Winding device with expansive mandrel and method for winding a wound module for an electric machine

Abstract

The invention relates to a winding device for winding a wound module (3), the winding device comprising a mandrel (1) having a body (6) and a head (15) bearing a set of jaws comprising at least a first unmovable or movable jaw (14a) and a second movable jaw (14b), each movable jaw being movable radially between a retracted position and an extended position, and a wire feeder. The invention further relates to a winding method, the method comprising: presenting a winding support (2) close to the mandrel with the movable jaws in the retracted position; - inserting the winding support onto the mandrel head (15); - controlling a movement of the movable jaws into the extended position; - attaching a wire end to a wire catch; - rotating the mandrel and allowing the feeder to turn; - stopping the rotation; - cutting the wire; and - controlling a movement of each movable jaw into the retracted position in order to remove the wound module.

Description

[0001] DESCRIPTION

[0002] TITLE OF THE INVENTION: Winding Equipment with Expanding Mandrel and Winding Method for a Wound Module for an Electrical Machine. The present invention relates to winding equipment or an installation for winding a wound module for an electrical machine and a winding method for winding such a module, said module comprising a winding support and a coil of conductive wire. The conductive wire in question is coated with a layer of insulation, for example, an insulating varnish, so that two adjacent wire sections are not in electrical contact.

[0003] [0 It is known to proceed by winding such a conductive wire onto teeth of a ferromagnetic assembly in an electrical machine to form poles of a stator or even a wound rotor.

[0004] In the configuration of interest, a winding support is used so that a wound module is formed comprising the winding support and the winding itself.

[0005] [0 The wound modules are each mounted around a tooth of the ferromagnetic assembly. Therefore, the module includes a central recess designed to receive and house the tooth.

[0006] It is relevant to manufacture the winding support from non-metallic synthetic material, e.g. a polymer resistant to the physico-chemical environment and to the fairly demanding mechanical stresses required for the winding support function.

[0007] Furthermore, the winding must be well-ordered, meaning that successive sections of wire must be neatly arranged next to each other. In addition, there are several layers of wire plies, one on top of the other (i.e., several thicknesses of turns).

[0008]

[0007] If the winding support is not held correctly during the winding operation, then the winding support may undergo elastic, or even non-elastic, deformations.

[0009] If the winding support deforms under the stress of the winding operation, the arrangement of the coil wires may be non-compliant, or even disorderly.

[0010] A winding support that has undergone deformation can cause difficulties in inserting the ferromagnetic assembly onto the tooth, or lead to imbalances in the flow of cooling fluid that comes to lick the wound modules.

[0011]

[0010] The inventors sought to propose a solution to ensure proper positioning of the coil wires during the operation of winding the coils around the winding support.

[0012]

[0011] To this end, a winding device is proposed for winding a wound module comprising a winding support and a winding of conductive wire,

[0013] The winding equipment includes:

[0014] - a chuck with a body and a chuck head carrying a set of jaws, said set of jaws comprising at least one first fixed or movable jaw and one second movable jaw, each movable jaw being radially movable between a retracted position and an extended position, the chuck being mounted to rotate about a chuck axis,

[0015] - a wire feeder, configured to hold a wire reserve, the chuck being able to receive a winding support while each movable jaw is in the retracted position, and being able to hold the winding support on the chuck head after each movable jaw has been moved to the out position,

[0016] the winding equipment being configured to wind conductor wire around the winding support by rotating the mandrel while allowing the wire reel to rotate.

[0017] As a result, thanks to the good support of the winding support provided by the expansion of the jaws, the winding support retains its mechanical properties and does not undergo deformation which is detrimental to the maintenance of the dimensional chains when the winding modules are assembled on the ferromagnetic assembly.

[0018] Thanks to the radial movements of the movable jaws, the jaws conform to the internal wall of the winding support body and prevent it from deforming under the forces induced by the winding operation.

[0019] Note that the initial operation is to attach one end of the wire to the head of the mandrel (or to the winding support) so as to be able to properly initialize the winding process around the winding support.

[0020]

[0015] The chuck rotates on an X axis, the body of the chuck is mounted for motorized rotation around the X axis, the unwinder can be mounted for rotation on an axis positioned in any way relative to the axis of the chuck.

[0021]

[0016] After winding is complete, the initial portion of the wire caught in a wire clip can be cut. Of course, the wound module can then also be removed from the mandrel head.

