Method for separating groups of conductors from a set of conductors arranged within a ferromagnetic core, and separation tool therefor

Abstract

A tool (1) for separating groups (A) of legs (B) of different conductors (C) of a set of conductors (C) arranged within a ferromagnetic core (N). The tool (1) is constituted by an elongated body (2) extending along a respective longitudinal axis (9) and configured to be arranged radially with respect to the ferromagnetic core (N) with the longitudinal axis (9) lying on a plane substantially perpendicular to the central axis (E) of the core (N). The tool (1) comprises two seats (3, 10): the first distal end seat (3) is delimited between 4 walls (4, 5, 6, 7), of which the front and terminal wall (4) has a height (H1) which is lower than the height (H) of the other walls (5, 6, 7), forming an access aperture (8) in the first seat (3) also along a direction which is parallel to the direction of the longitudinal axis (9), i.e., in a radial direction (R) with respect to the core (N).

Description

[0001] METHOD FOR SEPARATING GROUPS OF CONDUCTORS FROM A SET OF CONDUCTORS ARRANGED WITHIN A FERROMAGNETIC CORE, AND SEPARATION TOOL THEREFOR

[0002] The present invention relates to a method for separating groups of conductors from a set of conductors arranged within a ferromagnetic core and to the separation tool therefor.

[0003] The present invention relates to apparatuses and methods for aligning conductors (generally constituted by an appropriately shaped portion of metal wire having any transverse shape) inserted within the slots of a ferromagnetic core of an electrical machine (with reference to a rotating electrical machine, although application of the present invention also on transformers or autotransformers is not excluded).

[0004] The use of apparatuses and methods adapted for providing inductive windings for electrical machines is known in the background art: such windings are provided by inserting the conductors in the slots of a core of an electrical machine according to a specific arrangement.

[0005] Electrical continuity of the winding is subsequently obtained by mutually and permanently joining, typically welding, groups (usually pairs) of conductors. Generally, the conductors are shaped like a hairpin (according to a geometry with an appropriately contoured U-shape) and are termed “hairpins” in the industry (this term identifies a conductor provided with two legs and a connecting portion between them). However, it is not excluded that conductors provided with only one leg (termed I-pins in industry jargon) or otherwise shaped might be adopted.

[0006] A portion of each hairpin-shaped conductor, for example the connecting portion between the two legs, extends axially toward the outside of the ferromagnetic core, from one of its faces; the legs, on the other hand, pass through the axial slots until they protrude from the opposite face of the core. Through the electrical connection (generally obtained by welding) of groups (usually pairs) of legs of different conductors it is possible to provide a continuous electrical circuit that corresponds to the inductive winding to be provided. Ferromagnetic cores provided with inductive windings constituted by conductors of the type known as “hairpin” are frequently used for vehicles.

[0007] The manufacturing process can provide for the automatic arrangement of the conductors (for example hairpins) according to the configuration of interest in a stator core template that reproduces the shape and arrangement of the slots of the ferromagnetic core: once the entire set of conductors (for example hairpins) has been provided, it is possible to extract it monolithically from the stator core template (which is inside a machine configured to provide it) and insert it into the slots of the ferromagnetic core in which the inductive winding is to be provided. After inserting the set of conductors (for example hairpins) in the ferromagnetic core, the ends of said conductors (for example hairpins) have to be spread apart from each other so that the groups (for example pairs) to be connected (e.g., by mutual welding) are close to each other.

[0008] The arrangement of the conductors (for example hairpins) is usually achieved by means of a separation tool, by virtue of which the groups (or pairs) of stems of the conductors (e.g., hairpins) are separated from the others of the set, then allowing easy twisting thereof according to the pattern of interest.

[0009] The twisting device comprises at least one first ring and one second ring which are mutually coaxial and extend circumferentially about the axis of the ferromagnetic core. The rings comprise a first and a second circular series of pockets, respectively, and are rotatable with respect to each other about a twisting axis, so as to assume at least one first and one second configuration in which respective pockets of the first and second series are radially aligned with each other in pairs with respect to the twisting axis. When the device for twisting the groups (pairs) of conductors (for example hairpins) is in the first configuration, the ends of the legs of the conductors (for example hairpins) that protrude from the ferromagnetic core can be inserted into the respective pockets. After rotating the rings into the second configuration, the legs that had been radially aligned in the first configuration are offset radially from each other by a predefined step in the second configuration. It is essential, in order to allow perfect twisting of the legs of the conductors (for example hairpins), that their respective ends be accurately and repeatably positioned (alignment must be ensured between the ends of the conductors of each individual group and with respect to the pockets of the twisting device).

[0010] In view of the need for high productivity, the same applicant has identified, through the inventive concept described in International Patent Application No. WO2020127718, a tool for separating groups of conductors (for example hairpins) that allows to quickly and accurately arrange the ends of the conductors (for example hairpins) in preparation for a subsequent welding step.

[0011] The separation tool described in application No. WO2020127718 is a slider, provided with respective cavities, arranged, in plan view, along the perimeter of the ferromagnetic core on which the operations for separating the groups of legs of conductors (for example hairpins) are to be performed.

