Method for forming shaped groups of conductor elements for windings of electric machines

Abstract

The present invention relates to a method (1) for forming shaped groups (A) of conductor elements (B, C, D) for inductive windings (E) intended for subsequent insertion into electric machines. The method (1) comprises: a preliminary cutting step (2) of the conductor elements (B, C, D) according to a set of predefined different lengths; a layering step (3) of at least two conductor elements (B, C, D); a bending step (4) of the layered conductor elements (B, C, D), substantially through a U-shaped bending, obtaining a compact group (G); a forming step (5) of the compact group (G) for the formation of a shaped group (A), a step (5) which in turn is constituted by respective distancing and alignment sub-phases.

Description

[0001] METHOD FOR FORMING SHAPED GROUPS OF CONDUCTOR ELEMENTS FOR WINDINGS OF ELECTRIC MACHINES

[0002] The present invention relates to a method for forming shaped groups of conductor elements for windings of electric machines. The manufacturing of electric machines involves the provision of at least one electric element wound in coils or turns on a ferromagnetic cores, for interlinking to a magnetic field, either inductive or induced; such elements are normally called windings.

[0003] It is known the use of conveniently- shaped conductor elements in order to provide such windings. Generally, conductor elements are U-shaped and comprise two straight prongs connected by a transverse bridge, shaped like split pins or, in the most widely-used terminology in the sector, ’’hairpins”. Such conductor elements, conveniently arranged and shaped according to specific design criteria, are inserted into the respective ferromagnetic core and subjected to the welding operations necessary to create a winding by closing the electric circuit formed by several conductor elements (in conformance with the aforementioned design criteria).

[0004] The operations for shaping the conductor elements are geared to adapt the shape thereof to the position of the slots of the ferromagnetic core into which they are to be inserted in order to form the winding (each prong needs to be inserted into a respective slot).

[0005] In particular, such operations make use of an apparatus designed to apply mechanical stresses for suitably shaping the conductor elements by way of the plastic deformation thereof, providing them with a suitable shape for its subsequent insertion into the slots of the ferromagnetic core.

[0006] The shaping of individual conductor elements (“hairpins”) does not present any particular problems and is executed in an extremely efficient manner in the prior art.

[0007] However, if the need arises for shaping a group of conductor elements (“hairpins”) that are superimposed (i.e. each conductor element being arranged with one side thereof juxtaposed to another conductor element of the same group), the prior art does not offer any solutions for ensuring the holding of the necessary configurations of maximum proximity (ideally, juxtaposition very close to each other, without contacting) between the mutually facing surfaces of contiguous conductor elements of the group.

[0008] It is known, from EPl 117172, the use of shaping apparatuses provided with twisting recesses (i.e. these are seats and / or accommodations shaped to temporarily accommodate one end of the conductor element, defining some degrees of restriction for it) which are adapted to accommodate the ends of the conductor elements (“hairpins”): such recesses can be moved independently in order to generate the necessary misalignment (twisting) between respective groups of prongs of groups of conductor elements. The technical solution according to EPl 117172 differs from the respective prior art in that at least one of the movable recesses, in addition to executing the twisting stroke, is also translatable in height, applying a thrust on the end of the conductor element associated with it, thus ensuring the holding of the substantial juxtaposition (maximum possible proximity) between the facing surfaces of contiguous conductor elements.

[0009] This embodiment, while ensuring the holding of the substantial juxtaposition of the above mentioned surfaces, generates groups of conductor elements that are at least partially distanced proximate to their central portion (at least in a region proximate to the transverse bridge between the two prongs, which in turn is constituted by a curved connecting portion).

[0010] The above-mentioned partial distancing is extremely negative since it can complicate the subsequent insertion of the group of conductor elements into the respective slots of the ferromagnetic core, or since it can determine an interference with parts of other groups of conductor elements (interference that would not be possible if the conductor elements of a same group had the facing surfaces completely aligned and juxtaposed for their entire length).

[0011] The main aim of the present invention is to solve the above mentioned drawbacks, by providing a method for forming shaped groups of conductor elements for windings of electric machines that allows to maintain perfectly aligned, and with facing surfaces substantially juxtaposed, the conductor elements of each group during the step of shaping / twisting thereof.

[0012] Within this aim, an object of the invention is to provide a method for forming shaped groups of conductor elements for windings of electric machines that shapes groups of conductor elements with minimum space occupation.

[0013] Another object of the invention is to provide a method for forming shaped groups of conductor elements for windings of electric machines that are adapted to be inserted into the slots of a ferromagnetic core according to a predefined pattern, without interfering with other groups of conductor elements.

[0014] Another object of the invention is to provide a machine for forming shaped groups of conductor elements for windings of electric machines that prevents, during their shaping / twisting, the conductor elements of a same group from undergoing mutual misalignments.

[0015] Another object of the invention is to provide a machine for forming shaped groups of conductor elements for windings of electric machines that prevents, during the shaping / twisting of the conductor elements, the respective group from undergoing an increase in space occupation in crosssection.

[0016] Another object of the present invention is to provide a method for forming shaped groups of conductor elements for windings of electric machines and a machine for forming shaped groups of conductor elements for windings of electric machines that are low cost, easily and practically implemented, and safe in use. This aim and these objects are achieved by a method for forming shaped groups of conductor elements for windings of electric machines according to claim 1.

[0017] Such aim and such objects are also achieved by a machine for forming shaped groups of conductor elements for inductive windings of electric machines according to claim 12.

[0018] Further features and advantages of the invention will be clearly exposed in the detailed description that follows of a preferred, but not exclusive, embodiment of the method for forming shaped groups of conductor elements for windings of electric machines, which is illustrated by way of non-limiting example in the accompanying drawings wherein:

[0019] Figure 1 is a representative schematic diagram of the method according to the invention;

[0020] Figure 2 is a schematic perspective view of the stator of an electric machine in which shaped groups of conductor elements obtained by applying the method according to the invention are arranged;

[0021] Figure 3 is a schematic side view of a first instant of a forming step of the method according to the invention;

[0022] Figure 3a is an enlarged view of a detail of Figure 3;

[0023] Figures 4 to 9 are schematic perspective views of the sequence of movements of the prongs of the conductor elements that occur during the forming step of the method according to the invention;

[0024] Figure 10 is a schematic view from above of the last configuration of the forming step shown in Figure 9 from which the shaped group is obtained;

[0025] Figure 11 is a schematic perspective view of the initial configuration of the forming step shown in Figure 4, before starting the forming step;

[0026] Figure 12 is a schematic perspective view of the initial configuration of the forming step shown in Figure 4, before starting the mentioned forming step, executed by a different embodiment of the machine according to the invention;

[0027] Figure 13 is a schematic perspective view of the last instant shown in Figures 9 and 10, at the end of the forming step, executed by the embodiment of the machine of Figure 11;

[0028] Figures 14 to 20 are schematic perspective views of the sequence of movements that occur during the forming step, Figure 20 showing the last instant of the forming step which obtains the shaped group;

[0029] Figure 21 is a schematic perspective view of a second bending station of a machine according to the invention in a first configuration;

[0030] Figure 22 is a schematic perspective view of the second bending station of Figure 21 in a second configuration;

[0031] Figure 23 is a schematic perspective view of a forming station according to the invention, which is also adapted to constitute part of a machine according to the invention, in a first configuration;

[0032] Figure 24 is a schematic perspective view of the forming station of Figure 23 without the containment shell, in said first configuration;

[0033] Figure 25 is a schematic perspective view of the forming station of Figure 23 in a second configuration;

[0034] Figure 26 is a schematic perspective view of the forming station of Figure 23 without the containment shell, in said second configuration;

[0035] Figure 27 is a cross-sectional schematic side view, taken along a transverse plane, of the forming station of Figure 23;

[0036] Figure 28 is the cross-section of Figure 28 in which three conductor elements shaped like hairpins are accommodated;

[0037] Figure 29 is a partially cross-sectional schematic view from above of the forming station of Figure 23.