[0022]

[0017] In this document, the terms "inside" and "outside" will be used to describe the position of certain elements with respect to the central area of ​​the winding support and with respect to the mandrel axis.

[0023] In one embodiment, the winding equipment may include a wire feed nose, capable of guiding the wire delivered from the reel towards the winding support. This allows the wire feed nose to optimally guide the wire in three-dimensional space relative to the coil to be wound at any given time. It is understood that there is no deviation between the wire feed nose and the winding support; the wire is in a straight line in this section and under sufficient tension, given the braking system discussed later.

[0024] According to one embodiment, a mechanism is provided for moving the wire exit nose in order to move the wire exit nose in a synchronized manner with the rotation of the mandrel and the progressive filling of the winding support.

[0025]

[0020] According to one embodiment, the wire exit nose is mounted on a carriage with a back-and-forth movement, along an axis parallel to the axis of the mandrel, the back-and-forth movement being synchronized with the rotation of the mandrel and / or the filling of the coils.

[0026]

[0021] It is noted that it is not excluded that the carriage on which the wire exit nose is mounted has a second degree of freedom, in order to finely adjust the relative position of the wire exit with respect to the coil being wound at time t.

[0027] This ensures proper arrangement of the winding turns; the winding is carried out respecting the prescribed arrangement of the wire in the dedicated slot of the winding support. [0] Note that this creates several well-ordered layers. The entire set of turns does not extend beyond the edges / flanges of the slot designed to hold the winding turns.

[0028] For example, the winding can consist of 6 distinct layers of wire. In one embodiment, a wire keeper attached to the mandrel head is provided. This allows one end of the wire to be attached to the mandrel head so that the winding process around the winding support can be correctly initiated.

[0029] In one design, a braked pulley is provided on the wire path from the spool to the wire exit nozzle. This allows the wire tension to be adjusted to ensure proper filling of the winding support or the previous row of turns.

[0030] The braking thus allows sufficient tightening of the wire, which then perfectly conforms to the body of the winding support for the first row of turns, and this also applies mutatis mutandis to the following rows of turns.

[0031] [0 According to one embodiment, the jaw assembly comprises one fixed jaw and two movable jaws. This allows for the creation of outward radial pressure in an isostatic manner, i.e., with three pressure zones evenly distributed around the circumference of the chuck head.

[0032] In one embodiment, the jaw assembly comprises four movable jaws. This solution allows for independent and well-balanced pressure to be applied to the four corners of the winding support. This is particularly suitable for a generally quadrilateral winding support configuration.

[0033] According to one embodiment, the chuck head includes a control member movable along the chuck axis and cooperating by cam effect with each movable jaw, to move them selectively radially inwards or radially outwards.

[0034] Advantageously, the control element is provided for in the axial area of ​​the chuck, which allows the relationship between the rotating chuck and the control to be managed, the control element being preferably in a stationary position.

[0035] According to one embodiment, the control element is formed as a portion of a conical tube.

[0036] The outside of the cone allows the chuck to close for the winding support (extension of the movable jaws), while the inside of the cone controls the opening of the chuck (retraction of the movable jaws).

[0037] The present invention also relates to a winding equipment as described above and one or more winding support(s), each for receiving a winding as discussed in this document.

[0038] The present invention also relates to a winding method for winding a wound module comprising a winding support and a winding of conductive wire, the winding method comprising the steps: a1- providing a mandrel with a body and a mandrel head carrying a set of jaws, said set of jaws comprising at least one first fixed or movable jaw and one second movable jaw, each movable jaw being radially movable between a retracted position and an extended position,

[0039] a2- Provide a wire reel, configured to hold a supply of wire.

[0040] b- present a winding support near the chuck with the movable jaw(s) in the retracted position,

[0041] c- Insert the winding support onto the chuck head,

[0042] d- to command a movement of each movable jaw towards the exit position, thus immobilizing and holding the winding support on the chuck head,

[0043] d- Attach one end of the wire to a wire clip attached to the chuck head, e- Rotate the chuck and allow the wire feeder to rotate.

[0044] f- stop the rotation, cut the wire, and command a movement of each movable jaw towards the retracted position.

[0045] At step c-, the jaws are surrounded or encircled by the inner wall of the winding support body.