[0012] By means of a first translation of the tool according to a stroke for approach (up to respective alignment) to the legs of the conductors (for example hairpins) that it has to group and separate from the others of the set of conductors (for example hairpins), it is possible to align the legs of interest to at least one seat of each slider; the tool subsequently undergoes a translation along the direction of the axes of the legs of the conductors (for example hairpins) toward them, until the legs of the group of interest enter the respective seat. A subsequent stroke for spacing from the axis of the ferromagnetic core of the tool then allows to move the legs of the conductors (for example hairpins) of the group of interest away from all the others that are present in the core. A separator device may comprise a plurality of separation tools substantially arranged along the perimeter of the ferromagnetic core, which are configured to perform (individually) the strokes described above.

[0013] Unfortunately, this technical solution does not allow to achieve optimal operational performance, since the conductors (for example hairpins) of the set thereof present in the core do not always have an ideal position and shape (with reference to the portion of their legs protruding from the ferromagnetic core slots). It may therefore happen that some separation tools fail to arrange in their seats all the legs of the conductors (for example hairpins) of the group (for example a pair) to be formed, impairing considerably the quality of the separation performed. This entails the need to perform meticulous quality control operations on the ferromagnetic cores before starting the operations for welding the separated groups of legs of conductors (for example hairpins). Any error in the separation of the groups, at the end of the welding operations, results in serious nonconformity of the inductive winding which entails the need to discard it.

[0014] The aim of the present invention is to avoid the drawbacks described above by devising a method for separating groups of conductors from a set of conductors arranged within a ferromagnetic core that ensures optimal separation of the group of legs of conductors of interest.

[0015] Within the scope of this aim, an object of the invention is to devise a method for separating groups of conductors from a set of conductors arranged within a ferromagnetic core that is easy to perform and allows to achieve an optimal result regardless of the regularity of the shape of the legs of the conductors.

[0016] Another object of the invention is to provide a separation tool that allows to perform optimal separations of groups of conductors from the others that are present in a ferromagnetic core.

[0017] Another object of the invention is to provide a separation tool adapted to prepare in the ideal manner the legs of conductors for subsequent welding operations.

[0018] Another object of the invention is to provide a separation device that can operate on all conductors present in a ferromagnetic core to prepare them for the subsequent welding operations.

[0019] A further object of the present invention is to provide a method for separating groups of conductors from a set of conductors arranged within a ferromagnetic core and a separation tool that have low costs, are relatively simple to provide in practice, and of safe application.

[0020] This aim and these objects are achieved by a separation tool for separating groups of conductors from a set of conductors arranged within a ferromagnetic core according to claim 1.

[0021] This aim and these objects are also achieved by means of a method for separating groups of conductors from a set of conductors arranged within a ferromagnetic core according to claim 8.

[0022] This aim and these objects are also achieved by means of a device for separating groups of conductors from a set of conductors arranged within a ferromagnetic core according to claim 14.

[0023] Further characteristics and advantages of the invention will become better apparent from the description of a preferred, but not exclusive, embodiment of the separation tool and of the separation device, illustrated by way of non-limiting example in the accompanying drawings, wherein:

[0024] Figure 1 is a schematic axonometric view of a scheme of the provision of a device for separating groups of conductors from a set of conductors arranged within a ferromagnetic core according to the invention;

[0025] Figure 2 is a schematic top view of the scheme of the provision of the device of Figure 1;

[0026] Figure 3 is a schematic sectional side view, taken along a centerline plane, of a ferromagnetic core and of a tool according to the invention;

[0027] Figure 4 is a schematic axonometric view of an enlarged detail of a step of compacting the legs of conductors of a group;

[0028] Figure 5 is a schematic axonometric view of an enlarged detail of a step of gripping the legs of conductors of a group;

[0029] Figure 6 is a schematic axonometric view of an enlarged detail of a step of separating and bending (causing plastic deformation) of the legs of conductors of a group;

[0030] Figure 7 is a schematic sectional side view, taken along a centerline plane, of a tool according to the invention facing the terminals of legs of conductors of a group arranged in a ferromagnetic core;

[0031] Figure 8 is a schematic sectional side view, taken along a centerline plane, of a tool according to the invention abutting against the legs of conductors of a group arranged in a ferromagnetic core, for their compaction;

[0032] Figure 9 is a schematic sectional side view, taken along a centerline plane, of a tool according to the invention during the step of gripping the legs of conductors of a group arranged in a ferromagnetic core;

[0033] Figure 10 is a schematic sectional side view, taken along a centerline plane, of a tool according to the invention during the step of separating and bending (causing plastic deformation) the legs of conductors of a group arranged in a ferromagnetic core;

[0034] Figure 11 is a schematic axonometric view of a tool according to the invention;

[0035] Figure 12 is an enlarged-scale view of a detail of Figure 11;

[0036] Figure 13 is a view of the detail of Figure 12, shown in cross-section along a transverse plane in its terminal part.

[0037] With reference to the above-cited figures, a tool for separating groups A of conductors C from a set of conductors C arranged within slots of a ferromagnetic core N is generally designated by the reference numeral 1.