[0038] With particular reference to the figures, the reference numeral 1 generally designates a method for forming shaped groups A of conductor elements B, C, D, which comprise at least two conductors B, C and D, for providing inductive windings E of electric machines (the accompanying Figure 1 shows for the purposes of non-limiting example the winding E of a stator F of an electric motor).

[0039] In particular, the object of the method 1 is to provide shaped groups A of conductors B, C and D which have the ideal shape and dimensions to be used to provide an arm of an inductive winding E.

[0040] A predefined set of shaped groups A, mutually arranged, constitutes a circuit arrangement of the inductive winding E. Such circuit arrangement (which is generally a braid of groups A) can be axially inserted in the ferromagnetic core (for example the stator F), in particular into the axial slots of the ferromagnetic core, of the electric machine being produced. Axial slots are slots that extend along a direction parallel to the axis of the ferromagnetic core (for example the stator F). After such insertion, subsequent operations will be executed on the free ends of the conductors B, C and D of each shaped group A (i.e. the ends protruding from the stator F, in the example given previously) to close the electric circuit and complete the inductive circuit. The cited circuit arrangement, its insertion into the ferromagnetic core, and the operations necessary to close the electric circuit are outside the scope of this discussion, as they are operations subsequent to and independent of the production of the shaped groups A.

[0041] The method 1 according to the invention comprises a preliminary cutting step 2 of substantially straight pieces of a conductor wire, which define conductor elements B, C and D, according to predefined lengths. Through the cutting operation, an initial front Bi, Ci, Di and a terminal front B2, C2, D2are defined in each one of the conductor elements B, C, D.

[0042] The conductor elements B, C and D could therefore be obtained by cutting a continuous wire originating from, for example, a storage spool. The ways in which the preliminary cutting step 2 can be executed can be any, in conformance with what is envisaged in the prior art for operations of this type.

[0043] Subsequently, a layering step 3, generally referred to as a wire pieces layering step, is executed on at least two substantially straight wire pieces that define the conductor elements B, C, D.

[0044] The layering step 3 consists in facing and juxtaposing respective longitudinal surfaces of the at least two straight pieces that define the conductor elements B, C, D.

[0045] In the course of such layering step 3, the conductor elements B, C and D (in the accompanying figures three distinct layered conductor elements B, C and D are always shown, although the possibility is not ruled out that there can be only two, or there can be four, or even more than four) are mutually superimposed so that at least one face of each conductor element B or C or D comes into contact with a face of an additional conductor element C or D or B, so being juxtaposed therewith (thus obtaining a layered superimposition of such conductors B or C or D).

[0046] It is convenient to note that the layering step 3, which is executed by juxtaposing at least two wire pieces of conductor elements B, C and D, can be executed while keeping their initial fronts Bi, Ci and Di aligned and mutually substantially coplanar, so that the distancing owing to their possible difference in length is localized at the prongs B4, C4and D4which have mutually opposing terminal fronts B2, C2and D2(which therefore may show a different protrusion).

[0047] This particular arrangement makes it possible to localize the different length between the conductor elements B, C and D solely at the prongs B4, C4and D4, SO defining a configuration that will be advantageous during the subsequent forming step 5 (as will be explained in detail below).

[0048] Furthermore, also in the layering step 3, each layered set of wire pieces of conductor elements B, C and D can advantageously be constituted by at least three conductor elements B, C and D of different lengths which will determine different protrusions of the terminal fronts B2, C2and D2of the prongs B4, C4and D4(in the example shown for the purposes of nonlimiting example in the accompanying figures the terminal front B2is the one protruding the most and the terminal front D2is the one protruding the least; the terminal front D2has an intermediate protrusion with respect to the at least one other). However, the possibility is not ruled out of adopting specific lengths of the conductor elements B, C and D which determine different protrusions of the respective terminal fronts B2, C2and D2.

[0049] In such case, which is given solely for the purposes of non-limiting example, the initial fronts B Ci and Di of the wire pieces of conductor elements B, C and D of the layered set can be substantially coplanar and the terminal fronts B2, C2and D2can by contrast be distanced by a length that depends on the difference in length between the conductor elements B, C, D.

[0050] In the embodiment illustrated by way of non-limiting example in the accompanying figures, the conductor element B will be contiguous with the conductor element C (the conductor element B will have a face thereof juxtaposed with that of the conductor element C), which will be contiguous with the conductor element D (the conductor element C will have a face thereof juxtaposed with that of the conductor element D): in such configuration the conductor elements B (the one with the terminal front B2that protrudes the most) and D (the one with the terminal front D2that protrudes the least) will be facing outward.

[0051] Then the method exerts a bending step 4 of the substantially straight wire pieces that define the layered conductor elements B, C, D. A possible embodiment is shown in the accompanying Figures 21 and 22 by way of non-limiting example.

[0052] By means of the bending step 4, a compact group G of U-shaped conductor elements B, C, D shaped like split pins are obtained: each split pin generated comprises first B3, C3, D3and second B4, C4, D4prongs.

[0053] Each one of such prongs B3, C3, D3, B4, C4, D4can usefully comprise a respective first B3e, C3e, D3eor second B4e, C4e, D4elower portion shaped like a straight end, and curved central connecting segments joining each one of the first B3, C3, D3and second B4, C4, D4prongs of the conductor elements B, C, D.

[0054] More precisely, the first B3, C3, D3and the second B4, C4, D4prong can comprise respective lower portions B3e, C3e, D3e, B4e, C4e, D4eand adjacent upper portions B3m, C3m, D3m, B4m, C4m, D4m.

[0055] In the group G provided by means of the bending step 4, the innermost conductor element B is facing toward its surface: following the bending into a U-shape, the face of the conductor element B opposite from the face juxtaposed to the conductor element C, contiguous therewith, is in fact bent back on itself so that two distinct portions thereof are facing and proximate (being mutually inclined proximate to the curved connecting segment, and parallel below specific sections Bs and Bf respectively of the prongs B3and B4). Furthermore, generally (but not necessarily) the innermost conductor element B has a greater length than the at least one other, outermost conductor C, D.

[0056] The bending step 4 can be executed by applying a stress configured to produce a bending perpendicular to the longitudinal direction L of the wire pieces of conductor elements B, C, D: Figures 21 and 22 show a possible implementation of the bending step 4 exclusively by way of non-limiting example.

[0057] Lastly, the method 1 entails a forming step 5.

[0058] Such forming step 5 consists of subjecting the compact group G of Ilshaped conductor elements (or split pins) to stresses (for example of a mechanical nature, although the possibility is not ruled out of adopting different stresses) configured to produce plastic deformations by means of two separate sub-phases: the breakdown into sub-phases refers solely to the type of mechanical stresses applied, as they must necessarily be executed simultaneously so as to define a single forming step 5.