[0046] At step d-, the movable jaws in the exit position apply an outward radial force on the inner walls of the winding support body.

[0047] In step d-, the wire feeder is allowed to rotate, with a braking function on the wire feeder itself, or on the path of the wire between the wire feeder and the wire outlet. This function will be discussed in detail later.

[0048] [0 At step f-, the rotation is stopped when the desired number of turns is reached. Of course, the initial portion of wire caught in the wire holder can then be cut. Naturally, the wound module can then also be removed from the mandrel head.]

[0049] According to one embodiment, the winding equipment further includes a wire catcher attached to the mandrel head, and a wire outlet nose, suitable for guiding the delivered wire towards the winding support, the method providing for moving the wire outlet nose in a synchronized manner with the rotation of the mandrel and the progressive filling of the winding support.

[0050] More specifically, the process according to this option involves a back-and-forth movement along an axis parallel to the axis of the chuck, the back-and-forth movement being synchronized with the rotation of the chuck.

[0051] This ensures proper arrangement of the winding turns; the winding is carried out respecting the prescribed arrangement of the wire in the dedicated housing of the winding support.

[0052] According to one embodiment, the process may also include braking the reel or arranging a braked pulley on the path of the wire from the reel to the wire exit nose.

[0053] The braking function in question thus allows for good control of the tension.

[0054]

[0045] According to one embodiment, a sliding device is provided for each movable jaw to allow only translational movement for the jaw in a radial direction relative to the chuck head.

[0055] Depending on the design, the slide can use a male part on the jaw and a female part on the chuck head. Of course, the reverse is also perfectly possible.

[0056]

[0047] According to one embodiment, a high-performance polyamide or polyethylene polymer can be chosen for the winding support material. According to a particular option, the material can be chosen from the polyphenylene sulfide family.

[0057] According to one embodiment, the winding support includes a housing to receive the turns of wire, the housing being formed as an annular groove open radially outwards, the groove being framed by two flanges. According to one embodiment the bottom of the groove is grooved with 95 grooves, so as to help the correct positioning of the turns of the first layer.

[0058] According to one embodiment, a first flange extends outwards from the lower end of the winding support body and a second flange extends outwards from the upper end of the body.

[0059]

[0051] The present invention also relates to a coil obtained according to the winding process as described above. Using the proposed equipment and process, wound modules with a well-ordered winding of turns are manufactured.

[0060] The present invention also relates to an axial magnetic flux electric machine comprising at least one stator comprising a plurality of wound modules as described above and / or obtained according to the winding process as described above. The electric machine may, in particular, be intended to power a motor vehicle.

[0061] The invention will be further detailed by describing non-limiting embodiments, and based on the accompanying figures illustrating variants of the invention, in which:

[0062] - [Fig.1] schematically illustrates an axial flux electric machine; - [Fig.2] shows an exploded view of the stator according to an example of an embodiment of the invention;

[0063] - [Fig.3] schematically illustrates in perspective view an example of the realization of a winding module according to the invention;

[0064] - [Fig.4] illustrates, in perspective seen from below, an example of the realization of a winding support;

[0065] - [Fig.5] schematically illustrates a cross-sectional view in a plane perpendicular to the wires of turns on one side of a wound module obtained according to the process proposed by the invention, the turns of wire in the lower half of the figure not having been represented;

[0066] - [Fig.6] shows a top view of an example of a chuck head, in a configuration with one fixed jaw and two movable jaws, with the movable jaws in the retracted position on the left side of the figure, and the movable jaws in the extended position on the right side of the figure; - [Fig.7] schematically illustrates in perspective the body of the chuck and the chuck head on which there is a winding support in a winding start configuration, the initial part of the wire being held by a wire hook;

[0067] - [Fig.8] shows a top view of another example of a chuck head, in a configuration with 4 movable jaws, the movable jaws being in the out position;

[0068] - [Fig.9] schematically illustrates in perspective the body of the chuck and the chuck head on which there is a winding support during winding, the wire exit nose having been shown;

[0069] - [Fig.10] schematically shows an example of the principle of a movable control element along the chuck axis to move the movable jaws closer to or further from the axis;

[0070] - [Fig.11] schematically shows, in cross-section with respect to the radial direction, an example of a sliding guide system and return of the movable jaws relative to the chuck head, under the effect of a control element; - [Fig.12] is read in conjunction with figure 11 and schematically shows the example of jaw arrangement of figure 11 according to a cross-section in the radial direction;

[0071] - [Fig.13] schematically shows an example of wire path between the reel and the output nose with return pulleys and a braked pulley; - [Fig.14] schematically shows another example of the principle of a control element movable along the chuck axis to move the movable jaws closer to or further from the axis;

[0072] - [Fig.15] is analogous to the figure and shows an inverse configuration, namely an actuator that pushes upwards instead of pulling downwards.