[0038] In order to correctly identify the orientation and degrees of freedom of each individual component, a three-dimensional Cartesian reference system is defined which is identified by the axes X (having a radial direction with respect to the axis of symmetry E of the core N), Y and Z (having a vertical direction, substantially parallel to the direction of the axis of symmetry E of the core N).

[0039] The tool 1 is more precisely adapted to separate groups A of legs B of different conductors C of the set of conductors C arranged within the ferromagnetic core N.

[0040] Said core N has a central axis E: since it is generally (but not exclusively) a component (a rotor or stator) of rotating electrical machines, the core N may be axially symmetrical, preferably cylindrical, in shape.

[0041] As already mentioned previously at the definition of the Cartesian reference system, preferably the core N is arranged with the central axis E parallel to the axis Z of the reference system (i.e., with a vertical direction).

[0042] The conductors C are substantially U-shaped, and each of them comprises two substantially straight legs B joined by a connection bridge D, in which each of said legs B is provided with a terminal portion Bl . More conveniently, the two legs B of the conductor C are shaped so that they are substantially parallel to each other.

[0043] Preferably, the separation tool 1 is configured to separate legs B having respective terminal portions Bl provided with a tapered tip, therefore provided with an apex shape of a substantially pyramid-like, truncated pyramid-like, conical, frustum- shaped, hemispherical, spheroidal type, or any other convex shape. However, it is not ruled out that the terminal portions Bl may be of the prismatic type, with a constant crosssection, thus lacking a tapered apex shape.

[0044] The tool 1 is constituted by an elongated body 2 which extends in the direction of a respective longitudinal axis 9. Preferably, the elongated body 2 is substantially prismatic. Preferably, the lower part of the elongated body 2 is prismatic with a substantially flat base.

[0045] Said body 2 is configured to be arranged radially with respect to the ferromagnetic core N with the longitudinal axis 9 lying on a plane that is substantially perpendicular to the central axis E of the core.

[0046] The body 2 has an operational height H, with respect to its base, in the direction parallel to the vertical axis Z of the previously defined Cartesian reference system, i.e., according to an axis 9a which is parallel to the central axis E: the operational height H is the height of the side walls that delimit the body 2 at its region designed to abut against the terminals Bl of the legs B, as will become better apparent hereinafter.

[0047] The body 2 is associated with respective movement means 2a configured to translate the entire tool 1 along a radial direction R which is parallel to the respective longitudinal axis 9 and along a direction S which is parallel to the axis 9a and the axis E of the ferromagnetic core N. Preferably, the direction S is moreover parallel to the vertical axis Z of the Cartesian reference system.

[0048] The elongated body 2 has a first seat 3 and at least one second seat 10 which is adjacent to the first seat 3.

[0049] The first seat 3 is substantially parallel to the direction of the axis 9a and of the axis E of the ferromagnetic core N.

[0050] Moreover, the first seat 3 has a substantially quadrilateral crosssection. Preferably, the substantially quadrilateral cross-section has a substantially trapezoidal shape. Alternatively, the substantially quadrilateral cross-section may also be rectangular or substantially rectangular. The term “substantially rectangular” means that it has a shape conforming to that of a rectangle in which at least one of the sides has curved and / or irregular portions, such as for example chamfered edges at the vertices of two contiguous sides. The seat 3 has dimensions which are substantially complementary to those of a group A of legs B of conductors C, so as to be suitable for the temporary accommodation thereof.

[0051] The first seat 3, in particular its quadrilateral cross- section, is formed by a front wall 4, which is arranged at the distal end of the elongated body 2 with respect to the means 2a and substantially perpendicular to the longitudinal axis 9, by a shared wall 7, which is substantially parallel and opposite with respect to the front wall 4, and by two side walls 5, 6, which are arranged facing and at the sides of the front wall 4 and shared wall 7 on a respective vertical plane which is parallel to the central axis E of the core.

[0052] Preferably, the two side walls 5, 6 are arranged in substantially radial directions (along the direction R) with respect to the central axis E of the core N. In this case, the cross-section of the first seat 3 is substantially trapezoidal, in particular of the type shaped like an isosceles trapezoid in which the longitudinal axis 9 (its projection with respect to a horizontal plane) of the body 2 constitutes an axis of symmetry of the trapezoid. Alternatively, the two side walls 5, 6 can be mutually parallel to the longitudinal axis and perpendicular to the front wall 4 and shared wall 7, forming a first seat 3 with a substantially rectangular cross-section. In fact, the first seat 3 is defined as the space delimited by the front wall 4, shared wall 7 and side walls 5, 6 in a direction which is parallel to the axis E. Thus, it is to be noted that the upper part of the shared wall 7 and of the side walls 5, 6 also delimit the first seat 3, constituting in practice the upper portion of the first seat 3.

[0053] Moreover, the shared wall 7 (having an operational height H) of the seat 3 corresponds to the front wall which defines the second seat 10, due to the fact that the two seats 3, 10 are contiguous and aligned along the direction defined by the axis 9.

