core. The width of the center bottom portion of the contact surface corresponds to the radial width of the conductors.

[0038] The central bottom portion and the wall portion are preferably each formed by at least one rectangular flat surface.

[0039] The axial length of the base station may correspond to the axial length of the pre-formed insulator to be formed and may vary depending on the length of the conductor to be placed within the slot of the stator core. The axial lengths of the central bottom portion and the wall portion may be longer than the axial length of the slot and shorter than the axial length of the conductor.

[0040] Alternatively, the lengths of the central bottom and wall sections may be shorter than the pre-formed insulator to be formed.

[0041] The axial length of the wall sections may be shorter than the axial length of the central floor section. Multiple wall sections may be arranged along the length of the central floor section.

[0042] The base station may include several central bottom portions and / or several wall portions arranged along the axial length of the pre-formed insulator to be formed.

[0043] The bending station may further include a stamp member movable laterally with respect to the recess from an open position to a closed position. When the stamp member is placed within the recess, the stamp member is in a closed position. When the stamp member is outside the recess, the stamp member is in an open position.

[0044] The stamp member includes an internal contact surface for pressing the central portion of the cut sheet against the contact surface of the recess. When the stamp member is moved to a closed position, the internal contact surface of the stamp member and the external contact surface of the base member form the central portion of the circumference of the pre-formed insulator.

[0045] Preferably, the stamp member may include an inner bottom portion and two opposing side portions, wherein the side portions may be positioned perpendicular to the inner bottom portion.

[0046] The contact surface of the base member and the internal contact surface of the stamp member may have corresponding shapes and dimensions.

[0047] The inner bottom portion and / or side portion may each include at least one rectangular flat surface and may correspond to the shape and dimensions of the bottom portion and / or wall portion of the base member.

[0048] The stamp member also includes an external contact surface to form a second portion of the circumference of the pre-formed insulator.

[0049] The external contact surface is preferably positioned on the opposite side of the internal bottom portion.

[0050] Preferably, the outer contact surface has the same width as the central bottom portion of the stamp member.

[0051] The width of the external contact surface corresponds to the radial width of the pre-formed insulator to be formed and the radial width of the conductor to be placed within the slot of the stator core.

[0052] The external contact surface may include at least one rectangular flat surface.

[0053] The bending station further includes a first bending operator movable relative to the base station from an open position to a closed position, which includes a first bending surface for bending a first tail of the cut sheet relative to the outer contact surface of the stamp member when the stamp member is in the closed position.

[0054] The first bending operator is preferably in a closed position when the first bending surface is on the opposite side that is close to the outer contact surface of the stamp member.

[0055] The first bending surface may include at least one rectangular flat surface that can be pressed against the first tail of the cut sheet.

[0056] The bending station further includes a second bending operator movable relative to the base station from an open position to a closed position, which includes a second bending surface for bending a second tail of an insulator sheet against the first tail and / or the outer contact surface of a stamp member.

[0057] The second bending operator is preferably in a closed position when the second bending surface is on the opposite side that is close to the outer contact surface of the stamp member.

[0058] The second bending surface may include at least one rectangular flat surface that can be pressed against the second tail of the cut sheet.

[0059] The first bending surface and / or the second bending surface may include several rectangular flat surfaces that can be separated by an axially extending groove.

[0060] Preferably, the contact surface of the base station, the inner contact surface of the stamp member, the outer contact surface of the stamp member, the first bending surface, and the second bending surface can be formed and arranged to form a pre-formed insulator, so that the pre-formed insulator has a rectangular cross-section in a plane perpendicular to the axial direction.

[0061] By moving the stamp member, the first bending operator, and the second bending operator, a pre-formed insulator can be formed from an insulator sheet in just a few steps.

[0062] The base station, stamp member, first bending operator, and second bending operator may be separate parts and may be movable individually relative to each other.

[0063] These parts can also be connected to each other.

[0064] A bending station may include one base station, one stamp member, one first bending operator, and one second bending operator to form one pre-formed insulator. Alternatively, a bending station may include two or more base stations, two or more stamp members, two or more first bending operators and / or two or more second bending operators to form one pre-formed insulator, and these may each be positioned along the axial length of the pre-formed insulator to be formed.

