Winding machine and winding method for making multiple coils

Abstract

A winding method and machine for making multiple coils of conducting wires are described. Step A provides for prearranging a winding machine with a wire guiding device configured for guiding conducting wires in one or more bundles, a winding tool provided with two winding chambers in which the bundles of conducting wires are intended to be wound, a first spindle intended for rotating the winding tool, one or more storage satellites configured for storing a length of the bundles of conducting wires and a second spindle intended for rotating the storage satellites. The bundles of conducting wires are guided on the winding tool through the wire guiding device and are stored on the storage satellites. The first spindle rotates the winding tool on a rotation axis X-X to cause the winding of a first length of the bundles of conducting wires provided by the wire guiding device in a first winding chamber. The second spindle rotates the storage satellites about a rotation axis X-X and about the winding tool to cause the winding, in a second winding chamber, of second lengths of the bundles of conducting wires. The second lengths of the bundles are not withdrawn upstream from the wire guiding device, but downstream from the storage satellites.

Description

[0001] Winding machine and winding method for making multiple coils

[0002] ***

[0003] DESCRIPTION

[0004] Field of the invention

[0005] The present invention concerns a winding machine and a winding method for making multiple coils of conducting wire.

[0006] Known art

[0007] It is known to automatically make, with special winding machines, coils of conducting wire intended for being used on electric components, mainly electric motors, but also sensors, actuators, etc.

[0008] In either axial flux or radial flux electric motors, stators can be constructed with windings of the distributed type or concentrated type. As is known:

[0009] - a winding of the concentrated type provides that each stator pole is wound from a single coil of conducting wire, i.e. conducting wires are wound on a single stator tooth;

[0010] - a winding of the distributed type provides that each coil of conducting wire intercepts several stator teeth, i.e. conducting wires are wound on two or more teeth.

[0011] Conventionally, stator windings are made by winding the conducting wire directly on stator teeth, for example with a needle winding machine, or by preforming the coils on a winding tool of a winding machine and successively assembling the coils on the stator.

[0012] For some applications, such as for example the distributed winding referred above, it is necessary to make multiple coils of conducting wire, i.e. coils electrically connected in series and physically made, in succession, with the same conducting wire.

[0013] Moreover, for some applications, it is necessary to make coils with a substantially flat extent, characterized by low thickness.

[0014] A particular winding technique used for making flat and very thin windings is known under the acronym alpha winding (a-winding) and consists in forming the coils by stratifying the conducting wire in spirals on a single winding plane, and more precisely by making two opposing spirals, so that each coil extends radially from an inner perimeter of minimal diameter up to an outer diameter at the maximal diameter. For example, EP2629310 describes a method and a winding machine for making coils of alpha winding type.

[0015] With the alpha winding technique, it is also possible to make multiple coils, as those visible in figure 10 of EP2629310.

[0016] The Applicant has identified some limitations of the conventional solutions and, in particular, of the alpha winding solutions when it is necessary to make multiple coils.

[0017] A limitation consists in that a single conducting wire is generally used for making the coils in the alpha winding technique. Winding machines which allow to make coils by using two conducting wires simultaneously were suggested but, in this case, it is not possible to control the stratification of the wires, in the sense that the reciprocal position of the two wires in the completed coils is disorderly. Instead, it is important to be able to stratify the conducting wires by keeping as orderly an arrangement as possible of the same wires inside each coil, because this has a direct impact on the performance of the electric component on which the coils will be mounted. For example, in the case of stators of electric motor, a disorderly stratification of the conducting wires of the coils does not allow to reach a high filling factor defined as the ratio between the surface of the cross section occupied by the conducting wires inside a stator slot and the total area available (always considered in cross section) in the stator slot. It is instead desirable to be able to insert a greater number of conducting wires, or the same number of wires of greater diameter, into the same stator slot, other factors being equal, since this would result in improved performance of the electric motor.

[0018] Another limitation of conventional solutions consists in that they do not allow to make several coils simultaneously, but the formation of multiple coils anyhow provides for the formation of a coil at a time, as also described in EP2629310. This means that the winding means, typically flyer-based, are engaged at all times to form a single coil, and it is moreover necessary to provide for the displacement of the flyer or winding tool on an axis, at multiple stops, to make a number of coils equal to the number of stops. It is instead desirable to be able to increase productivity and to form several coils simultaneously, without having to axially displace the flyer.

[0019] Moreover, the use of the flyer for winding the conducting wire on a winding tool makes the winding machines complex, all the more so when the flyer is axially movable for making multiple coils.

[0020] The Applicant thus found that current solutions can be improved in order to obtain multiple high quality coils in short times, also by using more than one conducting wire, for example two wires of different diameters, with high- performance winding machines less complex than conventional machines.

[0021] Other known solutions are disclosed in US 2001 / 015393, US 7314195 and in EP 4010960

[0022] Summary of the invention

[0023] Aim of the present invention consists in providing a winding method and a winding machine for making multiple coils which overcome the limitations of conventional solutions described above and which allow to obtain multiple coils characterized by excellent stratification of one or more conducting wires in short times.

[0024] A first aspect of the present invention therefore concerns the method according to claim 1 for making multiple coils of conducting wire.

[0025] The method comprises steps A, B and C-D, with the steps C and D carried out simultaneously.

[0026] Step A provides to prearrange a winding machine with at least one wire guiding device configured for guiding conducting wires in one or more bundles, according to a reciprocal position and stratification of the conducting wires kept in accordance with the predetermined one. The machine must then be provided with a winding tool provided with, for each of the wire guiding devices, two winding chambers in which the bundles of conducting wires are intended to be wound, and a first spindle intended for rotating the winding tool. Moreover, the winding machine must be provided with one or more storage satellites configured for storing a length of the bundles of conducting wires used for making the coils, and a second spindle intended for rotating the storage satellites.

[0027] Step B provides for, for each wire guiding device, guiding one or more bundles of conducting wires through the wire guiding device, so that to arrange bundles of conducting wires at the winding tool and store a length of the bundles of conducting wires on the storage satellite, or storage satellites if more than one. The winding tool is therefore functionally interposed between the wire guiding device and the storage satellites, in the sense that the bundles of conducting wires must extend from the wire guiding device to the storage satellites by crossing the winding tool.

[0028] In step C, the first spindle rotates the winding tool on a first axis defined as rotation axis X-X, to cause the winding of a first length of the bundles of conducting wires provided by the corresponding wire guiding device in a first winding chamber. During step C, the bundles of conducting wires provided upstream by the corresponding wire guiding device (which is in turn supplied by outer wire spools) are therefore wound in a first winding chamber.

[0029] In step D, which is simultaneous with step C, the second spindle rotates the storage satellite, or storage satellites, about the rotation axis X-X and the winding tool. This causes second lengths of the bundles of conducting wires to be wound in a second winding chamber. The second lengths of the bundles are not withdrawn upstream from the wire guiding device, but downstream from the storage satellite(s).

[0030] The solution suggested allows to obtain multiple coils on several winding chambers without neither having to axially move, i.e. along the rotation axis X- X, the winding tool nor the storage satellites, and therefore neither the respective spindles.