[0054] The front wall 4 has a lower height Hl in the direction of the axis 9a with respect to the operational height H, i.e., lower than that of the other walls 5, 6 and 7 in the direction of the axis 9a. Said height Hl of the front wall 4 of the first seat 3 defines an access aperture 8 along a direction which is parallel to the longitudinal axis 9 of the elongated body 2 (the direction parallel to the longitudinal axis 9 corresponds substantially to the radial direction R). The movement of the body 2 along the direction of the respective longitudinal axis 9 for approach with respect to the central axis E of the core N produces the abutment of the shared wall 7 against a portion of the terminal portion Bl of the most externally arranged leg B in the group A of conductors C which is circumferentially aligned with the body 2. It is specified that there are means 2a responsible for the movement of a respective body 2.

[0055] Such an abutment has the purpose of compacting the terminal portions Bl of the legs B of the group A and occurs when said terminal portions Bl of the legs B have completely crossed the aperture 8 in the radial direction. Compaction substantially occurs in the radial direction R, approaching the axis E of the core N, and consequently along the direction of the longitudinal axis 9 of the body 2. Said terminal portions Bl, at the end of the approaching stroke in the radial direction R, find themselves resting against each other, with the terminal portion B 1 of the outermost leg B in the group A resting against the shared wall 7, after passing completely through the radial aperture 8, being in alignment with and / or partially inserted in the seat 3. More precisely, the legs B are located between the shared wall 7 and the projection, at right angles to the axis E, of the front wall 4, being already preset to be inserted in the seat 3 delimited by the front wall 4 and shared wall 7 and side walls 5, 6.

[0056] The legs B access the first seat 3 as a result of an axial movement along a direction which is parallel to the axis E (thus along the axis Z of the Cartesian reference system).

[0057] With reference to an embodiment of unquestionable interest in practice and in application, it is specified that the body 2 may moreover conveniently comprise a substantially C-shaped profile 8a which delimits the aperture 8 open in the radial direction.

[0058] The profile 8a is arranged in the upper part of the body 2 and is formed by an upper front portion 7a of the shared wall 7 and by upper portions 5a, 6a of the two side walls 5, 6. Said profile 8a has a profile height H2.

[0059] The front upper portion 7a is contiguous to the lateral upper portions 5a, 6a.

[0060] Said profile 8a, as a result of a radial approach between the body 2 and the terminals Bl of the legs B of the group A, along the direction of the longitudinal axis 9, is configured and sized to primarily arrange portions of the terminals Bl of legs B in interposition between the lateral upper portions 5a, 6a and to subsequently, following a further approach in the radial direction R parallel to the longitudinal axis 9, abut with the front upper portion 7a against a portion of the terminal portion Bl of the leg B located closest to the body 2 in the direction of the longitudinal axis 9.

[0061] The body 2 may advantageously comprise lower portions 4b, 5b, 6b, 7b of the respective front wall 4, side walls 5, 6, and shared wall 7 which form a part of the first seat 3 having a height Hl (height measured with reference to the direction of the axis 9a or the direction of the axis E of the core N).

[0062] The lower portions 4b, 5b, 6b, 7b of the walls 4, 5, 6, 7 form the quadrilateral section of the first seat 3.

[0063] The projections at right angles to the axis E of the upper portion 7a of the shared wall 7 and the upper portions 5a, 6a of the side walls 5, 6 coincide, two by two, with the respective lower shared portion 7b and lower lateral portions 5b, 6b (i.e., each upper portion 5a, 6a, 7a is contiguous and substantially coplanar with respect to the respective lower portion 5b, 6b, 7b).

[0064] It is noted that the sum of the height Hl of the front wall 4 and the height H2 of the upper portion 7a of the shared wall 7 of the first seat 3 substantially coincides with the operational height H of the body 2.

[0065] The second seat 10 is arranged behind (thus in a proximal position, with respect to the means 2a for moving the tool 1) the first seat 3, with reference to the axis 9 and / or the radial direction R with respect to the central axis E of the core N.

[0066] The second seat 10 also has a substantially quadrilateral cross-section (in this case also, the cross-sectional quadrilateral may also comprise curved and / or irregular sides), and extends along the direction of the longitudinal axis 9 of the elongated body 2 for a length greater than the outline of the group A of legs B.

[0067] The second seat 10, in particular its quadrilateral cross- section, is formed by the shared wall 7, by a rear wall 17, which is arranged at a proximal end of the elongated body 2 and placed substantially parallel and facing the shared wall 7, and by two side walls 18, 19, which are arranged facing each other and at the sides of the rear 17 and shared 7 walls.

[0068] The side walls 18, 19 of the second seat 10 extend along the direction of the longitudinal axis 9 of the elongated body 2 for a length greater than that of the side walls 5, 6 of the first seat 3, so that the second seat 10 is able to accommodate a plurality of groups A of legs B already separated in the first seat 3.

[0069] The second seat 10 is conveniently sized to accommodate groups A of legs B already previously separated by means of the first seat 3, following axial and radial movements of the body 2 with respect to the central axis E of the core N.

[0070] The body 2 furthermore comprises an upper edge 11 arranged in the upper part of the front wall 4. The upper edge 11 is shaped at least partially like an inclined plane relative to the front wall 4 and is substantially perpendicular to the side walls 5, 6. The expression “substantially perpendicular” means an arrangement of the edge 11 inclined by a predefined angle (roughly having a breadth between 80° and 100°, preferably around 90°).