[0065] The bending station may include operating members, such as hydraulic, pneumatic and / or electric drivers, for moving a stamp member, a first bending operator, and a second bending operator.

[0066] According to a preferred embodiment of the present invention, the first bending operator and / or the second bending operator are rotatably mounted on a base station.

[0067] To move the first bending operator and / or the second bending operator from an open position to a closed position, the first bending operator and / or the second bending operator are rotated around the base station.

[0068] The stamp member can be mounted to the base station by a connecting arm, and the connecting arm can be moved laterally, or the stamp member can be moved along it toward the base station or away from the base station.

[0069] Since the sum of the widths of the first bending surface and the second bending surface corresponds to the width of the stamp member, particularly the width of the outer contact surface, the first bending surface and the second bending surface completely cover the width of the outer contact surface in the closed position.

[0070] The second bending surface preferably has a wider width than the first bending surface.

[0071] Even after the first bending operator reaches the closed position and the first tail contacts the external contact surface, there is still space to position the second tail of the insulator sheet to allow an overlapping section on the stamp member and the first tail.

[0072] Advantageously, the outer contact surface of the stamp member includes a recess for receiving a first tail of the insulator sheet. When the first tail is pressed onto the stamp member by the first bending member, the outer surface of the first tail and the remaining free surface of the stamp member are aligned within the same plane so that the second tail can be pressed by the second bending member. The tails of the insulator sheet can be pressed together tightly, and the pre-formed insulator has a closed shape without gaps.

[0073] In a further preferred embodiment of the present invention, the stamp member comprises at least one groove extending in a direction parallel to the bending line of the insulator on the side facing the base station. The base station comprises at least one groove extending in a direction parallel to the bending line of the insulator. The grooves are opened in opposite directions when the stamp member is in a closed position.

[0074] Additionally or alternatively, the stamp member may include at least one groove extending in a direction parallel to the bending line of the insulator positioned on the side facing away from the base station. The second bending surface may include at least one groove extending in a direction parallel to the bending line of the insulator. The grooves are opened in opposite directions when the second bending operator is in a closed position.

[0075] The above slot enables the introduction of an ejection tool for ejecting a formed insulator from a bending station when the stamp member and bending operators are in a closed position.

[0076] The pre-formed insulator can be transferred directly into the slot of the stator core or into the transfer station.

[0077] The extraction tool is inserted into a groove on one axial side of the bending station and can push out a pre-formed insulator from the other axial side of the bending station.

[0078] In a beneficial embodiment, the device further includes a supply station for supplying insulating material from a continuous strip.

[0079] The supply station includes a cutter for cutting flat sheets of insulating material of a continuously supplied sheet of insulating material.

[0080] This may further include an embossing unit for applying longitudinal embossing to form predefined bending lines within the insulating material.

[0081] The feed station may further include a feed unit. The feed unit may feed a cut sheet or a continuous strip to the bending station, and the sheet is cut before or after bending.

[0082] If the sheet is cut after at least partial bending, the second tail remains connected to the continuous strip.

[0083] Additionally or alternatively, the device may include an insertion station for inserting at least two pre-formed insulators into slots of a stator core. The insertion station may include an ejection tool for ejecting a completely closed insulator from a bending station and optionally transferring the pre-formed insulator into a slot of the stator.

[0084] Insertion may preferably be realized by transferring a sheet of a completely closed shape to a transfer station for temporarily receiving at least two sheets, and transferring at least two sheets from the transfer station into a slot of the stator.

[0085] According to another aspect of the present invention, a method is provided for preparing a pre-formed insulator from an insulating sheet for a stator, preferably using an apparatus as described above.

[0086] A cut insulating sheet of flat insulating material is provided to the bending station of the device between the base station and the stamp member, which includes a recess.

[0087] Next, a portion of the insulator sheet is pressed into the recess by moving the stamp member laterally into the recess. This forms a U-shaped insulator sheet having a first tail and a second tail.

[0088] The first bending operator is moved relative to the base station so that the first tail contacts the outer contact surface of the stamp member. The second bending operator is moved relative to the base station so that the second tail contacts the outer contact surface of the stamp member and / or the first tail. The first bending member and the second bending member can press the first tail and the second tail of the stamp member over the entire outer contact surface.