[0031] Moreover, the coils are made simultaneously, i.e. the method allows to obtain multiple coils in a single winding cycle defined at steps C and D, unlike known solutions in which the multiple coils are obtained one at a time by repeating the winding steps for each individual coil.

[0032] The method allows for scalability, in the sense that it is possible to add wire guiding devices and winding chambers for producing the desired number of coils at the same time.

[0033] Despite the method does not provide for the axial movement of the components, as explained above, the multiple coils are immediately obtained with the desired pitch corresponding to the pitch between the winding chambers.

[0034] The method also allows multiple coils to be made by using even more than one type of wire at a time for forming the bundles of conducting wires, for example by using two wires, one of a larger diameter, the other of a smaller diameter.

[0035] Another advantage is the absence of flyers. The method provides for the use of storage satellites which are not similar to flyers. A flyer is actually supplied by an outer spool of conducting wire which is subjected to twisting and oscillations during the rotation of the flyer. The storage satellites are spools in which bundles of conducting wires are stored while keeping the reciprocal position between the wires and the stratification imposed upstream by the storage device. Clearly, while being wound on the winding tool, the bundles of conducting wires drawn from the storage satellites are orderly, i.e. have a spatial distribution and stratification which could not be obtained with a flyer.

[0036] More in detail, considering the most simple case of only two winding chambers, a first coil is formed by winding one or more bundles of conducting wires in the first winding chamber, by withdrawing the bundles of conducting wires from the wire guiding device located upstream of the winding tool with respect to the displacement direction of the bundles themselves. A second coil is formed by winding the same bundles of conducting wires in the second winding chamber, this time by withdrawing the bundles of conducting wires from one or more of said storage satellites positioned downstream with respect to the forward direction of the bundles from the wire guiding device (but anyhow upstream for the winding tool). Possible further coils are formed by winding the same bundles of conducting wires in corresponding further winding chambers provided on the winding tool, by still withdrawing the bundles of conducting wires from one or more storage satellites.

[0037] Clearly, the method allows multiple coils to be obtained with two or more coils, therefore ensuring quality between the coils to be maintained.

[0038] The winding of conducting wires on the winding tool is preferably carried out by making the storage satellites perform two revolutions about the rotation axis X-X (and about the winding tool) per each revolution made by the winding tool on the same rotation axis X-X. This way, the storage satellites, which rotate in the same direction as the winding tool, complete two revolutions overall but one revolution only relatively to the winding tool, since the latter has been in turn rotated, with the consequence of obtaining the correct number of coils of identical characteristics and, in particular, the same number of loops, i.e. a coil directly wound on the winding tool and a coil wound from the storage satellites.

[0039] To avoid any misunderstandings, it is specified that the multiple coils are obtained in succession along the same bundle of conducting wires, i.e. are obtained by using the same bundle or the same bundles of conducting wires, and therefore stay connected by the bundle or bundles used and are for this reason defined as coils in series.

[0040] More in detail, step B provides for a preparatory step B’, during which the winding tool is rotated by an angle on a second axis Y-Y orthogonal to the rotation axis X-X. For example, the axis X-X is horizontal and the axis Y-Y is vertical. A portion of the bundles of conducting wires is locked (fastened) on the winding tool in an intermediate position between the at least two winding chambers. The winding tool is therefore brought back coaxial to the rotation axis X-X before starting steps C and D, therefore causing the localized deformation of the locked portion of the bundles of conducting wires. This locked portion of the bundles of conducting wires will become the portion connecting two consecutive completed coils. Fastening a portion of the bundles of conducting wires to the winding tool, by deforming this locked portion of the bundles before starting the winding C and D, allows the bundles of conducting wires to be optimally aligned with the winding chambers on the winding tool.

[0041] The bundles of conducting wires preferably comprise a plurality of equal or different conducting wires, for example having different diameters or different cross sections, which are guided through the wire guiding device according to a controlled, i.e. predetermined, reciprocal position and stratification.

[0042] It is preferable to implement the method so that to keep the reciprocal position and stratification of the conducting wires unchanged both while winding on the storage satellites referred to in step A and while winding on the winding tool referred to in steps C and D. This way, the coils will all substantially be identical and will allow to maximize the filling factor of the slots of the electric components for which they are intended.

[0043] The multiple coils are preferably formed with at least one first linear length and at least one second linear length which in turn comprise a plurality of individual linear lengths of conducting wire. It is sufficient to shape the winding tool correspondingly to achieve this characteristic. At the end of steps C and D, before removing the coils formed from the winding tool, the first linear length and the second linear length of each coil are subjected to a step E of pressing and / or thermal carburizing treatment.

[0044] Step E involves subjecting the linear lengths of the coils, still accommodated on the winding tool in a condition in which, as stated above, the reciprocal position and stratification of the conducting wires corresponds to the one imposed and controlled by the wire guiding device, to pressing and / or thermal carburizing treatment, so as to compact the individual linear lengths of conducting wire and make the reciprocal position and stratification of the wires permanent.

[0045] The pressing and / or carburizing step E preferably comprises pressing the linear lengths of the coils with one or more presser elements and heating the linear lengths of the coils by means of one or more heating devices while the coils are wound on the winding tool. The heading devices can be independent of the presser elements, or can be included in, or functionally coupled to, the presser elements.

[0046] Before removing the coils formed and possibly pressed and carburized from the winding tool, the linear lengths of each coil are preferably enveloped by an insulating material, for example a slot liner.

[0047] As mentioned above, the bundles of conducting wires can be configured with main conducting wires and complementary conducting wires, the latter having a smaller section than the section of the main conducting wires, so that the complementary conducting wires occupy the free spaces between the main conducting wires, always with a view to maximizing the filling factor.

[0048] A second aspect of the present invention concerns the winding machine according to claim 12 for making multiple coils of conducting wires.

[0049] More in detail, the winding machine comprises at least one wire guiding device, a winding tool, a first spindle, one or more storage satellites and a second spindle. Each wire guiding device is configured for guiding conducting wires in one or more bundles towards the winding tool and towards the storage satellites, so as to impose the reciprocal position of the conducting wires and the respective stratification. The winding tool is provided with at least two winding chambers for each wire guiding device, which are intended to accommodate the bundles of conducting wires while winding, so that the reciprocal position of the conducting wires and the respective stratification imparted by the wire guiding device stay unchanged in the winding chambers. The first spindle is intended for rotating the winding tool on the first axis X-X, defined as rotation axis, for example a horizontal axis. The storage satellites are configured for storing a length of the bundle or bundles of conducting wires provided by the corresponding wire guiding device. The second spindle is intended for rotating the storage satellites about the rotation axis X-X and about the winding tool (about, not on the rotation axis X-X).

[0050] For each of the wire guiding devices, the rotation of the winding tool on the rotation axis X-X causes the winding of each bundle of conducting wires in a corresponding first winding chamber. The rotation of the storage satellites about the rotation axis X-X and the winding tool causes the winding of each bundle of conducting wires in the second winding chamber.