[0073] [0 In the various figures, the same references designate identical or similar elements. For the sake of clarity, some elements are not necessarily shown to scale.

[0074] This document focuses on electrical machines used in motor vehicles. These can be fairly powerful machines belonging to an electric motor unit capable of propelling the vehicle, i.e., so-called traction machines.

[0075] The electrical machine in question can operate in motor mode or generator mode depending on certain operating phases.

[0076] It should be noted, however, that the principle and technical solution put forward in this document can be applied to electrical machines other than traction machines or even outside of use in a motor vehicle.

[0077] General Architecture

[0078] An electric machine generally comprises a rotor forming a rotating part around a machine axis, and a stator (or two) forming a complementary non-rotating part, all housed in a casing.

[0079]

[0060] There are many configurations of machines with so-called 'radial' flux. In this document, however, we are particularly interested in machines with so-called axial flux. The magnetic field in the air gap is oriented mainly parallel to the machine axis.

[0080]

[0061] In axial flux machine configurations, the rotor has a general shape of a thick disk which has a thickness much smaller than its diameter.

[0081] As already mentioned in the introductory part and visible in Figure 1, an axial flux electric machine denoted MEL generally comprises a rotor ROT forming a rotating part around a machine axis A, and at least one stator forming a complementary non-rotating part.

[0082] In the illustrated example, two stators ST,ST2 are planned, namely one stator on either side of the rotor.

[0083] The rotor is fixedly connected to a machine shaft marked 88, mounted to rotate about axis A, relative to the housing by means of bearings as known per se.

[0084] The rotor carries a series of permanent magnets, while a series of coils is carried by the stators. When the coils are energized by an electric current, the rotor, which is fixed to the machine shaft 88, is subjected to a torque resulting from the magnetic field.

[0085]

[0066] The rotor has a thickness denoted much smaller than its diameter D9. D9 can take a value between 150 mm and 300 mm. The axial thickness E9 of the rotor can take a value between 10 mm and 25 mm.

[0086] The machine shaft 88 can be coupled to the input of a reducer, for example a planetary reducer of general cylindrical shape and axis coinciding with the machine axis; it thus forms an integrated geared motor assembly with a shape easy to place in a vehicle architecture.

[0087] Stator

[0088] We describe below a stator. In the case where the machine is equipped with 2 stators, the second is substantially identical to the first and placed in mirror image of the first with respect to a median plane of the machine as shown in figure 1.

[0089]

[0070] Referring to Figure 2, the stator comprises a support disc 110 and a ferromagnetic assembly 100. The support disc 110 can be an integral part of a machine housing or can be fixed to a machine housing.

[0090]

[0071] The support disc 110 forms a base for the ferromagnetic assembly 100, i.e., the ferromagnetic assembly 100 is mounted and fixed on the upper face of the support disc. The ferromagnetic assembly comprises a base ring and teeth 103 extending from the base ring parallel to the main axis A, with a substantially trapezoidal cross-section.

[0091] The number N of teeth, 10³, can in a preferred example be chosen as a value between 12 and 24. Lower or higher values ​​for N are also not excluded. N=18 in the example illustrated in the figures.

[0092] The teeth can be grouped into subsets, each subset being excited by one of the 3 excitation phases (U,V,W), as is well known in the field of electrical machines.

[0093] Two adjacent teeth are separated by a notch. The teeth are regularly spaced around the axis. A pair (tooth + notch) occupies an angular sector of N / 360, expressed in degrees.

[0094] The ferromagnetic assembly is made of a material permeable to the magnetic field and allows the magnetic flux to be channeled from the stator to the air gap. The base ring and teeth preferably comprise a stack of ferromagnetic sheets or plates.

[0095] Each tooth 103 occupies an angular sector with an amplitude between 10° and 20°.