[0059] A distancing sub-phase, which entails the application of stresses (for example of a mechanical nature, although the possibility is not ruled out of adopting different stresses) between the first B3, C3, D3and the second B4, C4, D4prongs of the conductor elements B, C, D. In this first sub-phase, the first B3e, C3e, D3eand second B4e, C4e, D4eends of the prongs B3, C3, D3, B4, C4, D4of the split pins are arranged parallel to an axial direction X, and the initial fronts Bi, Ci, Di of the respective conductor elements B, C, D are kept mutually locked together, coupling them to each other. The stress (for example mechanical) applied ensures that the initial fronts B Ci, Di and the terminal fronts B2, C2, D2are mutually moved along a distancing stroke on planes perpendicular to the axial direction X, along a predefined breadth and a predefined trajectory for the distancing, i.e. the mutual distancing, of the prongs B3, C3, D3and B4, C4, D4of the conductor elements B, C, D shaped like a split pin.

[0060] A second sub-phase entails the application of mechanical stresses to align the terminal fronts B2, C2, D2. At least one of the terminal fronts B2, C2is moved along a compaction stroke in the axial direction X, in order to axially push such at least one second prong B4, C4for the progressive axial alignment of the terminal fronts B2, C2until they are substantially coplanar, with the consequent forcing of the corresponding conductor element B, C onto the surface of the contiguous conductor element C, D, so obtaining a shaped group A of conductor elements from each compact group G of split pins.

[0061] With particular reference to an embodiment of undoubted practical and applicative interest, during the forming step 5 the initial fronts Bi, Ci, Di of the respective conductor elements B, C, D advantageously can be kept mutually locked by holding them in a first settlement 6 (locking means 6) (for example by inserting them into the settlement 6, which is shaped like a pocket to receive them) and the terminal fronts B2, C2, D2can be held in a respective seat 7, 8, 9 (locking means 7, 8, 9) (for example, in this case again, each terminal front B2, C2, D2can be inserted into a respective seat 7, 8, 9, which is pocket-shaped in order to receive it). The settlement 6 (locking means 6) and the seats 7, 8, 9 (locking means 7, 8, 9) are then mutually moved along a distancing stroke on planes perpendicular to the axial direction X: such stroke has a predefined breadth and a predefined trajectory for the mutual distancing of the first B3, C3, D3and second B4, C4, D4prongs, so accomplishing the first sub-phase described above.

[0062] At least one of the seats 7, 8 is by contrast moved with respect to the at least one other seat 8, 9 along a compaction stroke in the axial direction X in order to axially push at least one second prong B4, C4, so determining the progressive axial alignment of the second B4e, C4e, D4eends of the conductor elements B, C, D, until the terminal fronts B2, C2, D2are substantially coplanar.

[0063] In this embodiment, the lower portions B3e, C3e, D3e, B4e, C4e, D4eare longer than the upper portions B3m, C3m, D3m, B4m, C4m, D4m, and the lower portions B3e, C3e, D3e, B4e, C4e, D4eare substantially straight even after the forming step 5 of the shaped group A of superimposed conductor elements B, C, D. In particular, during the forming step 5, the lower portions B3e, C3e, D3eof the first prongs B3, C3, D3(or tines) are kept in a fixed position by means of a locking element 6. The lower portions B4e, C4e, D4eof the second prongs B4, C4, D4(or tines) are by contrast moved away from the first prongs B3, C3, D3(or tines) and the upper portions B4m, C4m, D4mof the second prongs B4, C4, D4(or tines) are bent with respect to the respective lower portions B4e, C4e, D4eof the second prongs B4, C4, D4(or tines) by means of a first bending element 11 acting on the upper portions B4m, C4m, D4mof the second prongs B4, C4, D4(or tines), and the upper portions B3m, C3m, D3mof the first prongs B3, C3, D3(or tines) are bent with respect to the respective lower portions B3e, C3e, D3eof the first prongs B3, C3, D3(or tines) by means of a second bending element 12. These bending operations are executed so that the upper portions B3m, C3m, D3m, B4m, C4m, D4mof the first prongs B3, C3, D3(or tines) and of the second prongs B4, C4, D4(or tines) form respective bent portions of the superimposed conductor elements B, C, D.

[0064] During the forming step 5, the first 11 and the second 12 bending element are movable on a plane R substantially perpendicular to the direction X, preferably moving along a circular trajectory.

[0065] With particular reference to the embodiment illustrated by way of non-limiting example in the accompanying Figures 23, 24, 25 and 26, in the forming step 5, the settlement 6 (locking means 6) and the seats 7, 8, 9 (locking means 7, 8, 9) can be mutually moved along a substantially circular distancing stroke on planes perpendicular to the axial direction X according to a predefined angular extent, for the distancing, spacing apart, of the prongs B3, C3, D3and B4, C4, D4of the conductor elements B, C, D.

[0066] Forming the group A is accomplished in two stages, i.e.: a bending step 4 wherein the plurality of straight pieces of conductor B, C, D is subjected to bending, wherein such plurality of conductors B, C, D (pieces that initially are substantially straight) remain substantially on a single plane, generating a plurality of split pins that are substantially concentric and mutually juxtaposed, and a forming step 5 wherein the plurality of split pin-shaped conductors B, C, D is subjected to mechanical stresses in order to produce the plastic deformation thereof, so as to confer the complex forkshape or hairpin-shape on the group G, so ensuring substantial juxtaposition between the plurality of conductors B, C, D of a same group G, so producing a shaped group A.

[0067] The distancing stroke can be linear or curved (for example corresponding to an arc of circumference as illustrated by way of nonlimiting example in the accompanying Figures 24 and 26) in order to ensure that the shaped group A that will be produced has a shape complementary to that of the slots of the ferromagnetic core (for example a stator F of an electric motor) into which it will be inserted to form the winding E. If the shaped group A is intended to be inserted into a ferromagnetic core of a rotating machine (an electric motor or an electricity generator), the distancing stroke is traveled along a circular trajectory.

[0068] As explained above, in other words during such forming step 5, at least one of the seats 7, 8 is furthermore also movable along a compaction stroke that is substantially coaxial with the axis of the prong B4, C4coupled thereto (in a direction parallel to the axis X), in order to axially push such prong B4, C4and consequently force the corresponding conductor element B, C up against the surface of the contiguous conductor element C, D.

[0069] It should further be noted that the operations of the forming step 5 can conveniently be executed while keeping the initial fronts B Ci and Di of the conductor elements B, C and D and the terminal front D2of the outermost conductor element D of the group G substantially coplanar.

[0070] With particular reference to the embodiment illustrated by way of non-limiting example in the accompanying figures, the initial fronts Bi, Ci and Di are all at the same height, at which the terminal front D2of the outermost conductor element D of the group G (which is the shortest) is also.

[0071] The height is defined with respect to the direction identified by the axis X, parallel to the axis of an initial part B3e, C3e, D3e, proximate to the initial front Bi, and of a terminal part B4e, C4e, D4e, proximate to the terminal front B2of the conductor elements B, C and D. In such case, the settlement 6 (locking means 6) and only the seat 9 of the outermost conductor element D of the group G are therefore substantially coplanar.