[0089] A flat insulating material is bent to form a pre-formed insulating member having a closed shape. Preferably, the second tail is pressed against the first tail so that the formed shape is completely closed.

[0090] Advantageously, the first bending operator and the second bending operator are rotated about their respective rotational axes with respect to the base station.

[0091] This method may include an additional step of introducing an ejection tool of the insertion station into the opposing slots of the stamp member and the base station and / or into the opposing slots of the stamp member and the second bending operator. The ejection tool may come into contact with the pre-formed insulator and move within the device to eject the pre-formed insulator from the bending station of the device.

[0092] At least two pre-formed insulators can be placed in a transfer station preferably close to each other. For example, the pre-formed insulators can be extruded from a bending station into the transfer station. At least two pre-formed insulators can be inserted into a slot of a stator core in a single step.

[0093] An insulating sheet provided by MYLAR under the name NOMEX may be used to form a pre-formed insulator. The thickness of this sheet may be 0.1 mm to 0.5 mm, preferably 0.18 mm to 0.3 mm.

[0094] The present invention will be described below with reference to preferred embodiments and drawings. Brief explanation of the drawing

[0095] FIG. 1 is a perspective view of a stator core; FIG. 2 is a schematic plan view of a slot of a stator core having an insulating sheet; FIG. 3 is a schematic plan view of a slot of a stator core; FIGS. 4a to 4e are schematic plan views of a bending station at different locations; FIG. 5 is a schematic diagram of the device; FIG. 6a is a schematic cross-sectional view along the longitudinal axis of the receiving section; FIG. 6b is a front view of the exit opening of the receiving section according to FIG. 6a. Specific details for implementing the invention

[0096] FIG. 1 illustrates a perspective view of a stator core (10). The stator core (10) has a plurality of slots (11) that extend in the axial direction (A) and are arranged in the circumferential direction (C) of the stator core (10). Two conductors (20, 21) are arranged along the radial direction (R) of each slot (11). Each conductor (20, 21) is surrounded by an individual insulator (30).

[0097] FIG. 2 shows a schematic plan view of a slot (11) of a stator core (10) equipped with an insulating sheet (30).

[0098] Each individual insulator (30) extends around the outer circumference (22) of the conductors (20, 21), and thus the insulator (30) includes a single layer section (37) and an overlapping section (31), the overlapping section extends along the entire axial length (29) of the insulator (30) (see FIG. 4).

[0099] Two insulators (30) placed in one slot (11) overlap on the same side (23) of the conductors (20, 21).

[0100] Figure 3 shows a schematic plan view of the slot (11).

[0101] The slot (11) is open toward the axial center (12) of the stator core (10) and includes a constricted portion (13) in the radial inner end (14) of the slot (11) having a radially extended centerline (15).

[0102] The circumferential distance (16) between the first side wall (17) of the slot (11) and the center line (15) is greater than the circumferential distance (18) between the second side wall (19) of the slot (11) and the center line (15). This difference corresponds to the thickness (32) of the insulator (30) (see FIG. 2).

[0103] FIGS. 4a through 4e illustrate schematic plan views of a bending station (39) for forming a pre-formed insulator from an insulator sheet (33), i.e., plan views in a plane perpendicular to the axial direction (A) (see FIG. 1) during various stages of the bending process.

[0104] The bending station (39) includes a base station (40) having a recess (41).

[0105] The recess (41) includes a contact surface (42) for forming a first portion of the outer circumference of the pre-molded insulator (30).

[0106] The contact surface (42) consists of the central bottom portion (47) and two opposing wall portions (46) of the base station (39).

[0107] The bending station (39) includes a stamp member (50). The stamp member (50) and the base station (40) can be moved parallel to each other, and thus the stamp member can be moved laterally with respect to the recess (41) from an open position as shown in FIG. 4a to a closed position as shown in FIG. 4c through FIG. 4e.

[0108] The insulating sheet (33) can be inserted between the base station (40) and the stamp member (50) and held in a predetermined position by a spring-loaded clamping element (56). The clamping element (56) can be pressed into the recess of the base station (40), for example, when the base station (40) and the stamp member (50) approach each other and the stamp member (50) takes a closed position.