[0071] The edge 11 has a maximum height (measured with respect to the base of the body 2) at its distal edge with respect to the movement means 2a and a minimum height at its proximal edge with respect to the movement means 2a, forming a chute for conveyance toward the inside of the first seat 3 for the terminal portions Bl of the legs B at an abutment thereof on said upper edge 11, following a movement of the body 2 toward the terminal portions Bl in a direction which is parallel to the direction of the axis 9a (a possible shape of edge 11 is shown by way of non-limiting example in the accompanying Figure 12).

[0072] Moreover, the body 2 comprises distal edges 12, 13 (with respect to the movement means 2a and facing, in the configuration for use, toward the axis E of the core N). Each one of said edges 12, 13 is arranged in the distal part with respect to the movement means 2a of a respective side wall 5, 6 of the first seat 3 (in practice, the edges 12 and 13 delimit the aperture 8 in its portion directed toward the axis E of the core N).

[0073] Each of the distal edges 12, 13 is arranged on a vertical plane which is parallel to the central axis E of the core N and is inclined with respect to the respective side wall 5, 6 on which it is arranged, having the maximum protrusion with respect to the longitudinal axis 9 of the body 2 at its outer edge that is proximate to a respective lateral surface of the elongated body 2, and the minimum protrusion at its inner edge that is proximate to a respective inner face 5a, 6a of the first seat 3.

[0074] In this way, the distal edges 12, 13 form a chute for conveyance toward the inside of the first seat 3 for the end Bl of the legs B of the conductors C of a group A at an abutment thereof on the distal edge 12, 13.

[0075] It is noted that the body 2 further comprises upper edges 14, 15, 16 (with respect to the direction identified by the axis 9a): each of them is arranged in the upper part of the side walls 5, 6 and of the shared wall 7 of the first seat 3, again with reference to the direction identified by the axis 9a.

[0076] Each of the upper edges 14, 15 of the side walls 5, 6 is arranged substantially on a plane which is parallel to the longitudinal axis 9 of the body 2 and is inclined with respect to the respective side wall 5, 6 on which it is arranged.

[0077] The upper edge 16 of the shared wall 7 is arranged in an inclined plane relative to wall 7 and is substantially perpendicular to the side walls 5, 6.

[0078] The upper edges 14, 15, 16 have the minimum protrusion at the respective inner edge that is proximate to a respective inner face 5a, 6a, 7a of the respective reference wall 5, 6, 7 of the first seat 3, forming a chute for conveyance toward the inside of the first seat 3 for terminal ends B 1 of legs B of conductors C of a group A, at an abutment thereof on said upper edges 14, 15, 16.

[0079] The edges 11, 12, 13, 14, 15, 16 are defined as substantially flat surface portions which are inclined with respect to the walls 4, 5, 6, 7 in accordance with specific preferred embodiments. Alternative embodiments to those described and shown in the accompanying figures of the present invention provide that at least one of the edges 11, 12, 13, 14, 15, 16 may have a curved surface, such as cylindrical, hyperbolic, parabolic, irregularly curved surface, etc.; by virtue of these specific shapes it is possible to achieve effects similar to those obtained with flat edges in terms of conveyance of the legs B into the first seat 3.

[0080] The protection afforded by the present invention also extends to a method for separating groups A of legs B of different conductors C from a set of conductors C arranged within a ferromagnetic core N, provided with at least one tool 1 for separating groups A of the type described above.

[0081] The core N has a central axis E; the conductors C are substantially U- shaped and are constituted by two legs B joined by a connection bridge D with each of said legs B having a terminal portion Bl. In a preferred embodiment, the legs B of a conductor C are substantially parallel to each other.

[0082] Conveniently, the core N may be arranged with the central axis E oriented vertically, i.e., parallel to the vertical axis Z of the Cartesian reference system.

[0083] Preferably, the separation tool 1 is configured to separate legs B with the respective terminal portions B 1 having a tapered apex shape, such as, for example, pyramid-like, truncated pyramid-like, conical, frustum-shaped, hemispherical, spheroidal, or any other convex apex contour. Alternatively, the terminal portions Bl may also be of a prismatic type, with a constant cross-section substantially equal to the cross-section of the entire leg B.

[0084] It should be noted that the method according to the invention is particularly interesting for production lines in which the conductors C have legs B with uncut apex terminal portions B 1. The method according to the invention consists in performing a series of steps.

[0085] First of all, there is a step (illustrated by way of non-limiting example in the accompanying Figure 9) of gripping a group A of legs B of conductors C.

[0086] Then, an approaching step is carried out, consisting of the translation in the radial direction R (shown by way of non-limiting example in the accompanying Figure 10) of the group A of legs B, moving away from the central axis E of the ferromagnetic core N, with consequent plastic deformation of the legs B of said group A.