[0072] The seat 7 (in which the terminal front B2of the conductor element B can engage) and the seat 8 (in which the terminal front C2of the conductor element C can engage) are by contrast at different heights (the minimum height is the height at which the seat 7 is owing to the greater protrusion of the terminal front B2of the conductor element B temporarily coupled thereto) to the heights at which the settlement 6 (locking means 6) and the seat 9 are.

[0073] It should further be noted that during the forming step 5 it is advantageously possible to perform a substantial transverse mutual locking of the group G of layered conductor elements B, C and D, i.e. by applying at least one movable mutual engagement between portions of the first B3, C3, D3and second B4, C4, D4prongs in positions proximate to the curved connecting segments and, respectively, far from the initial Bi, Ci, Di and terminal B2, C2, D2fronts of the compact group G of layered conductor elements B, C, D, in order to prevent the distancing between the conductor elements B, C, D at the portions of the first B3, C3, D3and second B4, C4, D4prongs.

[0074] The transverse locking (transverse with respect to the direction of the axis of the prongs B3, C3, D3and B4, C4, D4of the conductor elements B, C and D) can be profitably executed independently on mutually opposite and facing regions of the prongs B3, C3, D3and B4, C4, D4of the conductor elements B, C and D of a group G: by executing the locking independently on specific regions of the prongs B3, C3, D3and on specific regions of the prongs B4, C4, D4it is therefore possible, during the forming step 5, to splay them, by executing the distancing stroke defined above. It will be seen below that components can be provided for transversely locking the prongs B3, C3, D3and B4, C4, D4which are adapted to cooperate in order to produce a correct shaping of the group G by splaying the prongs B3, C3, D3and B4, C4, D4and distancing them: in particular, the movable mutual engagement is accomplished by a locking unit 10 which temporarily accommodates respective portions of the first B3, C3, D3and second B4, C4, D4prongs of a same group G. In such case the locking unit 10 produces the movable mutual engagement of the portions of prongs B3, C3, D3and B4, C4, D4held by said locking unit 10 on a plane of engagement R that is substantially perpendicular to the axial direction X, during the forming step 5, in order to keep the layered alignment of the conductor elements B, C, D at the at least one portion thereof that is arranged proximate to such plane of engagement R. For most of their length, the prongs B3, C3, D3and the prongs B4, C4, D4are mutually facing and aligned, before execution of the forming step 5 : they will by contrast be distanced (for most of their length) after the forming step 5.

[0075] It is necessary to specify that the completion of the forming step 5, accomplished at the end of the distancing stroke along the predefined trajectory, and at the end of the compaction stroke, leads to a substantial coplanarity of all the terminal fronts B2, C2and D2and of all the initial fronts Bi, Ci and Di of the prongs B3, C3, D3and of the prongs B4, C4, D4.

[0076] The movable mutual engagement of the conductor elements B, C, D can be accomplished by a locking unit 10 constituted by locking bodies 11, 12, which temporarily accommodate respective portions of the first B3, C3, D3and second B4, C4, D4prongs of a same group G.

[0077] These locking bodies 11, 12 are mutually movable, preferably along circular trajectories, on the plane of engagement R perpendicular to the axial direction X during the forming step 5.

[0078] With particular reference to an embodiment of undoubted practical and applicative interest, the bending step 4 of the layered conductor elements B, C and D entails bending them into a U- shape until the juxtaposition of an initial end B3e, proximate to the initial front B and of a terminal part B4ethereof, proximate to the terminal front B2, of a surface of the conductor element B arranged opposite from the surface that fits against the face of the conductor element C contiguous thereto, in order to obtain a compact group G of bent conductor elements B, C, D, with the shape of a split pin.

[0079] Once all the shaped groups A are produced, they need to be placed in the destination ferromagnetic core according to the circuit diagram of the winding E that it is intended to provide.

[0080] Preferably the shaped groups A can be arranged on a template (which in the jargon is called “false stator” or “false ferromagnetic core”) so as to provide the desired circuit diagram for the winding E: at this point the entire winding E (constituted by the shaped groups A, conveniently arranged and interleaved) can be taken from the template and inserted in the respective ferromagnetic core (for example the stator F of an electric motor).

[0081] It should be noted that the layering step 3 can be executed on substantially straight wire pieces, defining the conductor elements B, C, D, of a conducting wire with a substantially rectangular cross-section. In such case, the layering step 3 of at least two wire pieces consists preferably in the superimposition of such wire pieces, juxtaposing corresponding faces with the longest side of the rectangle that constitutes their outline. However, the possibility is not ruled out of adopting a different superimposition criterion.

[0082] The scope of protection offered by this discussion also extends to a station 100 for forming shaped groups A of conductor elements B, C, D to be used for providing inductive windings E of electric machines, wherein each one of the shaped groups A comprises at least two conductors B, C, D and is shaped initially like a split pin-shaped compact group G of a corresponding number of conductors B, C, D, wherein each one of such conductors B, C, D of the compact group G comprises: a respective first B3, C3, D3prong, which comprises a respective straight end B3e, C3e, D3eand an initial front Bi, Ci, Di; a respective second B4, C4, D4prong, which comprises a respective straight end B4e, C4e, D4eand a terminal front B2, C2, D2; curved central connecting segments joining each one of first B3, C3, D3and second B4, C4, D4prongs.

[0083] The station 100 comprises forming means 101 which can move with respect to a central axis Y and are provided with at least one first settlement 6 (locking means 6) configured to hold initial fronts B Ci, Di of conductor elements B, C, D of a first prong B3, C3, D3of the group G and at least one seat 7, 8, 9 (locking means 7, 8, 9) configured to hold at least one terminal front B2, C2, D2of at least one respective conductor element B, C, D of at least one respective prong B4, C4, D4of the group G. The settlement 6 (locking means 6) and the seats 7, 8, 9 (locking means 7, 8, 9) are configured to accommodate the first B3e, C3e, D3eand the second B4e, C4e, D4estraight ends in a direction substantially parallel to the central axis Y, and furthermore the settlement 6 (locking means 6) and the seats 7, 8, 9 (locking means 7, 8, 9) are conveniently mutually movable, on a plane P perpendicular to the central axis Y (and therefore perpendicular to the direction of the axis of the prongs B3, C3, D3and B4, C4, D4before they are formed, i.e. the plane P is also perpendicular to the mentioned axis X), along a distancing stroke with a predefined breadth and a predefined trajectory, for distancing the prongs B3, C3, D3and B4, C4, D4of such conductor elements B, C, D of the group G.

[0084] At least one seat 7, 8 is advantageously also movable along a compaction stroke substantially parallel to the central axis Y (i.e. also parallel to the direction of the axis of the second prong B4, C4, D4coupled thereto), before its distancing deformation, when it is subjected to an axial push induced on at least one of the second prongs B4, C4(or tines) in order to progressively axially align the second free ends B2, C2, D2of the second prongs B4, C4, D4, until these second free ends B2, C2, D2are brought into substantial mutual co-planarity, thus superimposing contiguous conductor elements B, C or C, D and thus obtaining for each group G a shaped group A of superimposed conductor elements B, C, D. For example, such compaction stroke is configured to axially push such at least one second prong (for example) B4, C4and consequently force the at least one corresponding conductor element B, C onto the surface of the conductor element C, D contiguous thereto during the distancing deformation for the substantial alignment of the terminal fronts B2, C2, D2in a configuration of substantial co-planarity.