[0051] If necessary, depending on the number of winding chambers provided, the winding machine can be provided with two or more wire guiding devices and two or more storage satellites, such that each wire guiding device provides wires to a first storage chamber and at least one storage satellite provides wires to at least one second winding chamber adjacent to the first.

[0052] The winding machine comprises an electronic control unit with program means programmed for selectively adjusting the rotation speed of the winding tool and of the storage satellites, with respect to the rotation axis X-X, which rotate in the same direction.

[0053] The control unit is preferably programmed so that the rotation speed v2 of the storage satellites is twice the rotation speed v1 of the winding tool: v2 = 2v1 , i.e. the storage satellites perform two revolutions about the rotation axis X- X per each revolution completed by the winding tool on the rotation axis X-X. This detail, considering the relative rotation speed of the storage satellites with respect to the winding tool, allows a coil from the bundles of wires coming from the wire guiding device to be deposited per each coil deposited by the storage satellites.

[0054] In the preferred embodiment, the winding tool is rotatable by an angle on a second axis Y-Y orthogonal to the axis X-X, preferably a vertical axis Y-Y, to assume a temporary rotated position during preparations before starting winding. The winding tool comprises means for restraining the at least one bundle of conducting wires, wherein the restraining means are intermediate between the at least two winding chambers. If there are more than two winding chambers, the winding machine will clearly have a sufficient number of restraining means. In the rotated position of the winding tool, at least one bundle of conducting wires extends from each wire guiding device to the storage satellites and a portion thereof, defined as locked portion, is fastened to the winding tool by using the restraining means. In the position in which the first spindle is once again coaxial to the rotation axis X-X, the locked portion of the bundle of conducting wires is locally deformed, for example S-shaped, to allow the alignment of the bundle with respect to both the adjacent winding chambers.

[0055] If the winding machine comprises, for example, four winding chambers, the locked portions of the bundles of conducting wires will be two, the first between the first two winding chambers and the second between the last two winding chambers.

[0056] When the winding machine comprises two or more wire guiding devices, it also comprises one or two storage satellites per each wire guiding device; the winding tool comprises two winding chambers per each wire guiding device.

[0057] The winding tool preferably comprises a plurality of supports forming the winding chambers in which the conducting wires are wound. The supports can be arranged on the rotation axis X-X with the axial distance corresponding to the pitch desired between the completed coils.

[0058] The storage satellites preferably are spools in which the reciprocal position and stratification of the conducting wires stay unchanged.

[0059] The winding chambers are preferably shaped for obtaining coils having at least one first linear length and at least one second linear length which in turn comprise a plurality of individual linear lengths of conducting wire. The winding machine preferably comprises a pressing and / or carburizing apparatus movable on the linear lengths of the coils, when the latter are still accommodated on the winding tool, to perform the pressing and / or a thermal carburizing treatment precisely on the linear lengths, in the desired order or simultaneously. This detail allows the individual linear lengths of conducting wire to be compacted and the reciprocal position and stratification assumed by the conducting wires on the winding tool to be made permanent. This result allows to maximize the filling factor of the slots of the electric component into which the linear lengths of the coils will be inserted.

[0060] The pressing and / or carburizing apparatus comprises one or more presser elements and one or more independent heating devices either integrated in, or functionally coupled to, the presser elements.

[0061] The advantages provided by the winding machine are the same as those described with regard to the method.

[0062] Brief list of the figures

[0063] Further characteristics and advantages of the invention will become clearer from the description of some preferred, but not exclusive, embodiments of a method for making a stator, which are depicted by way of example and without limitations with the aid of the accompanying drawings, in which:

[0064] - figure 1 is a perspective and elevation view of a conducting wire coil made with the method and the winding machine according to the present invention;

[0065] - figure 2 is an isometric view of a winding machine according to the present invention, shown in a first configuration;

[0066] - figure 3 is a perspective view of the winding machine shown in figure 2, in a second configuration;

[0067] - figure 4 is a perspective view of the winding machine shown in figure 2, in a third configuration corresponding to the start of the coil making step;

[0068] - figure 5 is a perspective view of the winding machine shown in figure 2, at a second time during the coil making step;

[0069] - figure 6 is a perspective view of the winding machine shown in figure 2, at a third time during the coil making step;

[0070] - figure 7 is a perspective view of the winding machine shown in figure 2, at a fourth time during the coil making step;

[0071] - figure 8 is a perspective side view of a detail of figure 6, in particular of the winding tool;

[0072] - figure 9 is a top plan view of the detail of figure 8;

[0073] - figure 10 is a front perspective front view of a detail of figure 7, in particular of the winding tool;

[0074] - figure 11 is a top plan view of the detail of figure 10;

[0075] - figure 12 is a perspective view of the winding machine shown in figure 2, at a fifth time during the coil making step;

[0076] - figures 13-25 are perspective views of the winding machine shown in figure 2, at corresponding times during the coil making step;

[0077] - figure 26 is a perspective view of a portion of the winding machine shown in figure 2, at a time corresponding to a completed coil;

[0078] - figure 27 is a perspective view of a coil still wound on the winding tool;

[0079] - figure 28 is a perspective view of the coil shown in figure 27 and of a pressing and / or carburizing apparatus;

[0080] - figure 29 is a perspective view of the coil shown in figure 27 and of the pressing and / or carburizing apparatus, at a first time corresponding to the start of the pressing and / or carburizing step of the linear lengths of the coil;

[0081] - figure 30 is a sectional view of figure 29, considered on a horizontal plane;

[0082] - figure 31 is a perspective view of the coil shown in figure 27 and of the pressing and / or carburizing apparatus shown in figure 28, at a second time corresponding to the start of the pressing and / or carburizing step of the linear lengths of the coil;

[0083] - figure 32 is a sectional view of figure 31 , considered on a horizontal plane;

[0084] - figure 33 is a perspective view of the coil shown in figure 27 and of the pressing and / or carburizing apparatus shown in figure 28, at a third time corresponding to the start of the pressing and / or carburizing step of the linear lengths of the coil;

[0085] - figure 34 is a sectional view of figure 33, considered on a horizontal plane;

[0086] - figure 35 is a perspective view of the coil shown in figure 27 and of the pressing and / or carburizing apparatus shown in figure 28, at a fourth time corresponding to the start of the pressing and / or carburizing step of the linear lengths of the coil;

[0087] - figure 36 is a sectional view of figure 35, considered on a horizontal plane;

[0088] - figure 37 is a perspective view of the coil shown in figure 27 and of insulating elements ready to be wound on the linear lengths of the coil;

[0089] - figure 38 is a perspective view of the coil shown in figure 27 with insulating elements wound on the linear lengths of the coil;

[0090] - figure 39 is a perspective view of the coil shown in figure 27 and of the winding tool disassembled for releasing the coil;

[0091] - figures 40A, 40B and 40C are sectional views of the loops of different possible winding types;

[0092] - figures 41 A, 41 B and 41 C are sectional views of the loops of different winding types according to an optional solution.

