A polyphase stator or rotor winding with high configurability is provided. A stator or rotor using the polyphase stator or rotor winding with high configurability, where single-layer hairpins having different pitches so as to differ at least by two positions in the slot is also provided. Such an arrangement allows obtaining a wider family of windings and electrically balanced stators or rotors, maintaining the diameter at the air gap, the number of slots, and the dimensions of the conductor.
An assembly and insertion system for assembling and inserting, into a stator pack, a winding having one or more layers of basic conductors is provided. The assembly and insertion system has a circumferential containment of the basic conductors with a set of spaces or slots, and one or more removable inserters of the basic conductors into the circumferential containment, and elements for rotating the circumferential containment about the winding axis. A rotary table is configured to rotate about a table axis to bring the circumferential containment from an assembly position to an insertion position for insertion into the stator pack. The winding is assembled on one side of the rotary table while feeding elements of the stator pack and relative introduction elements of the winding into the stator pack at the insertion position act on the opposite side. A process for assembling and inserting a winding into a stator pack is also provided.
H02K 15/06 - Embedding prefabricated windings in the machines
H02K 15/02 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
3.
SYSTEM AND METHOD FOR INSERTING I-PINS INTO A STATOR OR ROTOR WINDING ASSEMBLY
A system and a method for inserting I-pins into a stator or rotor winding assembly are provided. The system has a cylindrical containment for hairpins and a circular inner containment axially inserted into the cylindrical containment for hairpins having a set of radial slots, an upper circular plate with one or more upper cam recesses, a lower circular plate with one or more lower cam recesses, and a vertical wall extending from the upper circular plate to the lower circular plate and rotatably mounted relative thereto. The upper and lower cam recesses accommodate a leg of the I-pins. The vertical wall has one or more voids positioned so that, upon rotation of the vertical wall with respect to the upper and lower circular plates, the upper and lower outlets lead into the voids releasing the leg in a radial slot of the cylindrical containment for hairpins.
The present invention relates to a stator or rotor winding with high configurability, and a stator or rotor using such a winding, wherein there are used single layer hairpins with different pitches so as to differ at least by two positions in the slot. Such an arrangement allows obtaining a wider family of windings and therefore of electrically balanced stators or rotors, preferably maintaining the diameter at the air gap, the number of slots, and the dimensions of the conductor.
A method and a system for inserting all hairpins of a k-th crown of a stator winding into the same region of space are provided. Progressively inserted hairpins are movable along a path of geometry so that the last hairpin of the crown is always insertable as if the last hairpin were the first hairpin, without hindrance. After inserting the last hairpin the crown centers itself by removing the apparatus that allowed insertion of the hairpins into the same region of space. Inner and/or outer containments allow the hairpins to follow the required profile. Rotation of the hairpins is obtainable by cylindrical or conical pins between the legs of the hairpins. After assembling one crown, outermost crowns are progressively assembled on the system to have the winding without handling the crowns. Once assembled, the innermost crown is vertically lowered along a winding axis to leave sufficient space to assemble an adjacent crown.
An apparatus for assembling a winding of hairpins is provided. The apparatus has a feeding section, an insertion section into a winding assembly cylinder, and a handling section having at least two arms configured so that when the end of one arm faces the feeding section, the end of the other arm faces the insertion section. Each arm has a gripper for picking and releasing a hairpin, the gripper being slidingly mounted along an extension direction of the corresponding arm. The insertion section has an assembly drum moved by a rotary mechanism, both mounted on the same axis, perpendicular to the rotation axis of the arms. The assembly drum has a series of inserts on its outer surface defining a series of radially open slots, the rotary mechanism being sized to leave free space between the arm and the slots. A method for assembling a winding of hairpins is also provided.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
7.
REMOVABLE DEVICE FOR INSERTING AND HANDLING SEGMENTED CONDUCTORS IN A MOULD TO FORMING A WINDING
The present invention relates to a removable device (500) for loading and handling basic conductors (255, 255-R, 255-1 P, 255-IVP) configured to load, handle and insert basic conductors in circumferential containment means (300, 600), each basic conductor comprising a head end and one or more legs with a respective free insertion end, the removable loading and handling device (500) being configured to assemble a stator or rotor winding (100) consisting of one or more sectors (100-CI) extending circumferentially about a winding axis (50), each sector comprising one or more layers, each layer consisting of a circumferential arrangement of basic conductors, the device comprising: a first (521) and a second (522) countermold configured to define a containment volume (52011, 52012, 521, 522) of basic conductors, the first and second countermolds each having an extension along an axial direction which is parallel, in use, to said winding axis (50); and loading means (530, 540) of the basic conductors into said containment volume; wherein said containment volume comprises an end volume (500F) of a basic conductor against said first and second countermolds, the end volume (500F) being configured to cause the basic conductor to slide along said axial direction (z) up to insertion into the circumferential containment means (300, 600) within a sector being assembled (100-CIN) of said one or more sectors (100-CI).