[0096]

[0077] The stator comprises a plurality of wound modules designated 3. In practice, all the wound modules 3 are identical. There are as many wound modules as there are teeth.

[0097] A "wound module" 3 is a subassembly consisting of a winding support 2 and the coil of wire wound 50 around the support (see Figure 3). This subassembly is prepared separately before being mounted on the ferromagnetic assembly 100. Each wound module 3 occupies an angular sector with an amplitude between 15° and 25°.

[0098] Each winding support 2 includes a central recess 25 which houses a tooth 103. Each winding support 2 includes a body 20 delimiting the central recess 25. The central recess is delimited by the internal walls 23 of the body 20. Once the winding support is assembled, the body surrounds the tooth.

[0099]

[0080] The body 20 receives the coil windings from the outside, which fit into a housing LG formed as an annular groove open radially outwards, the groove being framed by two flanges which will be seen later.

[0100] The body 20 comprises two non-parallel radial walls 26, 27. The two radial walls are not parallel; they are generally oriented in a radial direction. Each radial wall of the winding support faces, on its inner side, the corresponding radial wall of the tooth 103 surrounded by the support 2.

[0101] As can be seen in the cross-section of Figure 3, a conductive wire 5 is wound around the body of the support to form a coil comprising a fairly large number of turns.

[0102] [0 As illustrated in Figure 3, the conductor wire 5 comprises a first end 5a and a second end 5b which protrude radially towards the center of the machine, to be welded respectively to two connecting pads.

[0103] It is noted that 95 grooves can be provided to accommodate the first winding turns which are in direct contact with the outer faces of the support walls as illustrated in figures 4, 7 and 9.

[0104] Each winding support comprises a first flange 21 and a second flange 22 intended to frame the winding electrical wires in the axial direction.

[0105] The first flange 21 extends outwards from the lower end 20a of the body 20 and the second flange 22 extends outwards from the upper end 20b of the body.

[0106] As can be seen in figure 5, the available height between the two flanges 21, 22 to accommodate the wire turns is noted H5, slightly less than the height H1 of the module between the outer faces of the flanges 21, 22.

[0107] [0 Furthermore, the number of turns is such that all the wire sections housed by the winding support are neatly arranged. All the wire sections are slightly recessed from the outer edges of the flange, see Figure 5. This recess has a value of E2. The depth of the groove forming the LG housing is denoted R2.

[0108] [0 In the illustrated example, this is a configuration with 6 rows of superimposed turns. Generally, the number of turns in the winding module can be between 40 and 120, these values ​​being of course not limiting.

[0109] The winding support 2 is a part made of polymer material obtained by molding. The material chosen can be a polyamide polymer, a polypropylene, a polyethylene, ABS, etc.

[0110]

[0091] According to a preferred example, a polymer from the polyphenylene sulfide family can be chosen for the winding support material.

[0111] As shown in Figure 4, the winding support 2 includes reinforcing ribs 84, which contribute to the rigidity of the winding support. These reinforcing ribs 84 are located away from the LG housing intended to hold the windings and can, if necessary, assist in pre-positioning the winding support 2 on the mandrel head, which will be described below.

[0112] Winding equipment

[0113]

[0114] The winding equipment is used to wind the wound modules 3, the purpose of which has been explained above. The winding equipment comprises a mandrel 1 with a body 6 and a mandrel head 15. The mandrel 1 is mounted for rotation relative to a frame. The axis of rotation is denoted X. Furthermore, in the mandrel's coordinate system, the radial direction is denoted R and the tangential direction is denoted (see Figure 12).

[0115] The chuck head 15 carries a set of jaws intended to firmly immobilize the winding support intended to undergo the winding operation.

[0116]

[0096] According to a first embodiment illustrated in figures 6 and 7, the jaw assembly comprises a fixed jaw 13a and two movable jaws 13b, 13c. A fixed jaw is mounted rigidly on the chuck head 15.

[0117] According to a second embodiment illustrated in Figures 8 and 9, the jaw assembly comprises four movable jaws, designated 14a, 14b, 14c, and 14d. It can be seen that, in the illustrated example, the four jaws form four sections that cover the entire inner area of ​​the winding module. It should also be noted that the jaw travel between the refracted position and the exit position is quite modest, in practice a few millimeters, for example, between 2 and 4 mm.