[0085] The station 100 is dimensioned so that the settlement 6 (locking means 6), configured to hold the initial fronts B Ci, Di of the conductor elements B, C, D of the first prong B3, C3, D3of the group G, and the seat 9 that accommodates the terminal front D2of the second prong D4(i.e. of the outermost conductor element D of the second prong B4, C4, D4of the group G) are substantially coplanar. In such case, the at least one additional seat 7, 8 is movable along the compaction stroke from an initial configuration wherein it lies on a plane P7, Ps parallel to and unaligned with the plane Pe of arrangement of the settlement 6 (locking means 6) to a final configuration wherein it is translated toward the curved connecting segment of said group G and substantially arranged on the plane of arrangement of the settlement 6 (locking means 6).

[0086] The settlement 6 (locking means 6) and the seats 7, 8, 9 (locking means 7, 8, 9) can conveniently be provided on arc-shaped (and substantially tubular) bodies 6a, 7a, 8a, 9a.

[0087] In particular, the settlement 6 (locking means 6) is provided on an arcshaped (and substantially tubular) body 6a, preferably fixed; the seats 7, 8, 9 (locking means 7, 8, 9) are by contrast provided on respective concentric arc-shaped (and substantially tubular) bodies 7a, 8a, 9a, with progressively increasing diameters greater than the diameter of the arc-shaped (and substantially tubular) body 6a of the settlement 6 (locking means 6).

[0088] The arc-shaped (and substantially tubular) bodies 6a, 7a, 8a, 9a are configured to be mutually moved, by means of the rotation thereof with respect to the central axis Y of rotation.

[0089] The settlement 6 (locking means 6) can therefore be advantageously provided on a fixed arc-shaped (and substantially tubular) body 6a; the seats 7, 8, 9 (locking means 7, 8, 9) by contrast can profitably be provided on respective concentric arc-shaped (and substantially tubular) bodies 7a, 8a, 9a, with progressively increasing diameters larger than the diameter of the arc-shaped (and substantially tubular) body 6a provided with the settlement 6 (locking means 6). The arc-shaped (and substantially tubular) bodies 6a, 7a, 8a, 9a are validly configured to be mutually moved, by means of a rotation thereof, so as to accomplish the forming of the group A, starting from a compact group G.

[0090] By way of non-limiting example, the arc-shaped (and substantially tubular) body with the smaller diameter 6a provided with the settlement 6 (locking means 6) is fixed; by contrast, the arc-shaped (and substantially tubular) body 7a with a larger diameter than that of the arc-shaped (and substantially tubular) body 6a is provided with the seat 7; the arc-shaped (and substantially tubular) body 8a with a larger diameter than that of the arc-shaped (and substantially tubular) body 7a is provided with the seat 8; the arc-shaped (and substantially tubular) body 9a with a larger diameter than that of the arc-shaped (and substantially tubular) body 8a is provided with the seat 9; these last three arc-shaped (and substantially tubular) bodies 7a, 8a and 9a are able to rotate with respect to their own axis of symmetry Y, along an angular stroke of predefined breadth.

[0091] Furthermore, at least one of the arc-shaped (and substantially tubular) bodies 7a, 8a provided with the seat 7, 8 are also operatively associated with a respective cam which is configured to vary the respective axial height (during their rotation, explained in the previous paragraph) with consequent variation of the height, along the common central axis Y of the arc-shaped (and substantially tubular) bodies 7a, 8a (about which both can rotate during the forming step 5), of the respective seats 7, 8 and of the terminal fronts B2, C2accommodated in them (bringing these last into alignment with the terminal front D2).

[0092] The settlement 6 (locking means 6) and the seats 7, 8, 9 (locking means 7, 8, 9) are constituted by a slot parallel to the central axis Y and configured to receive, at least in the axial direction, the respective first and second prong B3, C3, D3, B4, C4, D4(or tine) along a direction parallel to the central axis Y

[0093] Each one of the arc-shaped (and substantially tubular) bodies 7a, 8a, 9a of the independent second locking means 7, 8, 9 (or seats 7, 8, 9) is operatively associated with a respective cam (not shown in the accompanying figures) which is configured to move at least one arc-shaped body 8a, 9a of the independent second locking means 8, 9 along an axial direction parallel to the central axis Y.

[0094] The forming means 101 present in the forming station 100 usefully comprise at least one transverse locking unit 10 (the term "transverse" here means with respect to the longitudinal axis of the conductor elements B, C, D) for mutually locking the group G of layered conductor elements B, C, D, and configured for the controlled deformation of portions thereof.

[0095] The locking unit 10 therefore engages the layered conductor elements B, C, D at at least one region thereof that is substantially proximate to the curved connecting segment of the respective first B3, C3, D3and second B4, C4, D4prongs, in order to maintain the layered alignment of such conductor elements B, C, D at such at least one region thereof during the distancing stroke.

[0096] In more detail, it should be noted that the transverse locking unit 10 can efficaciously lock the prongs B3, C3, D3, B4, C4, D4at least at a portion proximate to the curved central connecting segments thereof and maintain a layered alignment of the conductor elements B, C, D during the distancing stroke: in particular, the locking unit 10 can comprise a first locking body 11 configured to temporarily accommodate portions of first prongs B3, C3, D3and a second locking body 12 configured to temporarily accommodate portions of second prongs B4, C4, D4of a same group G.

[0097] The first locking body 11 and the second locking body 12 are movable integrally with the respective region of the first prongs B3, C3, D3and of the second prongs B4, C4, D4accommodated in them during the forming step 5.

[0098] The first B3, C3, D3and the second B4, C4, D4prong (or tine) comprise respective lower portions B3e, C3e, D3e, B4e, C4e, D4eand upper portions adjacent B3m, C3m, D3m, B4m, C4m, D4m, wherein the lower portions B3e, C3e, D3e, B4e, C4e, D4eare longer than the upper portions B3m, C3m, D3m, B4m, C4m, D4m. The locking unit 10 comprises a first locking body 11, configured to retain the upper portions B3m, C3m, D3mof the first prongs B3, C3, D3(or tines), and a second locking body 12, configured to retain the upper portions B4m, C4m, D4mof the second prongs B4, C4, D4(or tines) of conductor elements B, C, D arranged in the same group G. Each one of the first 11 and second 12 locking bodies is movable integrally with the respective area of the upper portions B3m, C3m, D3mof the first prongs B3, C3, D3(or tines) and of the upper portions B4m, C4m, D4mof the second prongs B4, C4, D4(or tines).

[0099] Either or both of the first 11 and the second 12 locking body is configured to be moved along a circular trajectory about the central axis Y within a plane of engagement R perpendicular to the central axis Y.

[0100] The first 11 and the second 12 locking body are both configured to be moved in the same direction, from a respective initial position ill, il2 to a final position fll, fl 2. The initial positions ill, il2 are preferably aligned with respect to a predefined radial direction, and the second locking element 12 is configured to rotate more rapidly and / or through an angle of greater breadth than the first locking element 11, so that the distance between the final position fl 2 and the initial position il2 of the second locking element 12 is greater than the distance between the final fll and initial ill positions of the first locking element 11.