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
8.
SYSTEM AND PROCESS FOR ASSEMBLING A STATOR OR ROTOR WINDING
The present invention relates to an assembly and insertion system for assembling and inserting, into a stator pack (400), a winding (200) comprising one or more layers of basic conductors. The system comprises circumferential containment means (500,540,580) of the basic conductors with a set of spaces or slots (550), as well as removable insertion means (210,220,230) of the basic conductors into the circumferential containment means (500,540,580), and rotation means of such circumferential containment means (500,540,580) about the winding axis (200A). The system further comprises a rotary table (300) configured to rotate about a table axis (300A) so as to bring the circumferential containment means (500,540,580) from a first winding assembly position (200) to a winding insertion position for the insertion into the stator pack (400). The winding is assembled on one side of the table while feeding means of a stator pack (400) as well as relative introduction means of said winding (200) into said stator pack (400) at said insertion position act on the opposite side. The invention further relates to a process for assembling and inserting a stator winding (200) into a stator pack (400), wherein the process makes use of the assembly and insertion system of the invention.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
H02K 15/06 - Embedding prefabricated windings in the machines
9.
APPARATUS AND METHOD FOR DEFORMING THE CONDUCTORS OF AT LEAST ONE WINDING ASSEMBLY, PROTRUDING FROM A SIDE OF A STATOR OR ROTOR OF AN ELECTRIC MACHINE
An apparatus for deforming conductors of at least one winding assembly protruding from a side of a stator or rotor of an electric machine is provided. The conductors are arranged with at least one leg inserted into cavities of the stator or rotor, having at least one free end. The apparatus has at least one twisting matrix rotating about an axis and having at least one pocket for insertion of the at least one free end, a radial backing member provided close to the at least one twisting matrix, and in particular close to the at least one pocket on an insertion side of the at least one free end. The radial backing member has an inner radial backing surface for a portion of the at least one leg protruding from the side of the stator or rotor.
System, method and device for assembling and inserting all hairpins of one or each winding layer of a stator winding is presented. All hairpins of said layer are progressively inserted into a containment tool. Last hairpins of one layer is meshed under pre-assembled hairpins of said layer without hindrance by insertion and moving means. Said means comprises two openings to retain said last hairpins and tapered portions a specially shaped circumferential end portions to enable the meshing into the pre-stacked hairpins. After inserting said last hairpin into its position, the insertion and moving means is removed and one entire winding layer retains itself into place and is able to be inserted into the core and free ends of hairpin legs are bend in the known manner and a next layer may be preformed.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
H02K 15/06 - Embedding prefabricated windings in the machines
11.
METHOD AND APPARATUS FOR ASSEMBLING A WINDING OF HAIRPINS
The present invention relates to an apparatus for assembling a multiple crown winding of hairpins or the like, comprising a hairpin feeding section, a hairpin insertion section into a winding assembly cylinder, a hairpin handling section from the feeding section to the insertion section in the assembly cylinder; wherein: - the hairpin handling section comprises at least two arms arranged at 180° and configured so that when the end of one arm faces the feeding section, the end of the other arm faces the insertion section; - each of said arms comprises a gripper for picking and releasing a hairpin, the gripper being mounted in a sliding manner along the extension direction of the corresponding arm; - the insertion section comprises an assembly drum moved by a rotary mechanism, both mounted on the same axis, perpendicular to said rotation axis of the arms, wherein the assembly drum comprises a series of inserts on its outer surface defining a series of radially open slots, said rotary mechanism being sized to leave the space between said arm and said slots free. The invention further relates to a method for assembling a multiple crown hairpin winding, in particular using the apparatus according to the invention.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
H02K 15/06 - Embedding prefabricated windings in the machines
A drive system for a hybrid or electric vehicle includes an electrical energy source; an electric machine, a switching device linked to the electric machine and selectively switchable between a first configuration, and a second configuration, an adjusting device linked to the electric machine and configured to vary its operating parameters, and a control unit. The first electrical configuration includes a first number of conductors in series by phase supplying a first driving torque with a first knee speed and a first no-load operation speed. The second electrical configuration includes a second number of conductors in series by phase supplying a second driving torque, lower than the first driving torque, and a second knee speed higher than the first knee speed. A ratio between the first no-load operation speed and the second knee speed is between 0.7 and 1.3.