[0093] Detailed description of the invention

[0094] Figure 1 is a perspective and elevation view of a series 1 of coils 2, 3 formed with the winding method and with the winding machine according to the present invention. The series 1 of coils 2, 3 can be made by using a single conducting wire or several conducting wires having different characteristics, for example having different diameter. For simplicity, in figure 1 , the single conducting wire cannot be distinguished and the lengths of the coil 1 are schematized. In the example shown in figure 1 , two coils 2, 3 in series are shown, but it is generally possible to make more of coils in series. The series 1 of coils shown in figure 1 has two terminals 4 and 5.

[0095] Each coil 2, 3 of the series 1 comprises two linear lengths 6 and 7, i.e. rectilinear, an outer header 8 and an inner header 9. The headers 8 and 9 are substantially curved, anyhow also being able to be made with linear lengths. Each linear length 6 and 7 is made by stratifying at least one conducting wire.

[0096] With reference to figures 2-39, a winding method and a winding machine usable for making coils 2, 3 will now be described, the winding method and the winding machine being particularly adapted for making coils 2, 3 having linear lengths 6 and 7 of a length equal to 3 cm or greater.

[0097] The method and the winding machine are apparently similar to methods and winding machines conventionally used for making coils with alpha windings (a-winding coils), but the winding is actually formed differently.

[0098] In particular, figure 2 shows, in perspective, the winding machine 400 which comprises:

[0099] - a wire guiding device 401 which is intended for guiding the wires 10 coming from corresponding wire spools,

[0100] - a first spindle 402 intended for rotating a winding tool 20”;

[0101] - one or more satellites 404 for storing the wire 10;

[0102] - a second spindle 403 intended for rotating the satellites 404 and the respective motors about the respective rotation axis X-X (horizontal).

[0103] As can be noted, the wire guiding device 401 is provided with a plurality of holes 405 into which corresponding wires 10 are slidably inserted. After having crossed the holes 405, the bundle of wires 10 is inserted into the wire guiding tube 406 which ensures the perfect stratification of the wires 10, i.e. the perfect orderly arrangement of the wires, one with respect to the other. The wire guiding tube 406 is oriented towards the winding tool 20” mounted on the first spindle 402.

[0104] The first spindle 402 is mounted on a frame 407 and the second spindle 403 is mounted on a frame 408. The first frame 407 is rotatable on the axis (vertical) Y-Y defined by a pin 409. The axis Y-Y is orthogonal and incident to the axis X-X of the second spindle 403. For simplicity, the actuator which controls the rotation of the frame 407 and of the first spindle 402 on the axis Y-Y is not shown. Reference 410 denotes the motors of the satellites 404 for storing the wire 10. Thanks to this configuration, the winding machine 400 is configurable:

[0105] - with the spindles 402 and 403 aligned on the rotation axis X-X of the second spindle 403 and the rotation axis X-X is thus also the rotation axis of the winding tool 20”, or

[0106] - with the first spindle 402 misaligned with respect to the rotation axis X-X of the second spindle 403, by making the frame 407 and the first spindle 402 rotate on the (vertical) axis Y-Y.

[0107] The winding tool 20” is provided with two or more winding chambers arranged in succession and generally denoted by 24. This allows to make coils

[0108] 2, 3 in series, which is useful for obtaining, for example, distributed winding on a stator. In the example shown in the figures, the winding tool 20” has two winding chambers 24’ and 24”.

[0109] It is specified that what has just been described is the minimal configuration with a single wire guiding device 401 ; the winding machine 400 can actually be configured with several wire guiding devices 401 in case the winding tool 20” has more than two winding chambers 24’ and 24”. More in detail, the winding machine 400 can be configured with a wire guiding device 401 every two winding chambers 24’ and 24”.

[0110] The start of the making step of the series 1 of coils 2, 3 is shown in figure

[0111] 3, the frame 407 of the first spindle 402 is rotated on the axis Y-Y so that an acute angle is defined between the vertical plane containing the rotation axis X- X of the winding tool 20” and the median vertical plane passing through the wire guiding tube 406. The storage satellites 404 are raised. As will be made clearer hereunder, directing the bundle of wires 10 (appropriately stratified) at an angle with respect to the rotation axis X-X of the winding tool 20” is a characteristic feature of the present solution with respect to conventional systems for obtaining alpha windings in which the conducting wire is always fed in the orthogonal direction to the rotation axis of the winding tool.

[0112] At this initial time, in the upper part, the winding tool 20” is devoid of the supports 421 defining the winding chambers 24’, 24”, with the exception of the central support 42T provided with a chase 422 for the passage of the wires 10. The chase 422 is a niche, or anyhow a seat into which the wires 10 are inserted, so that to bring them to the height of the winding surface of the winding tool 20”. The supports 421 are installed successively on opposite parts with respect to the central support 42T. In the lower part, the winding tool 20” is instead already provided with the supports 421 .

[0113] Figure 4 shows a successive time during the step of making the coils 2, 3. Two distinct bundles 11 and 12 of wires 10 extend from the wire guiding tube 406 towards a corresponding storage satellite 404. In particular, the upper bundle 11 of wires 10 extends between the wire guiding tube 406 and the most radially outward storage satellite 404, and the lower bundle 12 of wires 10 extends between the wire guiding tube 406 and the most radially inward storage satellite 404.

[0114] Each bundle 11 , 12 of wires 10 will generally be wound on a corresponding storage satellite 404; therefore, if it is provided to make coils 2, 3 with several layers of wire 10, the winding machine 400 will be provided with a number of storage satellites 404 corresponding to the number of layers of wire 10 to be managed.

[0115] A length of the corresponding bundle 11 , 12 of wires 10, corresponding to the length required for making a coil 2, 3, is wound on each storage satellite 404. In short, each storage satellite 404 therefore stores a bundle 11 , 12 of wires 10 for a length sufficient for making the corresponding coil 2, 3.

[0116] Figure 5 shows a successive time during the step of making the coils 2, 3. The storage satellites 404 are rotated on the axis X-X, staying radially aligned and resulting in overlapping the bundles 11 and 12 of wire 10 which are then inserted through the chase 422 present in the central support 42T of the winding tool 20”.

[0117] The insertion of the bundles 11 and 12 of wire 10 into the chase 422 of the central support 42T allows to locally deform the bundles 11 and 12 of wire 10 precisely at the support 42T, as will now be explained, by performing a rotation of the frame 407 and realigning the two spindles 402 and 203. In practice, the central support 421’ of the winding tool is therefore used as a tool for locally deforming the wires 10 and allows, on the one hand, to align the bundles 11 and 12 of wire 10 present on the storage satellite 404 with a winding chamber 24” and to align the bundles 11 and 12 coming out of the wire guiding tube 406 with the other winding chamber 24’, on the other hand.

[0118] Figure 6 shows a successive time during which the winding tool 20” is completed, in its upper part, with the mounting of two supports 421 on opposite parts with respect to the central support 42T. Two winding chambers 24’ and 24” are configured this way. The side supports 421 have a lower chase to allow the passage of the bundles 11 and 12 of wire 10.