[0118] [0 It is also noted that the entire front face of the jaws interacting with the inner wall 23 of the winding support module covers almost the entire inner wall. This results in a nearly continuous contact, which is very beneficial in preventing any deformation of the winding support under winding load. However, the invention also addresses the case where the movable jaws provide substantially discontinuous contact around the perimeter of the inner wall of the winding support.]

[0119] In some developments presented later in the document, movable jaws will be generically referred to by reference 14.

[0120]

[0100] Other jaw configurations are of course possible. It can thus be stated in general that the jaw assembly comprises at least one first fixed or movable jaw and a second movable jaw.

[0121] In practice, there may be a fixed or non-fixed jaw. The preferred number of jaws is 3 or 4. However, it is not impossible to have 2 jaws, or even more than 4.

[0122] Each movable jaw can be moved radially between a retracted position and an extended position. The retracted position is illustrated in Figure 6 on the left and in Figure 14 in its central portion; this position is also called the closed position of the chuck head.

[0123] The exit position is shown in Figure 6 on the right, in Figure 8, and in Figure 14 on the left; this position is also called the open position of the chuck head.

[0124] The front contact surface 19 of each jaw may have a certain roughness to avoid any risk of slippage relative to the winding support which is being immobilized.

[0125]

[0105] The chuck body 6 extends along the X axis to a certain height; it may have a height of at least 10 cm or more to provide a comfortable free space around the winding support.

[0126] The chuck and its head can receive different types of jaws, so as to be able to handle several sizes of winding supports and several form factors relating to the winding supports.

[0127] The chuck body 6 is rotatably mounted on a frame or chassis designated 60 (see Figure 10). The chuck body can rotate relative to the stationary chassis. In practice, the rotation of the chuck body is motorized, and the angular velocity, and even the angular position, is controlled by a control unit responsible for operating the winding equipment.

[0128] According to the example shown in Figure 10, the body of the chuck is mounted on the frame in particular by means of a tapered roller bearing 61, but any other solution for guiding rotation can of course be adopted.

[0129] [1 The winding equipment includes a wire feeder 8. The wire feeder contains a wire reserve 5. The wire feeder can be a spool of varying size and with varying storage capacity in terms of the length of wire in reserve. The wire feeder spool is mounted for rotation (axis A8, Figure 13). Preferably, it is not braked, except for the inherent bearing friction.]

[0130] The cross-section of wire 5 can be between 0.2 mm 2 and 1.5 mm 2 As is known in the field of winding, the conductor wire is coated with a layer of insulation, for example an insulating varnish.

[0131] The winding equipment includes a wire outlet nose 7, suitable for guiding the wire 5 delivered from the reel 8, towards the winding support.

[0132] As illustrated in Figure 13, the wire follows a predefined path between the unwinding spool 8 and the wire exit nozzle. In the example shown, there is a first idler pulley 81 with axis A1, then a braked pulley 82 with axis A2. Finally, there is a second idler pulley 83 with axis A3. These are grooved pulleys, for example. This type of arrangement is common in the winding and wire-drawing industries and is not described in further detail here.

[0133] It should be noted, however, that the braking torque applied to the braked pulley 82 is adjustable, which allows the winding process to be adapted to the shape and dimensions of the winding support, so that the wire perfectly follows the target turn path, whether for the first row of turns or for subsequent rows of turns.

[0134] In the illustrated example, the wire exit nose 7 includes two guide rollers 74. Here, they are mounted on an axis substantially parallel to the axis of the chuck, but it could be otherwise.

[0135] As shown in Figures 9 and 13, the wire exit nose 7 is mounted on a carriage 80 that can be moved along a direction parallel to the axis of the mandrel. More precisely, the carriage can move downwards F1, carrying the wire exit nose 7 with it, and conversely, the carriage nose can move upwards F2 in the opposite direction. The position of the carriage is controlled by a control unit that also manages the rotation of the mandrel. In practice, the method ensures that the wire exit nose is substantially opposite the coil being wound at time t, so as to avoid unwanted overlap of coils or undesirable gaps between coils.

[0136] Generically expressed, the process involves moving the wire exit nose 7 in a manner synchronized with the progressive filling of the winding support.

[0137] It is noted that in the illustrated example, only the wire exit nose is mounted on the mobile carriage 80. However, in an alternative embodiment, the wire feeder and the return pulleys could also be mounted on the mobile carriage 80. Furthermore, the winding equipment also includes a wire catcher 18 attached to the mandrel head 15, where the initial wire end can be clamped, for example in a V-shape.