[0109] The stamp member (50) has an internal contact surface (51), which presses the middle portion (34) of the insulator sheet (33) against the contact surface (42) of the recess (41) when moved to a closed position as shown in FIG. 4b and FIG. 4c.

[0110] The internal contact surface consists of a central inner bottom portion (48) and two opposite inner portions (49).

[0111] The contact surface (42) of the base member (40) and the inner contact surface (51) of the stamp member (50) form a first part of the pre-molded insulator (30) to be formed from the middle part (34) of the insulator sheet (33).

[0112] The stamp member (50) further includes an external contact surface (52) on the opposite side of the inner bottom portion (48).

[0113] The bending station (39) includes a first bending operator (60) movable relative to the base station (40) from an open position as shown in FIGS. 4a to 4c to a closed position as shown in FIGS. 4d and 4e.

[0114] The first bending operator (60) includes a first bending surface (61) for bending the first tail (35) of the insulating sheet (33) against the outer contact surface (52) of the stamp member (50), as shown in FIG. 4d.

[0115] The bending station (39) includes a second bending operator (70) comprising a second bending surface (71) movable relative to the base station (40) from an open position as shown in FIG. 4a to 4d to a closed position as shown in FIG. 4e. The second bending operator (70) presses the second tail (36) of the insulator sheet (33) against the first tail (35) and the outer contact surface (52) of the stamp member (50) as shown in FIG. 4e. This forms an overlapping section (31).

[0116] The first bending operator (60) and the second bending operator (70) can be rotated around their respective rotation axes (63, 74).

[0117] This rotational movement can be driven by a lever system connected to an air cylinder (not shown).

[0118] The sum of the width (62) of the first bending surface (61) (see FIG. 4c and FIG. 4e) and the width (72) of the second bending surface (71) (see FIG. 4c and FIG. 4e) corresponds to the width (44) of the stamp member (50), and thus the first bending surface (61) and the second bending surface (71) together with the outer contact surface (52) of the stamp member (50) form a second part of the pre-formed insulator (30).

[0119] As illustrated in FIGS. 4d and 4e, the stamp member (50) includes two grooves (54) extending in a direction parallel to the bending line of the insulator (33), and the base station (40) includes two grooves (45) extending in a direction parallel to the bending line of the insulator. The grooves (45, 54) are opened in opposite directions when the stamp member (50) is in a closed position (see FIG. 4d).

[0120] An additional groove (73) is provided on a second bending surface (71) that extends in a direction parallel to the bending line of the insulator. Additionally, the stamp member (50) includes an additional groove (55) on a side facing away from the base station (40) that extends in a direction parallel to the bending line of the insulator (30). The grooves (55, 73) are opened in opposite directions when the second bending operator (70) is in a closed position (see FIG. 4e).

[0121] When the bending station (39) is in a closed position, due to pairs of grooves (55, 74 and 45, 54) facing each other, the introduction of an ejection tool (91; see FIG. 5) for pushing out the formed insulator (30) from the bending station (39) becomes possible. The ejection tool includes blades (not clearly shown) for each pair of grooves (55 and 74, 55 and 74, and 45 and 54).

[0122] The axial length of the bending station (39) can correspond to the axial length of the pre-formed insulator (30) being formed.

[0123] Alternatively, a plurality of bending stations (39) may be arranged along the axial length to form a single pre-formed insulator (30).

[0124] The axial lengths of the stamp member (50), the first bending operator (60), and the second bending operator (70) may correspond to the axial length of the base station (40). Alternatively, a plurality of stamp members (50), a plurality of first bending operators (60), and / or a plurality of second bending operators (70) may be arranged along the axial length of the base station (40).

[0125] FIG. 5 illustrates a schematic diagram of the device (100).

[0126] This device (100) includes a bending station (39) as shown in FIGS. 4a to 4e.

[0127] This device (100) further includes a supply station (80).

[0128] The supply station (80) includes an embossing unit (81) for applying longitudinal embossing within a sheet (38) of insulating material that is continuously supplied.

[0129] The supply station (80) includes a supply unit (82) for supplying embossed insulating material (38) to the bending station (39).

[0130] The supply station (80) includes a cutter (83) for cutting a flat sheet (33) of insulating material (see FIG. 4a) from a sheet (38) of insulating material that is continuously supplied.