[0101] Furthermore, the forming means 101 can comprise at least one contoured abutment block 13, provided with a first edge 14 which is configured for the abutment of respective regions of first prongs B3, C3, D3of a group G (in particular of the respective upper portions B3m, C3m, D3m), and which is substantially parallel to the central axis Y of rotation. The contoured abutment block 13 is furthermore provided with a second edge 16 configured to guide the first locking body 11 on a final part of its trajectory, thus also being substantially perpendicular to the central axis Y. An inclined connecting edge 15 is conveniently interposed between the first edge 14 and the second edge 16 and is configured for their connection (the coupling thereof), and it is dimensioned to not interfere with the final shape of the shaped group A.

[0102] The at least one contoured abutment block 13 has an arc shape equidistant with respect to the central axis Y and is fixed within the forming means 101.

[0103] With particular reference to an embodiment of undoubted practical and applicative interest, the locking body 12 is movable in a guided manner within a respective guide slot 12a.

[0104] It should be noted that the use is envisaged of a containment shell 102, overlying the pin when the respective prongs B3, C3, D3are held by the settlement 6 (locking means 6) and the prong B4is held by the seat 7, the prong C4is held by the seat 8 and the prong D4is held by the seat 9. During the forming step 5, it can happen that the pin tends to translate vertically, leaving the settlement 6 (locking means 6) and the seats 7, 8 and 9 (locking means 7, 8, 9): the presence of the containment shell 102 above ensures that the pin remains stationary in the desired position, so that it can undergo the correct shaping deformations necessary for its forming and the production of the group A.

[0105] The protection offered by the present invention also extends to a machine for forming shaped groups A of conductor elements B, C and D, which comprise at least two conductors B, C, D, for providing inductive windings E of electric machines, which comprises means for the supply of conductor elements B, C and D of predefined lengths.

[0106] The machine according to the invention further comprises at least one first station configured for the layered juxtaposition of at least two conductor elements B, C, D.

[0107] The machine also comprises at least one second station 200 configured for bending the at least two layered conductor elements B, C, D by plastically deforming said conductor elements B, C, D and giving them the shape of a split pin: this split pin will be constituted by two substantially linear prongs B3, C3, D3and B4, C4, D4, connected by a curved connecting segment, defining a compact group G. In other words, each conductor element B, C, D comprises a first B3, C3, D3and a second B4, C4, D4substantially linear prong, connected by a curved connecting segment, so as to define a compact group G.

[0108] The machine also comprises at least one third station 100 of the type described previously.

[0109] With particular reference to an embodiment of undoubted practical and applicative interest, the means for the supply of conductor elements B, C, D of predefined lengths can advantageously comprise dispensing means for dispensing a (preferably) continuous conducting wire and cutting means configured to truncate the conducting wire according to preset cutting sequences, so obtaining conductor elements B, C, D of predefined lengths.

[0110] The term "continuous conducting wire" means any thin element made of electrically-conducting material (unipolar or multipolar), preferably covered with a layer of dielectric (electrically insulating) material: the category therefore includes all types of enameled copper wire (enameled being a term used to indicate the continuous covering with a dielectric film of its lateral surface), independently of their dimensions and of their crosssection.

[0111] The means for dispensing of continuous conducting wire, in turn, can comprise at least one storage spool of the wire and an entrainer configured to extract the wire from the spool (by unreeling it from the spool) and feed it to the cutting means. The possibility is not ruled out that contrivances can be interposed along the path of the continuous conducting wire, from the respective spool to the cutting means, for straightening the wire (which, owing to elastic memory, would otherwise partially retain the curvature with which it was wound on the spool).

[0112] The means for layered juxtaposition of the conductor elements B, C and D can advantageously comprise a plane acting as an abutment shoulder, which is configured for the abutment of the initial fronts B Ci and Di of all the juxtaposed conductor elements B, C and D, so that the set of layered conductor elements B, C and D comprises conductor elements B, C and D with the initial fronts Bi, Ci and Di substantially coplanar and aligned and the terminal fronts B2, C2and D2misaligned by virtue of the different length of the conductor elements B, C and D. In this manner, the conductor elements B, C, D will be juxtaposed and layered, keeping the initial fronts Bi, Ci and Di coplanar and locating any differences in lengths at the respective terminal fronts B2, C2and D2.

[0113] The second station 200 can profitably comprise a fixed lane 201 delimited, on one of its sides, by a removable containment tab 202 which is configured to accommodate a first section of the conductor elements B, C, D. The second station 200 is furthermore provided with a bending hub 203 which can rotate (following manual and / or automatic actuation) about a respective abutment pin 204 substantially aligned with the midpoint of the conductor elements B, C, D when they are accommodated within the fixed lane 201.

[0114] The hub 203 comprises, in turn, a recess 205 for the temporary accommodation of parts of the conductor elements B, C, D and can move from a first configuration in which the recess 205 does not interfere with the conductor elements B, C, D arranged in the lane 201 to a second, rotated configuration in which the recess 205 is facing and proximate to the lane 201 with the interposition of juxtaposed and aligned prongs B3, C3, D3and B4, C4, D4of the conductor elements B, C, D.

[0115] The rotation of the hub 203 therefore determines the bending of the wire pieces about the abutment pin 204 with consequent formation of the split pin that constitutes the compact group G.

[0116] Once all the shaped groups A necessary to form a winding E are produced, they can be arranged in conformance with the desired circuit diagram so as to provide a braided bundle of shaped groups A (for example on a template, which may be of the type called in the jargon “false stator” or, generically, “false ferromagnetic core”). The braided bundle of shaped groups A, once completed, can be inserted in the respective ferromagnetic core (for example a stator F of an electric motor), after which come the subsequent operations for mechanical deformation and respective welding of some or all the wire pieces of shaped groups A which protrude from the ferromagnetic core.

[0117] The possibility is not ruled out that the shaped groups A obtained using the method 1 according to the invention (and / or produced using the machine according to the invention) can be subjected to subsequent operations to cut their ends (proximate to the initial fronts B Ci and Di and to the terminal fronts B2, C2and D2for the purpose of adapting their dimensions to what is required for the specific template for assembling the winding E and / or the specific ferromagnetic core F.

[0118] Advantageously the present invention solves the above mentioned problems by providing a method 1 for forming shaped groups A of conductor elements B, C, D intended to constitute parts of windings E of electric machines, that makes it possible to maintain perfectly aligned, and with facing surfaces substantially juxtaposed, the conductor elements B, C and D of each group A during the step 5 of shaping / forming thereof.

[0119] Conveniently the method 1 according to the invention makes it possible to provide shaped groups of conductor elements with minimum space occupation, in that they do not deviate from their theoretical ideal shape (by contrast, such deviation is almost always present in shaped groups produced using the methods according to the prior art).

[0120] Advantageously the method 1 according to the invention makes it possible to provide shaped groups A that are adapted to be subsequently inserted into the slots of a ferromagnetic core according to a preset pattern, without interfering with other groups A of conductor elements (since their shape is compact and the conductors B, C and D are mutually layered and matching in each shaped group A obtained using the method 1 according to the invention).