[0138] Jaw kinematics and control

[0139] As previously mentioned, each of the movable jaws can be moved in a radial direction, that is, by moving towards the axis o

[0140]

[0141] u moving away from the X-axis.

[0142] According to an embodiment illustrated in Figures 11 and 12, a sliding device is provided to guide this radial movement. More specifically, in the example, a guide rail 31 is provided which cooperates by complementary shape with a guide groove 32 formed in the body of the jaw 14. A T-shaped tenon and mortise is shown, but of course other shapes can be adopted.

[0143] In this way, all degrees of freedom are prevented except translation along a radial axis R.

[0144] It is understood that a person skilled in the art may use any other sliding system to constrain the degrees of freedom of movement of the jaw relative to the chuck head 15.

[0145] The radial movement of the jaws 14 is caused by a control member 4 movable along the axis of the chuck X. The control member 4 cooperates by cam effect with each movable jaw.

[0146]

[0125] According to the example illustrated in figure 10, the control member 4 has a body with two lights 49 (as many lights as there are movable jaws in general).

[0147]

[0126] Each movable jaw includes a pin 48 which acts as a cam follower. More precisely, each pin 48 is received with a small functional clearance in a slot 49 in the control member.

[0148]

[0127] The pins 48 of the movable jaws 14 also contribute to the translational guidance of the jaws in their radial movement, in cooperation with grooves 92 provided on the chuck head 15.

[0149] More specifically, the lights 49 are inclined and when the control member 4 moves up or down, this accordingly moves the pins 48 to the right or to the left.

[0150] Thus, the lights 49 act as a cam in relation to the pawns 48 which act as a cam follower.

[0151]

[0130] The inclination of the lights with respect to X is small, for example 10°, given the stroke required for the radial movement of the jaws, so that an amplification effect of the force generated by the control member can be obtained.

[0152] The control element 4 is moved along the X-axis by means of a control actuator. In the example illustrated in Figure 10, a hydraulic cylinder 9 is used as the control actuator. The hydraulic cylinder 9 is shown symbolically; it could be much shorter. Alternatively, a pneumatic cylinder or a screw-nut type electric actuator could be used.

[0153] To return to the example illustrated in figure 10, the upper chamber 97 of the cylinder is controlled by a solenoid valve 91. To move the jaws from their retracted position to the extended position, it is therefore necessary to put pressure in the upper chamber 97 of the cylinder to move the rod 96 of the cylinder downwards and to drive with it the control member 4, the slots then pushing the pins 48 radially outwards.

[0154] The actuator can be backed by a support force adjustment system, which makes it possible to limit the downward pulling force and consequently the outward radial pressure that the jaws apply on the winding support 2.

[0155] Another way to control the outward radial pressure exerted by the jaws is to pilot the pressure in the upper chamber 97 of the cylinder 9.

[0156]

[0135] In the illustrated example, a single-acting cylinder has been shown, the opposing return being done by the action of the spring(s) 64 which can be individual springs or a single helical spring of considerable diameter which goes around.

[0157]

[0136] In this example, the natural rest position of the chuck corresponds to the retracted position of the jaws. Indeed, in the absence of force exerted by the cylinder 9, the springs 64 push the control member 4 upwards, which, the cam effect exerted on the pins 48, causes the jaws to return to the retracted position.

[0158] Furthermore, a rotating plate is provided to transmit the raising and lowering motion from the stationary part to the rotating part. More specifically, a plate 93 is selectively pushed or pulled by the cylinder 9 via the attachment point 98. A bearing 94 is provided between the plate and the body of the control mechanism. The plate 93 includes an upper flange 42 located above the bearing 94, while the control mechanism is connected to a mushroom-shaped bracket 41 located below the bearing. Of course, any other solution for transmitting a raising and lowering motion from the stationary frame to the rotating chuck can be adopted.

[0159] Referring back to Figures 11 and 12, the jaw movement can utilize a return system to the retracted position. Thus, at least one spring 34 is provided to return each jaw to the retracted position. Helical springs housed in cylindrical recesses 33 can be used.