[0131] The supply station (80) includes a supply unit (82) for supplying the cut sheet (33) to the bending station (39).

[0132] The device (100) includes an extraction tool (91) for pushing a pre-formed insulator (30) from a bending station (39) to a transfer station (90).

[0133] The transfer station (90) collects at least two pre-formed insulators (30) introduced into one slot (11) (see FIG. 6a) of the stator core (10).

[0134] FIG. 6a illustrates a schematic cross-sectional view of a portion of a bending station (39), a transfer station (90), and a stator (10). The transfer station (90) has three channels (98a, 98b, 98c) each having a receiving opening (99a, 99b, 99c). The transfer station (90) is displaceable laterally relative to the bending station (39) (see arrows in FIG. 5 and FIG. 6a). As a result, the receiving openings (99a, 99b, 99c) can be aligned with a pre-formed insulator (30) (see FIG. 4e) placed around the stamp member (50) of the bending station (39).

[0135] FIG. 6b illustrates a side view of a transfer station (90) having receiving openings (99a, 99b, 99c). When a pre-formed insulator is moved parallel along the bending station (39) by an extraction tool (91) (see FIG. 5), it exits the bending station (39) and is transferred into an aligned receiving opening (99c). When the pre-formed insulator is transferred into the receiving opening (99c) and the channel (98c), the transfer station (90) is moved laterally, thereby aligning another receiving opening (e.g., receiving opening (99b)) with the bending station (39), so that another pre-formed insulator can be received by the transfer station (90).

[0136] The receiving channels (98a, 98b, 98c) are separated from each other by a wall (101). The wall (101) exists only about 2 / 3 of the length of the transfer station (90), so that the channels (98a, 98b, 98c) merge to form a single merging channel (102) in the transfer station (90) (shown on the right side of FIG. 6a). The wall (101) is slightly tapered so as to converge slightly in the axial direction (from left to right) of FIG. 6a. When three pre-formed insulators are pushed axially through the channels (98a, 98b, 98c), these pre-formed insulators are pressed toward each other in the merging channel (102). Then, these three pre-formed insulators can be transported together from the exit opening (97) of the transfer station (90) to one slot (11) of the stator (10). Of course, if fewer than 3 or more than 4 pre-molded insulators need to be inserted into a single slot, fewer than 3 or more than 4 channels can be used.