[0121] Profitably the machine for forming shaped groups A of conductor elements B, C and D intended to constitute windings E of electric machines prevent, during their shaping / forming, the conductor elements B, C and D of a same group A from undergoing misalignments: this is ensured by virtue of the particular shape structure of the locking seats 7, 8 and 9 (and the compaction stroke of the seats 7 and 8) and by virtue of the presence of the locking unit 10 (which embrace specific regions of the conductors B, C and D, keeping them mutually aligned).

[0122] Positively the machine for forming shaped groups A according to the invention prevents, during the shaping / forming of the conductor elements B, C and D, the respective group A from undergoing an increase in space occupation in cross-section.

[0123] Positively the method 1 and the machine according to the invention are easily and practically implemented and low cost: such characteristics render the method 1 and the machine according to the invention innovations of certain application.

[0124] The invention, thus conceived, is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims. Moreover, all the details may be substituted by other, technically equivalent elements.

[0125] In the embodiments illustrated, individual characteristics shown in relation to specific examples may in reality be interchanged with other, different characteristics, existing in other embodiments.

[0126] In practice, the materials employed, as well as the dimensions, may be any according to requirements and to the state of the art.

[0127] The disclosures in Italian Patent Application No. 102023000019635 from which this application claims priority are incorporated herein by reference.

[0128] Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.

Claims

CLAIMS1. Method for forming shaped groups (A) of conductor elements (B, C, D) made from enameled wire, each of said shaped groups (A) comprising at least two conductor elements (B, C, D) for making inductive windings (E) of electric machines, said method comprising:- a layering step (3) of at least two substantially straight conductor elements (B, C, D), wherein said layering consists in facing and juxtaposing respective longitudinal surfaces of the at least two substantially straight conductor elements (B, C, D);- a bending step (4) of said layered conductor elements (B, C, D) to obtain a group (G) of conductor elements (B, C, D) shaped like a split pin, each obtained split pin comprising a first (B3, C3, D3) and a second (B4, C4, D4) prongs and a respective curved central connecting portions joining each of said first (B3, C3, D3) and second (B4, C4, D4) prongs of the conductor elements (B, C, D); said method being characterized by further comprising:- a forming step (5), wherein said group (G) of split pins is subjected to deforming stresses in order to determine plastic deformations by means of: a) a separating sub-phase between said first (B3, C3, D3) and second (B4, C4, D4) prongs of the split pins forming said group (G), wherein the first prongs (B3, C3, D3) are mutually blocked together keeping their respective free ends (Bl, Cl, DI) lying on a common plane (P) substantially perpendicular to an axial direction (X), and wherein said second prongs (B4, C4, D4) are distanced from the first prongs (B3, C3, D3) of said group (G) by reciprocally moving them over a distancing stroke according to a predefined distance and trajectory, and b) an alignment sub-phase, wherein at least one of said second prongs (B4, C4) is moved over a compaction stroke along the axial direction (X) due to an axial thrust induced on at least one of the second prongs (B4, C4)for progressively axially aligning second free ends(B2, C2, D2) of the second prongs (B4, C4, D4) of the respective group (G), until bringing said second free ends (B2, C2, D2) substantially coplanar to each other, by overlapping contiguous conductor elements (B, C; C, D), thus obtaining for each group (G) of split pins a shaped group (A) of overlapped conductor elements (B, C, D).

2. Method, according to claim 1, characterized in that in said forming step (5), said first free ends (Bl, Cl, DI) of the respective split pins (B, C, D) are housed into a common first seating (6) to keep them mutually blocked lying on said common plane (P), while said second free ends (B2, C2, D2) are housed in respective second independent seatings (7, 8, 9), said first prongs (B3, C3, D3) and said second prongs (B4, C4, D4) being reciprocally moved over the distancing stroke along a direction perpendicular to the axial direction (X) in order to distance said second independent seatings (7, 8, 9) with respect to the common first seating (6).

3. Method, according to claim 1 or 2, characterized in that said first (B3, C3, D3) and second (B4, C4, D4) prongs are reciprocally moved over the distancing stroke by moving the first (B3, C3, D3) and / or the second (B4, C4, D4) prongs along a trajectory of a type chosen between at least substantially circular and substantially linear.

4. Method, according to one or more of the previous claims, characterized in that during said forming step (5), the first prongs (B3, C3, D3) are distanced from the second prongs (B4, C4, D4) while keeping said first prongs (B3, C3, D3) substantially parallel and close to each other and said second prongs (B4, C4, D4) substantially parallel and close to each other.

5. Method, according to any one of the previous claims, characterized in that said first (B3, C3, D3) and second (B4, C4, D4) prongs comprise respective lower portions (B3e, C3e, D3e, B4e, C4e, D4e) and adjacent upper portions (B3m, C3m, D3m, B4m, C4m, D4m), wherein the lowerportions (B3e, C3e, D3e, B4e, C4e, D4e) are longer than the upper portions (B3m, C3m, D3m, B4m, C4m, D4m) and wherein said lower portions lower portions (B3e, C3e, D3e, B4e, C4e, D4e) remain substantially straight even after the forming step (5) of the shaped group (A) of overlapped conductor elements (B, C, D), wherein during the forming step (5), the lower portions lower portions (B3e, C3e, D3e) of the first prongs (B3, C3, D3) are kept in a fixed position by means of a blocking member (6), while the upper (B4m, C4m, D4m) and lower (B4e, C4e, D4e) portions of the second prongs (B4, C4, D4) are moved away from the first prongs (B3, C3, D3) and the upper portions (B4m, C4m, D4m) of the second prongs (B4, C4, D4) are bent with respect to the respective lower portions (B4e, C4e, D4e) of the second prongs (B4, C4, D4) by means of a first bending element (11) acting on the upper portions (B4m, C4m, D4m) of the second prongs (B4, C4, D4), and wherein the upper portions (B3m, C3m, D3m) of the first prongs (B3, C3, D3) are bent with respect to the respective lower portions (B3e, C3e, D3e) of the first prongs (B3, C3, D3) by means of a second bending element (12), so that the upper portions (B3m, C3m, D3m, B4m, C4m, D4m) of the first (B3, C3, D3) and second (B4, C4, D4) prongs forms respective bent portions of the overlapped conductor elements (B, C, D).

6. Method, according to the previous claim, characterized in that during the forming step (5), said first and second bending elements (11, 12) move on a plane (R) substantially perpendicular to the axial direction (X), preferably along a circular trajectory.

7. Method, according to one or more of the previous claims, characterized in that said layering step (3) of at least two conductor elements (B, C, D) is carried out maintaining their first free ends (Bl, Cl, DI) aligned and substantially coplanar.

8. Method, according to one or more of the previous claims, characterized in that in said layering step (3), said layered conductor elements (B, C, D) have the second free ends (B2, C2, D2) staggered, i.e.presenting a different overhang therebetween.

9. Method, according to one or more of the previous claims, characterized in that said bending step (4) of said layered conductor elements (B, C, D) involves a "U"-fold performed by applying a force configured to determine a bending perpendicular to a longitudinal direction (L) of said conductor elements (B, C, D), until the juxtaposition of a first end (B3e, C3e, D3e) close to the initial front (Bl), and of a second end (B4e, C4e, D4e), close to the final front (B2), of a surface opposite to the one matching with a face of the contiguous conductor element (C) ofcompatto avente la forma di una coppiglia a conductor element (B), to obtain a group (G) of bent elements having the shape of a split pin.