[0119] At this point, the bundles 11 and 12 of wire 10 therefore extend on a lying plane orthogonal to the axis X-X and oblique to the rotation axis of the spindle 402, which was rotated on the (vertical) axis Y-Y. The bundles 11 and 12 of wire 10 therefore extend obliquely with respect to the winding tool 20”, i.e. an acute angle is defined between the lying plane of the bundles 11 , 12 of wire 10 and the vertical plane passing through the axis of the spindle 402.

[0120] Figure 7 shows a successive time at which the frame 407 is rotated to the initial position shown in figure 2, i.e. with both spindles 402, 403 aligned on the rotation axis X-X. At this point, it is possible to operate the storage satellites 404 for performing the winding of the bundles 11 , 12 of wire 10 in the winding chambers 24 of the winding tool 20”.

[0121] Figure 8 is a magnification, in perspective, of the winding tool 20” in the configuration shown in figure 6. The central support 42T with the chase 422 open upward, which chase allowed to insert the bundles 11 and 12 of wire 10 from the top, are well visible, and the side supports 421 define the winding chambers 24’ and 24” together with the central support 42T. The same configuration of supports 421 and winding chambers 24’ is also present in the lower part of the winding tool 20”.

[0122] Figure 9 is a top plan view of the winding tool 20” in the configuration shown in figure 8, i.e. with the two bundles 11 and 12 of wire 10 extending, overlapping, through the chase 422 present in the central support 42T and through the two side supports 421 between the wire guiding tube 406 and storage satellites 404. As can be clearly seen, the rotation axis of the first spindle 402 is inclined with respect to the feed plane of the bundles 11 and 12 of wire 10.

[0123] Figure 10 is a magnification, in perspective, of the winding tool 20” in the configuration shown in figure 7, i.e. after the first spindle 402 and the second spindle 403 were once again aligned on the rotation axis X-X of the second spindle 403. The realignment of the spindles 402 and 403 caused the deformation of the bundles 11 and 12 of wire 10 inside the chase 422 of the central support 42T of the winding tool 20”, as mentioned above. The deformation obtained is well visible in figure 11 .

[0124] Figure 11 is a top plan view of the winding tool 20” in the configuration shown in figure 10, i.e. with the two spindles 402, 403 aligned on the axis X-X. As can be noted, the described above realignment of the spindles 402, 403 has allowed to obtain the localized deformation of the bundles 11 and 12 of wire 10 at the chase 422. The localized deformation of the wires 10, observed in plan, is almost S-shaped. The localized deformation of the wires 10 allows to achieve this result:

[0125] - a first length 10.1 of the bundles 11 and 12 of wire 10 extends between the wire guiding tube 406 and the central support 42T, staying aligned with the first winding chamber 24’ found to the left of the central support 42T, and

[0126] - a second length 10.2 of the bundles 11 and 12 of wire 10 extends between the central support 42T and the storage satellites 404, staying aligned with the second winding chamber 24” found to the right of the central support 421’.

[0127] In practice, the localized deformation of the wires 10 at 10x allowed to align the two winding chambers 24’ and 24” with the corresponding lengths 10.1 and 10.2 of wire 10 which - worth recalling - are grouped in two bundles 11 and 12 appropriately stratified thanks to the wire guiding device 401 and the wire guiding tube 406.

[0128] At this point, it is possible to start winding the wires 10 simultaneously in both the winding chambers 24’ and 24”, without having to make the storage satellites 404 move forward or else the wire guiding tube 406 along the axis X- X. The series 1 of coils which will therefore be made, corresponding to the series of coils shown in figure 1 , will have a first coil 2 made in the first winding chamber 24’ and a second coil 3 made in the second winding chamber 24”.

[0129] The detail just described therefore allows to obtain a series 1 of coils 2 and 3 without having to translate one of the spindles 402, 403, or the wire guiding tube 406 or the storage satellites 404, along the axis X-X.

[0130] Figure 12 is a perspective view of the winding machine 400 at a later time than the one shown in figures 10-11. The two spindles 402 and 403 are coaxial on the axis X-X. The first spindle 402 starts to rotate the winding tool 20” on the axis X-X and this results in the dragging of the bundles 11 and 12 from the wire guiding tube 406 and the consequent winding of the first length 10.1 of wires 10 in the first winding chamber 24’. The second spindle 403 simultaneously starts to rotate the storage satellites 404 about the axis X-X and this results in the winding of the second length 10.2 of wires 10 in the second winding chamber 24”. The arrows on the spindles 402 and 403 denote the direction of the rotation imparted.

[0131] Figures 13 to 25 show, in sequence, successive steps of the making of the series 1 of coils 2, 3. They are perspective views. As can be understood, the winding tool 20” and the storage satellites 404 each perform the number of revolutions required on the rotation axis X-X for completing the corresponding coil 2, 3. In other words, the number of revolutions of the two spindles 402 and 403 is selected to obtain the desired stratification of the bundles 11 and 12 of wire 10 respectively in the winding chamber 24’ as far as the wires 10 coming from the wire guiding device 401 are concerned and in the winding chamber 24” as far as the wires 10 coming from the satellite spindles 404 are concerned. In other words, the coil 2 in the winding chamber 24’ is made by withdrawing the wires 10 only from the wire guiding tube 406 and the coil 3 in the winding chamber 24” is made by withdrawing the wires 10 only from the storage satellites 404.

[0132] The winding tool 20” and the storage satellites 404 rotate in the same direction with respect to the rotation axis X-X.

[0133] In particular, the rotation speed v1 of the first spindle 402 and the rotation speed v2 of the second spindle 403, with respect to the rotation axis X-X, are selectively adjustable in the machine 400. In the example shown, v2 = 2v1 , i.e. the storage satellites 404 perform two revolutions about the rotation axis X-X per each revolution completed by the winding tool 20” on the rotation axis X-X. With this configuration of the winding machine 400, the storage satellites 404 perform two revolutions overall about the rotation axis X-X, but only perform one revolution of relative rotation with respect to the winding tool 20”, therefore being able to deposit in turn a loop of the bundles 11 and 12 of wire 10 on the winding tool 20” per each loop deposited directly by the wire guiding device 401 on the winding tool 20”.

[0134] Figure 25 shows one of the final steps of forming the coil 1 : the first length 10.1 of the bundles 11 and 12 of wire 10 was completely wound on the winding tool 20”, in the first winding chamber 24’. The wire guiding tube 406 is actually shown empty, free of wires 10. The storage satellites 404 are completing the last revolution about the rotation axis X-X.

[0135] Figure 26 shows the final step of making the coil 1 : The first spindle 402 is stopped and kept stationary for locking the winding tool 20”. The second spindle 403 (not shown) is also stopped and, when needed, backed up or moved away to give access to the winding tool 20”.

[0136] At this point, the winding tool 20” with the coil 1 wound thereon is ready to be withdrawn. It should be noted that the wires 10 composing the coil 1 still wound on the winding tool 20” have maintained the orderly arrangement and stratification imposed by the wire guiding device 401 and by the wire guiding tube 406, for example the arrangement and stratification shown in figures 40A to 41C.