[0087] In the course of all operations in which plastic deformation of the legs B is caused as a result of a spacing translation of the tool 1 (in particular of the elongated body 2) away from the core N, the tool 1 also performs small translations in different directions (for example, along the direction identified by the axis Z of the Cartesian reference system) to arrange and recover the changes in the space occupation of the legs B in particular, but not exclusively, in the vertical direction (thus parallel to the axis Z). In fact, the legs B, before deformation, have an overall space occupation in the vertical direction (parallel to the axis Z of the Cartesian reference system) that is certainly greater than that which they have after the separation operations, which, by providing for a deformation of the legs B (and thus their curving with respect to the initial configuration), occupy less space (especially in the direction identified by the axis Z of the Cartesian reference system).

[0088] These translations required to compensate for the change in the space occupation of the legs B (necessary to arrange and recover the variation in space occupation of the legs B from the initial configuration in which they are substantially linear and parallel to the axis Z of the Cartesian reference system to the final deformed configuration in which they are at least partially curved) are performed by the tool 1 as a function of the specific requirements observed, in manners substantially of a known type.

[0089] A releasing step is then carried out to release the group A of legs B arranged in the deformed configuration.

[0090] The method according to the invention consists, prior to the gripping step, in arranging the at least one tool 1 along the perimeter of the ferromagnetic core N, positioning the tool 1 at a predetermined height along the direction of the central axis E of the core N so as to arrange the shared wall 7 of the first seat 3 facing and proximate, in the radial direction R (which is parallel to the direction of the axis 9a of the tool 1), to the legs B of the conductors C of a group A. Said preventive arrangement is shown by way of non-limiting example in Figure 7.

[0091] Once the positioning of the tool 1 has been carried out, it is possible to proceed with the approaching step, consisting of translating in the radial direction R (in particular, the elongated body 2 is translated by the action of the movement means 2a) toward the central axis E of the core N until portions of the side walls 5, 6 are arranged at the sides of the terminal ends Bl of the legs B of group A by utilizing the radial aperture 8. At least one of said legs B then abuts against an upper portion 7a of the shared wall 7 of the first seat 3, with consequent compression and compaction of the ends Bl of all the legs B aligned with the legs B of the group A with respect to the radial direction R (parallel to the direction of the axis 9 of the elongated body 2). This preventive arrangement is illustrated by way of non-limiting example in Figure 8.

[0092] The gripping step advantageously consists of a vertical translation (in a direction parallel to the axis Z of the Cartesian reference system), along a direction S which is parallel to the central axis E of the core N and the axis of extension 9a of the seat 3, of the elongated body 2 approaching the ferromagnetic core N until the terminal portions Bl of legs B of the group A enter at least partially the first seat 3: said terminal portions Bl are surrounded perimetrically by the front wall 4, the shared wall 7 and the side walls 5, 6.

[0093] The step of spacing the group A of legs B, which takes place in the radial direction R away from the ferromagnetic core N (receding from it), with consequent plastic deformation of the legs B already inserted in the first seat 3: the internal face of the wall 4 (which delimits the seat 3) during said step abuts against a surface of a leg B of the group A, pushing on it and deforming it. The other legs B of the group A also deform, since they are arranged within the first seat 3 and are contiguous to each other.

[0094] The movement that forces the deformation of the terminal ends B 1 of the legs B of the group A consists of a translation of the elongated body 2 in the radial direction R, away from the central axis E of the core N, according to a stroke of predefined extent.

[0095] The step of releasing the group A of legs B, separated from the others that are present in the core N and are arranged in a deformed configuration, consists of the translation of the elongated body 2 in the direction S parallel to the central axis E of the core N, moving away from the core N until the legs B completely exit from the first seat 3.

[0096] The method according to the invention is applied to a ferromagnetic core N in which conductors C are arranged on a plurality of radial layers and for which a separation of a plurality of groups A of legs B is required. After performing the separation of a first group A of legs B that is arranged radially more outward than other groups A, the method according to the invention provides for the insertion in the first seat 3 of portions of legs B of an additional group A during at least one of the various sequential steps of the method for the separation of said other group A of legs B arranged more internally in the radial direction R (and thus closer to the axis E of the core N) than the first group A, without the legs B of the first group A that have already been separated interfering with the tool 1 (since the legs B of the first group A can be accommodated in the second seat 10, while the legs B of the new group A to be separated undergo the expected deformation operations while they are at least partially accommodated within the first seat A).

[0097] More specifically, the method provides for inserting at least one group A of already widened legs B in the second seat 10 located behind with respect to the axis E of the tool 1 during at least one of the steps of the method for separating the legs B of an additional group A (as shown by way of non-limiting example in the accompanying Figure 10).

[0098] In even greater detail, the step of approach of the elongated body 2 to the central axis E consists in performing operations for the compression and compaction of the ends Bl of the legs B, performed in the first direction R and applied with the upper portion 7a of the shared wall 7 until all the legs B are arranged between the upper portion 7a and the wall NW of the seat of the core N that is closest to the central axis E. This compression and compaction are applied so that the affected legs B are compressed and compacted together, eliminating any play between them and against the wall NW along the first direction R, so that the group A of legs B to be gripped next is properly oriented and indexed.

[0099] The present invention also extends its protection to a device 100 for separating groups A of legs B of different conductors C (substantially U- shaped conductors C constituted by two legs B joined by a connection bridge D), from a set of conductors C arranged within a ferromagnetic core N, comprising at least two separation tools 1 of the type described above.