10. Method, according to one or more of the previous claims, characterized in that said conductor elements (B, C, D) have a substantially rectangular section, said layering step (3) of at least two conductor elements consisting of the superposition of said conductor elements by juxtaposing faces corresponding to the longest side of the rectangular section thereof.

11. Method, according to one or more of the previous claims, characterized by further comprising a cutting step (2) of substantially straight conductor elements (B, C, D) according to a predefined length.

12. Station for forming shaped groups (A) of conductor elements (B, C, D) made from enameled wire for carrying out inductive windings (E) of electrical machines, each of said shaped groups (A) comprising at least two conductor elements (B, C, D) and being initially shaped as a group (G) in the shape of a split pin, wherein each of said conductor elements (B, C, D) of the group (G) comprises a first (B3, C3, D3) and a second (B4, C4, D4) straight prongs and a respective curved central connecting portions joining said first (B3, C3, D3) and second (B4, C4, D4) prongs of the conductor element (B, C, D), said station being characterized by comprising forming means (101) movable with respect to a central axis (Y) and provided with at least a first common blocking member (6) configured to keep free ends (B 1 ,Cl, DI) of said first prongs (B3, C3, D3) mutually blocked lying on a common plane (P6), and second independent blocking members (7, 8, 9) configured to hold the respective second free ends (B2, C2, D2) of the second prongs (B4, C4, D4), said first common blocking member (6) and said second independent blocking members (7, 8, 9) being further configured to be mutually movable on a plane (P) orthogonal to the central axis (Y) over a distancing stroke according to a predefined distance and trajectory, so that the second prongs (B4, C4, D4) are distanced from the first prongs (B3, C3, D3) of said group (G), and in that at least one of said second independent blocking members (7, 8) is also configured to be mobile over a compaction stroke substantially parallel to the central axis (Y), when subjected to an axial thrust induced on at least one of the second prongs (B4, C4) for progressively axially aligning the second free ends(B2, C2, D2) of the second prongs (B4, C4, D4), until bringing said second free ends (B2, C2, D2) substantially coplanar to each other, by overlapping contiguous conductor elements (B, C; C, D), thus obtaining for each group (G) a shaped group (A) of overlapped conductor elements (B, C, D).

13. Station, according to claim 12, characterized in that said first common blocking member (6) and said second independent blocking members (7, 8, 9) are seatings (6, 7, 8, 9) made on a respective arch-shaped body (6a, 7a, 8a, 9a) concentric with respect to the central axis (Y) and configured to be reciprocally rotated about said central axis (Y), and in that the arch-shaped bodies (7a, 8a, 9a) of the second independent housings (7, 8, 9) are radially distanced from each other.

14. Station, according to claim 13, characterized in that said seatings (6, 7, 8, 9) consist of a slot parallel to said central axis (Y) configured to hold the respective first and second prongs (B3, C3, D3, B4, C4, D4) at least in an axial direction parallel to said central axis (Y).

15. Station, according to claim 13 or 14, characterized in that each of said arc-shaped bodies (7a, 8a, 9a) of the second independent blockingmembers (7, 8, 9) is operationally associated with a respective cam NOTA DI MR: secondo me e impossibile identificare la rispettiva camma nelle figure 27 e 28 come richiesto dal cliente in riv 15 configured to move at least one arch-shaped (8a, 9a) of the second independent blocking members (8, 9) along an axial direction parallel to the central axis (Y).

16. Station, according to at least one of claims 12 to 15, characterized in that said forming means (101) comprise at least one locking unit (10) configured to bind together said first and second prongs (B3, C3, D3, B4, C4, D4) at least on a portion close to the curved central connecting portions thereof, and to maintain a layered alignment of said conductor elements (B, C, D) during said distancing stroke.

17. Station, according to the previous claim, characterized in that said first (B3, C3, D3) and second (B4, C4, D4) prongs comprise respective lower portions (B3e, C3e, D3e, B4e, C4e, D4e) and adjacent upper portions (B3m, C3m, D3m, B4m, C4m, D4m), wherein the lower portions (B3e, C3e, D3e, B4e, C4e, D4e) are longer than the upper portions (B3m, C3m, D3m, B4m, C4m, D4m) and in that said locking unit (10) comprises a first locking body (11), configured to hold the upper portions (B3m, C3m, D3m) of the first prongs (B3, C3, D3), and a second locking body (12), configured to hold the upper portions (B4m, C4m, D4m) of the second prongs (B4, C4, D4) of conductor elements (B, C, D) arranged in the same group (G), each of said first (11) and second (12) locking bodies being solidly movable together with the respective area of said upper portions (B3m, C3m, D3m) of the first prongs (B3, C3, D3) and said upper portions (B4m, C4m, D4m) of the second prongs (B4, C4, D4) held therewith.

18. Station according to the previous claim, characterized in that at least one between said first (11) and second (12) locking bodies is configured to move with a circular trajectory around the central axis (Y) within a constraint plane (R) which is perpendicular to said central axis (Y).

19. Station according to the previous claim, characterized in that boththe first (11) and the second (12) locking members are configured to move in the same direction, from a respective initial position (ill, il2) to a final position (fll, fl2), wherein the initial positions (ill, il2) are preferably aligned with respect to an radial direction (Nota di MR: non ha senso definire la specifica direzione radiale perche dipenderebbe dal disegno... non e fissa per qualsiasi forma di realizzazione) and wherein the second (12) locking member is configured to rotate faster and / or a greater angle than the first locking member (11), so that the distance between the final (fl 2) and the initial (il2) position of the second locking member is greater than the distance between the final (fll) and initial (ill) positions of said first locking member (11).

20. Station, according to at least one of claims 12 to 19, characterized in that said forming means (101) comprise at least one shaped abutment block (13) provided with:- a first edge (14) configured for supporting respective areas of said upper portions (B3m, C3m, D3m) of the first prongs (B3, C3, D3) of a group (G) and substantially parallel to the axis (Y) of rotation, and- a second edge (16) configured for guiding said first locking body (11) in a final part of its trajectory and substantially perpendicular to the rotation axis (Y), and- an inclined connecting edge (15), interposed between said first edge (14) and said second edge (16) and configured for connecting therewith and dimensioned so as to not interfere with the final shape of the shaped group (A).

21. Station, according to the previous claim, characterized in that said at least one shaped abutment block (13) presents and arc-shape equidistant with respect to the central axis (Y).

22. Station, according to claim 20 or 21, characterized in that said at least one shaped abutment block (13) is fixed within said forming means (101).

23. Machine for the formation of shaped groups (A) of conductor elements (B, C, D), each of said shaped groups (A) including at least two conductor elements (B, C, D), for carrying out inductive windings (E) of electric machines, comprising means for the supply of conductor elements (B, C, D) having predefined lengths, characterized in that it includes- at least a first station configured for the layered juxtaposition of at least two conductor elements (B, C, D);- at least a second station (200) configured for the bending of at least two of said layered conductor elements (B, C, D) by plastically deforming said conductor elements (B, C, D) and giving them the shape of a split pin, wherein each conductor element (B, C, D) includes a first (B3, C3, D3) and a second (B4, C4, D4) substantially straight prong connected by means of a curved junction section, defining a group (G );- at least a third forming station (100) according to at least one of claims 11 to 22.

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