[0137] The step of forming the series 1 of coils 2, 3 is now completed and it is possible to remove the coils 2, 3 and to possibly assemble them on an electric component, for example a stator.

[0138] In the case where the winding tool 20” is provided with more than two winding chambers 24’, 24”, for example it is provided with four chambers, the winding machine comprises a second wire guiding device 401 to feed the third winding chamber and comprises a third and possibly a fourth storage satellite to feed the fourth winding chamber.

[0139] In other words, the winding machine 400 is modular to increase the number of multiple coils that can simultaneously be formed.

[0140] Before removing the coils 2, 3 from the winding tool 20”, the coils 2, 3 are preferably subjected to a pressing and / or carburizing step in order to freeze the orderly arrangement and stratification of the wires 10 in the linear lengths 6, 7.

[0141] The pressing and / or carburizing step will now be described with reference to figures 27-36.

[0142] Figure 27 shows an isometric view of the winding tool 20” of the winding machine 400. The winding tool 20” can have been withdrawn from the winding machine 400 or can still be anchored to the first spindle 402: figure 27 omits this difference for simplicity. As can be observed, the coils 2, 3 are completely formed. The wire 10 or wires 10, 10’ defining the linear lengths 6 and 7 are perfectly orderly and keep the arrangement and stratification shown, for example, in figures 40A to 41 C.

[0143] Figure 28 shows the start of the optional pressing and / or carburizing step by an appropriate apparatus 500 comprising, in the example shown, presser elements 501 , 502 and a countering element 503. The presser elements 501 , 502 are intended for being inserted, radially from the outside, between the linear lengths 6, 7 of the coil 1 and for this reason are comb-shaped; the countering element 503 is intended for being inserted axially into the winding tool 20” through the coils 2, 3, to provide countering surfaces to the presser elements 501 , 502. In practice, the presser elements 501 , 502 and the countering element 503 therefore cooperate for surrounding the linear lengths 6, 7 of each coil 2, 3 throughout their extent.

[0144] Both the presser elements 501 , 502 and the countering element 503 are provided with heating elements 504, for example of inductive or resistive type.

[0145] The presser elements 501 , 502 are advantageously provided with wedge-shaped inserts 505 defining grooves 506 of a shape corresponding to the shape to be imparted to the linear lengths 6, 7 of the coils 2, 3, corresponding to the shape of the stator slots, so that to have a perfect shape coupling between the coils 2, 3 and the electric component for which they are intended. In other words, the presser elements 501 , 502, together with the countering element 503, impart the shape complementary to the inner volume of the seats for which they are intended, for example the stator slots, to the linear lengths 6, 7 of the coils 2, 3.

[0146] The countering element 503 moves axially along the axis X-X; the presser elements 501 , 502 move both axially, for being aligned with the linear lengths 6, 7 of the coils 2, 3, and radially, for pressing the linear lengths 6 and 7.

[0147] Figures 29 and 30 show the pressing and / or carburizing apparatus 500 moving further toward the winding tool 20”. In particular, figure 30 is a sectional and perspective view of figure 29, with the section considered on a horizontal plane containing the rotation axis X-X. The presser elements 501 , 502 are aligned with the linear lengths 6 and 7 of the coils 2, 3, with the presser element 501 positioned on the opposite part of the presser element 502 with respect to the winding tool 20”. The countering element 503 is inserted into the winding tool in the axial direction. As can well be observed in figure 30, the presser elements 501 , 502 are substantially comb-shaped for actually being slipped between the linear lengths 6 and 7 of the coils 2, 3, and allowing it to be heated on its three sides, encompassing all the layers 11 and 12 defining each linear length 6 or 7. The countering element 503 comprises a body 503’ and wedge-shaped elements 503” which can be inserted into corresponding seats formed in the body 503’. The wedge-shaped elements 503” are partially extracted from the body 503’ of the countering element 503 in figure 30.

[0148] Figures 31 and 32 show the pressing and / or carburizing apparatus 500 with the countering element 503 completely inserted through the winding tool 20” and through the coils 2, 3 wound on the winding tool 20”. In particular, figure 32 is a sectional and perspective view of figure 31 , with the section considered on a horizontal plane containing the rotation axis X-X. The countering element 503 defines an abutment surface inside the winding tool 20” so that, when the presser elements exert a radial thrust directed towards the countering element 503, an undesired deformation neither occurs in the linear lengths 6, 7 nor in the winding tool 20”. The wedge-shaped elements 503” are partially extracted from the body 503’ of the countering element 503 in figure 32.

[0149] Figures 33 and 34 show the pressing and / or carburizing apparatus 500 at a later time than the one shown in figures 31 -32: the wedge-shaped elements 503” were completely inserted into the body 503’ of the countering element 503 to cause an elastic deformation of the body 503’ such that the body 503’ exerts an outward thrust in the radial direction both on the linear lengths 6 of the coils 2, 3 and on the linear lengths 7 of the coils 2, 3, i.e. towards the presser elements 501 , 502. In practice, wedging the wedge-shaped elements 503” into the body 503’ results in the widening of the body 503’ and, therefore, in the application of a thrust directed radially from the inside to the outside of the winding tool 20” on the linear lengths 6 and 7.

[0150] The same technical solution is adopted on the presser elements 501 , 502: the wedge-shaped inserts 505 are actually slidingly movable at the body of the respective presser element to exert an axial thrust on the linear lengths 6 and 7 of the coils 2, 3, as will become clearer in the following paragraph.

[0151] Figure 35 and 36 show the pressing and / or carburizing apparatus 500 at a later time than the one shown in figures 33-34 and precisely show the final step of the pressing and / or carburizing process. As mentioned above, pressing and carburizing can be alternately or simultaneously carried out, at the same time or in succession, in the desired order.

[0152] Both the pressing and the carburizing of the linear lengths 6 and 7 of the coils 2, 3 are preferably carried out.

[0153] In the position shown in figure 35, the presser elements 501 and 502 are applying a force on the linear lengths 6 and 7 of the coils 2, 3, on opposite parts of the winding tool 20”, as denoted by the arrows, i.e. radially towards the axis X-X. The countering element 503 simultaneously applies a force directed radially towards the presser elements 501 , 502 on the linear lengths 6 and 7. Figure 36 is a sectional and perspective view of figure 35, with the section considered on a first horizontal plane containing the rotation axis X-X. In figure 36, by way of example, four arrows denote the direction of the force applied on each side on the linear length 6. The wedge-shaped inserts 505 and the wedge- shaped elements 503” are forcefully inserted into the respective seats to generate thrusts and, therefore, pressures, as described above.

[0154] The pressing and / or carburizing step preferably lasts between 15 seconds and 2 minutes and the heating elements 504 bring the temperature of the presser elements 501 , 502 and of the countering element 503 to a value within the range of 170°C - 210°C.