[0100] Said tools 1 are arranged substantially along the perimeter of the ferromagnetic core N in a configuration of substantial alignment with at least one group A of legs B of conductors C.

[0101] More specifically, and in accordance with the graphical examples shown by way of illustration in the accompanying figures, the separation tools 1 may efficiently be a plurality, mutually laterally adjacent and arranged in the radial direction R with respect to the ferromagnetic core N, substantially along the perimeter thereof.

[0102] Advantageously, the present invention avoids the drawbacks described earlier by devising a method for separating groups A of conductors C from a set of conductors C which is arranged within a ferromagnetic core N that ensures optimal separation of the groups A of legs B of conductors C of interest.

[0103] Conveniently, the method according to the invention is easy to execute and allows to achieve an optimal result, regardless of the regularity of the shape of the legs B of the conductors C.

[0104] Favorably, the separation tool 1 according to the invention allows to perform optimal separations of groups A of conductors C from the others that are present in a ferromagnetic core N.

[0105] Advantageously, the separation tool 1 according to the invention is suitable to prepare the legs B of the conductors C in the ideal manner for the subsequent welding operations.

[0106] Efficiently, the separation device 100 according to the invention can operate on all the conductors C that are present in a ferromagnetic core N to prepare them for the subsequent welding operations.

[0107] Validly, the method, the separation tool 1 and the device 100 according to the invention are relatively simple to provide in practice and low in cost: these characteristics make the method, the tool 1 and the device 100 according to the invention innovations of assured application.

[0108] The invention thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the inventive concept; all the details may furthermore be replaced with other technically equivalent elements.

[0109] In the embodiments shown, individual characteristics, given in relation to specific examples, may actually be interchanged with other different characteristics that exist in other embodiments.

[0110] In practice, the materials used, as well as the dimensions, may be any according to the requirements and the state of the art.

[0111] The disclosures in Italian Patent Application No. 102024000001062 from which this application claims priority are incorporated herein by reference.

[0112] 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. Tool for separating groups (A) of legs (B) of different conductors (C) of a set of conductors (C) arranged within slots of a ferromagnetic core (N), wherein said core (N) has a central axis (E), wherein said conductors (C) are substantially "U"-shaped and are made of two substantially straight legs (B) joined by a connection bridge (D), wherein each of said legs (B) has a terminal portion (Bl), said tool (1) being constituted by an elongated body (2) extending along a respective longitudinal axis (9), wherein said body (2) is configured to be arranged radially with respect to said ferromagnetic core (N) with said longitudinal axis (9) lying on a plane substantially perpendicular to said central axis (E) of the core (N), wherein said tool comprises movement means (2a) configured to translate said body (2) along a first direction (R) parallel to the respective longitudinal axis (9), and along a second direction (S) perpendicular to said first direction (R), said elongated body (2) being provided with a first seat (3) and a second seat (10) adjacent to each other, wherein said first and second seats (3, 10) have a substantially quadrilateral section with a shared wall (7) dividing the first (3) and second (10) seats, said first seat (3) being delimited by a front wall (4) arranged at a distal end of said elongated body (2), and lying on a plane substantially perpendicular to said longitudinal axis (9), by the shared wall (7) placed substantially parallel and facing said front wall (4), and by two respective side walls (5, 6) arranged facing each other and at the sides of said front (4) and shared (7) walls, characterized in that said front wall (4) has a height (Hl) in a direction perpendicular to the longitudinal axis (9) which is lower than a height (H) of said shared wall (7) so as to define an access aperture (8) configured to allow the terminal portions (Bl) of said group (A) of legs (B) to abut the shared wall (7), when said body (2) is moved along the first direction (R) by said movement means (2a), and subsequently to enter the first seat, when said body (2) is moved along the second direction (S) by said movement means (2a).

2. Tool according to the previous claim, characterized in that said side walls (5, 6) of the first seat (3) and said shared wall (7) comprise a respective upper portion (7a, 5a, 6a) forming a substantially "C"-shaped profile (8a) open at the access aperture (8), said respective upper portions (7a, 5a, 6a) being arranged in an upper part of the body (2) above the front wall (4) of the first seat (3), and having a height (H2) which is lower than the height (Hl) of the front wall (4).

3. Tool, according to the previous claim, characterized in that said side walls (5, 6) of the first seat (3) and said shared wall (7) comprise respective lower portions (5b, 6b, 7b) contiguous to said respective upper portions (5a, 6a, 7a) having a height (Hl) equal to the height (Hl) of the front wall (4) of the first seat (3).

4. Tool, according to any one of the previous claims, characterized in that the second seat (10) is delimited by said shared wall (7), by a rear wall (17) arranged at a proximal end of said elongated body (2) and placed substantially parallel and facing said shared wall (7), and by two respective side walls (18, 19) arranged facing each other and at the sides of said rear (17) and shared (7) walls, said side walls (18, 19) of the second seat (10) extending along the direction of the longitudinal axis (9) of said elongated body (2) for a length greater than that of said side walls (5, 6) of the first seat (3), so that the second seat (10) is able to accommodate a plurality of groups (A) of legs (B) already separated in the first seat (3).