Claims

Claim 1 An apparatus (100) for preparing a pre-formed insulator (30) from an insulator sheet (33), wherein the apparatus (100) comprises a bending station (39), and the bending station comprises: - a base station (40) comprising a recess (41) having a contact surface (42) forming a first portion of the outer circumference of the pre-formed insulator (30); - a stamp member (50) movable laterally with respect to the recess (41) from an open position to a closed position; - the stamp member (50) comprises an inner contact surface (51) for pressing a middle portion (34) of the insulator sheet (33) against the contact surface (42) of the recess (41) to form a first portion of the inner circumference of the pre-formed insulator (30); and the stamp member (50) comprises an outer contact surface (52) forming a second portion of the inner circumference of the pre-formed insulator (30); - from an open position to a closed position A preparation device for a pre-formed insulator, comprising: a first bending operator (60) movable with respect to the base station (40) and having a first bending surface (61) for bending a first tail (35) of the insulator sheet (33) against an external contact surface (52) of the stamp member (50); and a second bending operator (70) movable with respect to the base station (40) from an open position to a closed position and having a second bending surface (71) for bending a second tail (36) of the insulator sheet (33) against the first tail (35) and / or an external contact surface (52) of the stamp member (50). Claim 2 In claim 1, the first bending operator (60) and / or the second bending operator (70) is a pre-formed insulator preparation device rotatably mounted on the base station (40). Claim 3 A preparation device for a pre-formed insulator according to claim 1 or 2, wherein the sum of the width (62) of the first bending surface (61) and the width (72) of the second bending surface (71) corresponds to the width (44) of the outer contact surface (52) of the stamp member (50). Claim 4 A preparation device for a pre-molded insulator according to claim 1 or 2, wherein the outer contact surface (52) of the stamp member (50) includes a recess (53) for receiving a first tail (35) of the insulator sheet (33). Claim 5 A pre-formed insulator preparation device according to claim 1 or 2, wherein the stamp member (50) comprises at least one groove (54) extending in a direction parallel to the bending line of the insulator, and the base station (40) comprises at least one groove (45) extending in a direction parallel to the bending line of the insulator, and the grooves (45, 54) are opened in opposite directions when the stamp member (50) is in a closed position, thereby allowing the introduction of an extraction tool for extracting the formed insulator from the bending station (39) of the device (100). Claim 6 A pre-formed insulator preparation device according to claim 1 or 2, wherein the stamp member (50) comprises at least one groove (55) extending in a direction parallel to the bending line of the insulator, and the second bending surface (71) comprises at least one groove (73) extending in a direction parallel to the bending line of the insulator, and the grooves (55, 73) are opened in opposite directions when the second bending operator (70) is in a closed position, thereby allowing the introduction of an extraction tool for extracting the formed insulator from the bending station (39) of the device (100). Claim 7 A pre-molded insulator preparation device according to claim 1 or 2, wherein the device further comprises a transfer station (90) for inserting at least two pre-molded insulators (30) into a slot (11) of a stator core (10). Claim 8 A pre-formed insulating preparation device according to claim 1 or 2, wherein the device further comprises a supply station (80), and the supply station (80) comprises at least one of the following: - a cutter (83) for cutting a flat sheet (33) of insulating material from a sheet (38) of insulating material supplied continuously; - an embossing unit (81) for applying longitudinal embossing within the flat sheet (33) or within the sheet (38) of insulating material supplied continuously; and - a supply unit (82) for supplying the cut sheet (33) to the bending station (39) or supplying the sheet (38) of insulating material supplied continuously to the bending station (39) before cutting. Claim 9 A method for preparing a pre-formed insulator, comprising: a base station (40) having a recess (41) having a contact surface (42) forming a first portion of the outer circumference of the pre-formed insulator (30); and a stamp member (50) having an inner contact surface (51) for forming a first portion of the inner circumference of the pre-formed insulator (30) by pressing a portion of the insulator sheet (33) against the contact surface (42) of the recess (41) and an outer contact surface (52) for forming a second portion of the inner circumference of the pre-formed insulator (30), wherein a cut insulator sheet (33) of a flat insulating material is provided to a bending station (39) of an apparatus (100) for preparing a pre-formed insulator (30) from an insulator sheet (33); wherein a portion of the insulator sheet (33) is pressed into the recess (41) by moving the stamp member (50) laterally into the recess (41), thereby thereby a A step of forming a U-shaped insulating sheet having a first tail (35) and a second tail (36); a step of bringing the first tail (35) into contact with the outer contact surface (52) of the stamp member (50) by moving a first bending operator (60) having a first bending surface (61) for bending the first tail (35) against the outer contact surface (52) of the stamp member (50) with respect to the base station (40); and a step of bringing the second tail (36) into contact with the outer contact surface (52) of the stamp member (50) and / or the second bending operator (70) having a second bending surface (71) for bending the second tail (36) against the first tail (35) and / or the outer contact surface (52) of the stamp member (50) with respect to the base station (40). A method for preparing a pre-formed insulator, comprising the step of contacting the tail (35). Claim 10 A method for preparing a pre-formed insulator, wherein the first bending operator (60) and the second bending operator (70) are rotated around their respective rotation axes (63, 74). Claim 11 A method for preparing a pre-molded insulator according to claim 9 or 10, wherein the second tail (36) is pressed against the first tail (35) to form an overlapping section (31). Claim 12 A method for preparing a pre-formed insulator according to claim 9 or 10, wherein - an extraction tool is introduced into the opposing slots (43, 54, 55, 73) of the stamp member (50) and the base station (40) and / or the second bending operator (70), - the extraction tool comes into contact with the pre-formed insulator (30), and - the extraction tool is moved within the device (100) so as to extract the pre-formed insulator (30) from the bending station (39) of the device (100). Claim 13 A method for preparing a pre-formed insulator according to claim 9 or 10, wherein at least two pre-formed insulators (30) are placed in a transfer station (90) and inserted into a slot (11) of a stator core (10) in one step. Claim 14 delete Claim 15 delete Claim 16 delete Claim 17 delete

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