[0155] At this point, the pressing and / or carburizing step being completed, the presser elements 501 and 502 and the countering element 503 are moved away from the winding tool 20” to allow the coils 2, 3 to be extracted.

[0156] Figures 37 and 38 are isometric views of the winding tool 20” with the coils 2, 3 still wound, although preferably already subjected to the pressing and / or carburizing step which substantially made the linear lengths 6 and 7 non- deformable, having shaped them complementary to the seats of the electric motor or electric component for which they are intended. At this time, an insulating slot liner P, which will stay interposed between the wires 10 and the electric component, is applied on the linear lengths 6 and 7. The insulating element P is a sort of small box opened on one side which, once closed, takes the parallelepiped shape and which is normally named slot bottom insulation, or slot liner. The insulating element P is applied with an appropriate manipulator (not shown).

[0157] Figure 38 shows the coil 1 completed and insulated with the insulating material P at the linear lengths 6 and 7.

[0158] At this point, the winding tool 20” can be opened, i.e. disassembled, to release the completed coil 1 insulated with the insulating material P, ready for being used in a successive assembling step of an electric component.

[0159] Figure 39 is an isometric and exploded view of the winding tool 20” and the released series 1 of coils 2, 3.

[0160] Clearly, the solution described above is usable both for making individual coils 1 and for making multiple coils 2, 3: in the first case, the wires 10, or bundles 11 , 12 of wire 10, are only wound in the first chamber 24’, whereas in the second case, as described above, both chambers 24’ and 24” are used.

[0161] Figures 40A, 40B and 40C show three different examples of loops which can be obtained with the winding tool 20 or 20’, in which:

[0162] - in figure 40A, each loop S1 , S2 is formed by two layers: a first layer of five wires 10 and a second layer of four wires 10;

[0163] - in figure 40B, each loop ST, S2’ is formed by two layers, both of five wires 10;

[0164] - in figure 40C, each loop S1 ”, S2” is formed by three layers: a first layer of five wires 10, a second layer of four wires 10 and a third layer of five wires 10.

[0165] As can be noted, the wires with circular section tend to leave free spaces; in order to overcome this problem, it is possible to resort to an optional solution depicted in figures 41 A, 41 B, 41 C.

[0166] According to this optional and advantageous solution for the filling factor, during the coil making step and, more precisely, while winding, complementary conducting wires of a smaller section 10’, which occupy the space left free from the tangency of the wires 10 of a greater section (i.e. the free spaces between the aforesaid wires 10 of a greater section), are added to each loop ST, S2’ or S1 ”, S2”. This way, during the winding step, each loop ST, S1 ”, S2’, S2” will be formed by layers of wires of a different section, alternated with each other and which, once wound, allow to achieve an even greater filling factor in the stators of electric motor.

[0167] Ultimately, the apparatus and method according to the invention therefore allow to achieve:

[0168] - a perfect stratification of the conducting wire 10 in each coil 2, 3;

[0169] - the making of coils 2, 3 in series on a winding tool which provides the possibility to perform pressing and carburizing of the linear lengths 6, 7 of the coils 2, 3 without having to remove the coils 2, 3 from the winding tool 20” and, therefore, at a time at which the arrangement of the wires 10 is accurate;

[0170] - the perfectly stratified coils 2, 3 allow for maximal performance, all other factors being equal, from electric motors and other components on which the coils 2, 3 are mounted;

[0171] - the making of optimal quality coils 2, 3 in quick times, shorter than the times required by current technologies, and with better stratification of the wires 10, even with two or more wires 10, 10’.

[0172] Moreover, the winding machine has a simple structure and neither requires the use of flyers, to the advantage of the overall dimensions, nor the axial movement (along the axis X-X) of a flyer or the spindles 402, 403.

Claims

CLAIMS1. A winding method for making multiple coils (2, 3) of conducting wire (10, 10’), comprising:A) prearranging at least one wire guiding device (401 ) configured for guiding conducting wires (10, 10’) in one or more bundles (11 , 12), a winding tool (20”) provided with at least two winding chambers (24’, 24”), a first spindle(402) intended to rotate the winding tool (20”), one or more storage satellites (404) configured for storing a length of said at least one bundle (11 , 12) of conducting wires (10, 10’) and a second spindle (403) intended to rotate the storage satellites (404);B) guiding at least one bundle (11 , 12) of conducting wires (10, 10’) through the at least one wire guiding device (401 ) and at the winding tool (20”), and storing a length of said at least one bundle (11 , 12) of conducting wires (10, 10’) on said one or more storage satellites (404);C) rotating, through the first spindle (402), the winding tool (20”) about a first axis (X-X) named rotation axis, to cause the winding, in a first winding chamber (24’), of a first length (10.1 ) of said at least one bundle (11 , 12) of conducting wires (10, 10”) which is provided by at least one wire guiding device (401 );D) rotating, simultaneously to step C and through the second spindle(403), the storage satellites (404) about said rotation axis (X-X) and about the winding tool (20”) for causing the winding, in a second winding chamber (24”), of second lengths (10.2) of said at least one bundle (11 , 12) of conducting wires (10, 10’) which is withdrawn from said one or more storage satellites (404).

2. Method according to claim 1 , wherein:- a first coil (2) is formed by winding said at least one bundle (11 , 12) of conducting wires (10, 10’) in said first winding chamber (24’), by withdrawing said at least one bundle (11 , 12) of conducting wires (10, 10’) from a corresponding wire guiding device (401 ),- a second coil (3) is formed by winding said at least one bundle (11 , 12)of conducting wires (10, 10’) in said second winding chamber (24”), by withdrawing said at least one bundle (11 , 12) of conducting wires (10, 10’) from a corresponding one or more of said storage satellites (404), and- possible further coils are formed by winding at least one bundle (11 , 12) of conducting wires (10, 10’) in corresponding further winding chambers of the winding tool (20”), by withdrawing the bundle (11 , 12) of conducting wires (10. 10’) from a corresponding wire guiding device (401 ) and from one or more corresponding storage satellites (404).

3. Method according to claim 1 or 2, wherein the winding of said at least one bundle (11 , 12) of conducting wires (10, 10’) on the winding tool (20”) is carried out by making the storage satellites (404) complete two revolutions about the rotation axis (X-X) for every revolution completed by the winding tool (20”) about the rotation axis (X-X).

4. Method according to one or more of preceding claims 1 -3, wherein the coils (2, 3) are obtained in succession along the same bundle (11 , 12) of conducting wires (10, 10’).

5. Method according to one or more of preceding claims 1 - 4, wherein step B provides for a preparatory step B’ of:B’) rotating the winding tool (20”) by an angle about a second axis (Y-Y) orthogonal to the rotation axis (X-X), thus locking a portion (10x) of said at least one bundle (11 , 12) of conducting wires (10, 1 O’) on the winding tool (20”) in an intermediate position between the at least two winding chambers (24’, 24”), and bringing back the winding tool (20”) coaxial to the rotation axis (X-X) before starting steps C and D, thus causing the localized deformation of the locked portion (10x) of said at least one bundle (11 , 12) of conducting wires (10, 10’), which portion connects two consecutive completed coils (2, 3).