[0160] Continuing with this example, a single-acting cam mechanism can be used in which the control member 4' comprises a ramp 45 that pushes a corresponding ramp 46 located at the rear of the jaw. The positive action of the control member 4' pushes the jaw 14 outwards, while the passive return by means of the spring 34 tends to bring the jaw back inwards.

[0161]

[0140] In the example of figure 14, the control member is presented as a conical cup 47 or in other words a portion of a conical tube.

[0162] The outside of the cone 43 allows the closure of the chuck for the winding support (extension of the movable jaws 14), while the inside of the cone 44 controls the opening of the chuck (retraction of the jaws 14).

[0163] The cylinder or more generally the actuator which controls the raising or lowering of the conical cup 47 is here double-acting, that is to say it pushes upwards or pulls downwards depending on the need to extend or retract the jaws.

[0164] Each jaw includes a conical groove with an outer wall 17 adapted to be pushed by the outer wall of the conical cup, and an inner wall 16 adapted to be pushed by the inner wall of the conical cup.

[0144] The conical cup includes a base 40 which is linked to the piston 99, itself operated by a cylinder or any other actuator similar or equivalent to that described previously.

[0165] Figure 15 shows a configuration similar to Figure 10 but with the operating logic reversed; that is, the return springs 64 push the control member 4 downwards relative to the body 6, which defines the rest position of the jaws in the extended position. The lower chamber of the cylinder is pressurized to push the control member upwards against the return force of the springs. The remaining functionalities can be easily deduced, mutatis mutandis, from the preceding explanations and the description of Figure 10.

Claims

DEMANDS 1. Winding equipment for winding a wound module (3) comprising a winding support (2) and a winding (50) of conductive wire (5), the winding equipment comprising: - a chuck (1) with a body (6) and a chuck head (15) carrying a set of jaws, said set of jaws comprising at least one first jaw (13a) fixed or movable and one second jaw (13b) movable, each movable jaw being radially movable between a retracted position and an extended position, the chuck being mounted to rotate about a chuck axis (X), - a wire feeder (8), configured to contain a wire reserve (5), the chuck (1) being capable of receiving a winding support while each movable jaw is in the retracted position, and being capable of retaining the winding support on the chuck head after each movable jaw has been moved to the outward position, the winding equipment being configured to wind conductor wire around the winding support by rotating the mandrel while allowing the wire reel to rotate.

2. Winding equipment according to claim 1, further comprising wire outlet nose (7), suitable for guiding the wire delivered from the reel, towards the winding support, and preferably a mechanism for moving the wire outlet nose so as to be able to move the wire outlet nose in a synchronized manner with the rotation of the mandrel and the progressive filling of the winding support.

3. Winding equipment according to any one of claims 1 to 2, wherein the jaw assembly comprises one fixed jaw (13a) and two movable jaws (13b, 13c).

4. Winding equipment according to any one of claims 1 to 3, wherein the jaw assembly comprises four movable jaws (14a, 14b, 14c, 14d).

5. Winding equipment according to any one of claims 1 to 4, wherein the chuck head (15) comprises a control member (4) movable along the chuck axis (X) cooperating by cam action with each movable jaw, to move them selectively radially inwards or radially outwards.

6. Winding equipment according to claim 5, wherein the control member (4) is formed as a portion of a conical tube (47).

7. Method for winding a wound module (3) comprising a winding support (2) and a winding (50) of conductive wire (5). The process includes the following steps: - to use winding equipment according to any one of claims 1 to 6, b- present a winding support (2) near the chuck with the movable jaw(s) in the retracted position, c- Insert the winding support (2) onto the chuck head (15), d- to command a movement of each movable jaw towards the exit position, thus immobilizing and holding the winding support on the chuck head, d- attach one end of the wire to a wire clip (18) fixed to the chuck head, e- rotate the chuck and let the reel rotate, f- stop the rotation, cut the wire, and command a movement of each movable jaw towards the retracted position.

8. Method according to claim 7, wherein a wire outlet nose (7) is provided, suitable for guiding the wire delivered from the reel, towards the winding support, characterized in that the method provides for moving the wire outlet nose in a manner synchronized with the rotation of the mandrel and the progressive filling of the winding support.

9. Coil obtained according to the winding process according to any one of claims 7 to 8.

10. Axial magnetic flux electric machine (MEL) comprising a rotor (ROT) and at least one stator (ST) comprising a plurality of wound modules according to (3) of claim 9.

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