5. Tool, according to any one of the previous claims, characterized in that said front wall (4) of the first seat (3) comprises an upper edge (11) having a slanted portion.

6. Tool, according to one or more of the previous claims, characterized in that said side walls (5, 6) of the first seat (3) comprise a respective distal tapered edge (12, 13) at said access aperture (8), each of said distal tapered edges (12, 13) being arranged on a vertical plane parallel to said second direction (S) and defining a conveyance chute towards theshared wall (7) for facilitating the passage of the terminal portions (Bl) of said group (A) of legs (B) through the access aperture (8).

7. Tool, according to one or more of the previous claims, characterized in that said side walls (5, 6) and said shared wall (7) of the first seat (3) comprise respective upper tapered edges (14, 15, 16) defining a conveyor chute towards the inside of the first seat (3) for the terminal portions (Bl) of said group (A) of legs (B).

8. Method for separating groups (A) of legs (B) of different conductors (C) of a set of conductors (C) arranged within slots of a ferromagnetic core (N), wherein said core (N) has a central axis (E), said method being carried out with at least one tool (1) for the separation of groups (A) as in any of the previous claims, said method consisting of the steps of:- grabbing a group (A) of legs (B) of said conductors (C),- moving away said group (A) of legs (B) from said core (N) in a first direction (R) perpendicular to said central axis (E),- releasing said group (A) of legs (B) arranged in a deformed configuration, characterized in that it consists, before said grabbing step, in- arranging said at least one tool (1) along the perimeter of said ferromagnetic core (N), wherein said at least one tool (1) is positioned at a predetermined position along the direction of the central axis (E) of the core so as to arrange said shared wall (7) of the first seat (3) facing and close in the first direction (R), parallel to the direction of the central axis (E), with respect to the legs (B) of said conductors (C) of a group (A);- bringing said at least one elongated body (2) closer to the central axis (E) of the core (N), in the first direction (R), until portions of said side walls (5, 6) are positioned on the sides of the terminal portions of said legs (B) of said group (A) taking advantage of the access aperture (8) and of the relative abutment of at least one of said legs (B) on an upper portion (7a) ofsaid shared wall (7) of the first seat (3) resulting in compressing and compacting the ends of all the legs (B) aligned with the legs (B) of said group (A) in the first direction (R).

9. Method according to claim 8, characterized in that said grabbing step consists in translating said elongated body (2) in a second direction (S) parallel to the central axis (E) of the core (N), by approaching the ferromagnetic core (N) until the terminal portions (Bl) of legs (B) of group (A) enter, at least partially, into the first seat (3), said terminal portions (Bl) being surrounded by said front wall (4), said shared wall (7) and said side walls (5, 6).

10. Method, according to any one of claim 8 or 9, characterized in that said step of moving away said group (A), in the first direction (R) with respect to said ferromagnetic core (N) with consequent plastic deformation of said legs (B), consists in a translation of said elongated body (2) in the first direction (R) away from the central axis (E) of the core (N) according to a predefined stroke.

11. Method, according to any one of claims 8-10, characterized in that the step of releasing said group (A) of separate legs (B) arranged in a deformed configuration consists in the translation of the elongated body (2) in a second direction (S) parallel to the central axis (E) of the core (N) moving away from said core (N) until the complete exit of the legs (B) from the first seat (3).

12. Method, according to any one of claims 8-11, characterized in that said ferromagnetic core (N) comprises conductors (C) arranged on a plurality of radial layers requiring a separation of a plurality of groups (A) of legs (B) and that, upon completion of the separation of a first group (A) of legs arranged radially more external than the other groups (A), said method involves the insertion into the first seat (3) of portions of legs (B) of a further group (A) during at least one of the different sequential steps of said process for the separation of said other group (A) of legs (B) arrangedmore internally in the first direction (R) with respect to said first group (A), without the legs (B) of the first, already separated group (A) interfering with said tool (1).

13. Method, according to anyone of claims 8-12, characterized in that the step of bringing said at least one elongated body (2) closer to the central axis (E) consists of compressing and compacting the ends of the legs (B) in the first direction (R) with the upper portion (7a) of the shared wall (7) until all the legs (B) arranged between said upper portion (7a) and the wall (NW) of the slot proximal to the central axis (E) are compressed together without play against said wall (NW) in the first direction (R), so that the group (A) of legs (B) to be subsequently grabbed is properly indexed.

14. Device for separating groups (A) of legs (B) of different conductors (C), substantially "U"-shaped and made up of two legs (B) joined by a connection bridge (D), from a set of conductors (C) arranged within slots of a ferromagnetic core (N), characterized in that said device includes at least two separation tools (1) according to at least one of claims 1 to 7, said separation tools (1) being arranged substantially along the perimeter of said ferromagnetic core (N) in a configuration of substantial alignment with at least one group (A) of legs (B) of conductors (C).

15. Device, according to claim 14, characterized in that said separation tools (1) are a plurality, are arranged mutually alongside each other side by side and are arranged in a first direction (R) with respect to said ferromagnetic core (N), substantially along the perimeter thereof.

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