6. Method according to one or more of preceding claims 1 -5, wherein said at least one bundle (11 , 12) of conducting wires (10, 10’) comprises a plurality of identical or different conducting wires (10, 10’) guided through the wire guiding device (401 ) according to a controlled reciprocal position and acontrolled stratification.

7. Method according to claim 6, wherein the reciprocal position and stratification of the conducting wires (10, 10’) remain unchanged both while winding on the storage satellites (404), as referred to in step A, and while winding on the winding tool (20”), as referred to in steps C and D.

8. Method according to one or more of preceding claims 1 -7, wherein the coils (2, 3) formed on the winding tool (20”) comprise at least one first linear length (6) and at least one second linear length (7) which in turn comprise a plurality of individual linear lengths of conducting wire (10, 10”), and wherein, at the end of steps C and D and before removing the coils (2, 3) formed from the winding tool (20”), said first linear length (6) and said second linear length (7) of each coil (2, 3) are subjected to a step E of:E) pressing and / or thermal carburizing treatment, in the desired order or simultaneously, so that to compact said individual linear lengths of conducting wire (10, 10’) and make the reciprocal position and stratification assumed by the conducting wires (10, 10’) on the winding tool (20”) permanent.

9. Method according to claim 8, wherein said step E of pressing and / or carburizing comprises pressing the linear lengths (6, 7) of the coils (2, 3) with one or more presser elements (501-503) and heating said linear lengths (6, 7) by means of one or more heating devices (504) independent of, or integrated in, or functionally coupled to said pressure elements (501 -503), while the coils (2, 3) are wound on the winding tool (20”).

10. Method according to one or more of the preceding claims, wherein the coils (2, 3) formed on the winding tool (20”) comprise at least one first linear length (6) and at least one second linear length (7) which in turn comprise a plurality of individual linear lengths of conducting wire (10, 10’) and wherein, at the end of steps C and D and before removing the coils (2, 3) formed from the winding tool (20”), said first linear length (6) and said second linear length (7) of each coil (2, 3) are wound by an insulating element (P) named slot liner.

11. Method according to one or more of the preceding claims, whereincomplementary wires (10’) having a smaller section than the section of said conducting wires (10) are added to said one or more conducting wires (10), so that said complementary wires (10’) occupy the free spaces between said conducting wires (10).

12. A winding machine (400) for making multiple coils (2, 3) of conducting wires (10, 10’), comprising at least one wire guiding device (401 ) configured for guiding conducting wires (10, 10’) in one or more bundles (11 , 12), a winding tool (20”) provided with at least two winding chambers (24’, 24”), a first spindle (402) intended to rotate the winding tool (20”) about a first axis (X-X) named rotation axis, one or more storage satellites (404) configured for storing a length of said at least one bundle (11 , 12) of conducting wires (10, 10’), and a second spindle (403) intended to rotate the storage satellites (404) about the rotation axis (X-X) and the winding tool (20”), and wherein the rotation of the winding tool (20”) about the rotation axis (X-X) causes the winding of said at least one bundle (11 , 12) of conducting wires (10, 10’) in a first winding chamber (24’) of said at least two winding chambers (24’, 24”), and wherein the rotation of said one or more storage satellites (404) around the winding tool (20”) causes the winding of said at least one bundle (11 , 12) of conducting wires (10, 10’) in a second winding chamber (24”) of said at least two winding chambers (24’, 24”).

13. Winding machine (400) according to claim 12, wherein the rotation speed (v1 ) of the first spindle (402) and the rotation speed (v2) of the second spindle (403), with respect to the rotation axis (X-X), are selectively adjustable.

14. Winding machine (400) according to claim 13, wherein the first spindle (402) and the second spindle (403) rotate in the same direction with respect to the rotation axis (X-X) and v2 = 2v1 , i.e. the storage satellites (404) perform two revolutions about the rotation axis (X-X) for each revolution completed by the winding tool (20”) about the rotation axis (X-X).

15. Winding machine (400) according to any one of preceding claims 12- 14, wherein the winding tool (20”) is rotatable by an angle about a second axis (Y-Y) orthogonal to the rotation axis (X-X) to assume a temporarily rotatedposition, and the winding tool (20”) comprises means (421’) for restraining said at least one bundle (11 , 12) of conducting wires (10, 10’), wherein said restraining means (42V) are intermediate between said at least two winding chambers (24’, 24”) and wherein, in the rotated position of the winding tool (20”), said at least one bundle (11 , 12) of conducting wires (10, 10’) extends from the wire guiding device (401 ) to the storage satellites (404) and one of its portions (10x) is locked at the winding tool (20”) by the restraining means (42V), and wherein, in the position of the first spindle (402) coaxial to the rotation axis (X-X), the locked portion (10x) of said at least one bundle (11 , 12) of conducting wires (10, 10’) fastened to the winding tool (20”) is locally deformed.

16. Winding machine (400) according to any one of preceding claims 12-15, wherein the wire guiding device (401 ) is configured for guiding identical or different conducting wires (10, 10’), according to a predetermined reciprocal position and a predetermined stratification.

17. Winding machine (400) according to any one of preceding claims 12-16, wherein the winding tool (20”) comprises a plurality of supports (421 , 42V) forming one or more winding chambers (24’, 24”) inside which said conducting wires (10, 10”) are wound with the reciprocal position and stratification imposed by the wire guiding device (401 ), and wherein the supports (421 , 42V) can be arranged with the axial distance, on the rotation axis (X-X), corresponding to the pitch between the completed coils (2, 3).

18. Winding machine (400) according to any one of preceding claims 12-17, wherein the storage satellites (404) are spools inside which the reciprocal position and stratification of the conducting wires (10, 10’) remain unchanged.

19. Winding machine (400) according to any one of preceding claims 12-18, wherein the winding chambers (24’, 24”) are shaped for obtaining coils (2, 3) having at least one first linear length (6) and at least one second linear length (7) which, in turn, comprise a plurality of individual linear lengths of conducting wire (10, 10’), and wherein the winding machine comprises a pressing and / orcarburizing apparatus (500) movable on said linear lengths (6, 7) of the coils (2, 3) accommodated on the winding tool (20”) to perform the pressing and / or a thermal carburizing treatment, in the desired order or simultaneously, so that to compact said individual linear lengths of conducting wire (10, 10’) and make the reciprocal position and stratification assumed by the conducting wires (10, 10’) on the winding tool (20”) permanent.

20. Winding machine (400) according to claim 19, wherein the pressing and / or carburizing apparatus (500) comprises one or more presser elements (501-503) and one or more heating devices (504) integrated in, or functionally coupled to, said presser elements (501-503).

21. Winding machine (400) according to any one of preceding claims 12- 20, the winding machine (400) being modular to change the number of coils (2, 3) which can be formed simultaneously, it being able to be configured with one or more wire guiding devices (401 ) and one or more storage satellites (404) for each wire guiding device (401 ) and with the winding tool comprising two winding chambers (24’, 24”) for each wire guiding device (401).

Images