B60L 15/20 - Methods, circuits or devices for controlling the propulsion of electrically-propelled vehicles, e.g. their traction-motor speed, to achieve a desired performanceAdaptation of control equipment on electrically-propelled vehicles for remote actuation from a stationary place, from alternative parts of the vehicle or from alternative vehicles of the same vehicle train for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
B60L 50/15 - Electric propulsion with power supplied within the vehicle using propulsion power supplied by engine-driven generators, e.g. generators driven by combustion engines with additional electric power supply
13.
APPARATUS AND METHOD FOR DEFORMING THE CONDUCTORS OF AT LEAST ONE WINDING ASSEMBLY, PROTRUDING FROM A SIDE OF A STATOR OR ROTOR OF AN ELECTRIC MACHINE
An apparatus (200) for deforming conductors of at least one winding assembly (100), protruding from a side of a stator or rotor (114) of an electric machine, which comprises a plurality of base conductors (102) each arranged with at least one leg (104, 106) inserted into cavities (115) of stator or rotor (114), each having at least one respective free end (108, 110). The apparatus comprises at least one twisting matrix (201) adapted to rotate about an axis (X), comprising at least one pocket (204) adapted to insert a free end portion (108, 110). The apparatus (200) comprises a radial backing member (300) provided close to the at least one twisting matrix (201), and in particular close to the at least one pocket (204), on the insertion side of said free end (108, 110). The radial backing member (300) comprises an inner radial backing surface (302) for a portion of leg (104, 106) protruding from said side of said stator or rotor (114).
A switching device for an electric motor provided with a plurality of phases includes a fixed body equipped with a plurality of connection portions and at least one moveable body that can be moved with respect to the fixed body between at least a first position, in which the phases are arranged in a first electrical configuration, and a second position, in which the phases are arranged in a second electrical configuration. The second electrical configuration is separate from the first one due to the connection between the phase fractions within each phase and/or due to the reciprocal connection between the phases.
An assembly for assembling a winding group of a bar winding for an electric machine is provided. The winding group includes a plurality of bar conductors, each bar conductor having a first leg, a second leg and a bridge portion connecting the first leg to the second leg, and being shaped so that the first and second legs are mutually spread by a predetermined distance. The assembly includes an annular fixture delimiting a plurality of slots, each slot receiving at least one portion of either the first leg or the second leg, a guiding device defining an annular containment housing, receiving at least partially the first and second legs of the plurality of legs of the plurality of bar conductors that are housed in the plurality of slots, forming at least one radial containment wall for the first and second legs.
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
H02K 15/06 - Embedding prefabricated windings in the machines
B23P 19/02 - Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformationTools or devices therefor so far as not provided for in other classes for connecting objects by press fit or for detaching same
16.
Apparatus for deforming conductors protruding from a side of a stator or of a rotor of an electric machine
An apparatus (200) for deforming conductors of at least one winding assembly (100), protruding from a side of a stator or of a rotor (114) of an electric machine. The at least one winding assembly (100) comprises a plurality of basic conductors (102) comprising at least one leg inserted into cavities (115) of stator or rotor (114), each having at least one respective free or terminal end (108, 110). The apparatus (200) comprises at least one twisting matrix (202, 203) adapted to rotate about an axis (X), comprising at least one gripping element (204) adapted to grip at least one free end (108, 110) and adapted to be moved in radial direction with respect to said axis (X). The apparatus comprises at least one guide (206, 207) adapted to guide the at least one gripping element (204) along the radial direction with respect to the axis (X); and a radial actuator (208), adapted to put in motion the at least one gripping element (204) along the radial direction with respect to the axis (X).
An assembly for assembling a winding group of a bar winding for an electric machine is provided. The winding group includes a plurality of bar conductors, each bar conductor having a first leg, a second leg and a bridge portion connecting the first leg to the second leg, and being shaped so that the first and second legs are mutually spread by a predetermined distance. The assembly includes an annular fixture delimiting a plurality of slots, each slot receiving at least one portion of either the first leg or the second leg, a guiding device defining an annular containment housing, receiving at least partially the first and second legs of the plurality of legs of the plurality of bar conductors that are housed in the plurality of slots, forming at least one radial containment wall for the first and second legs.
B23P 19/00 - Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformationTools or devices therefor so far as not provided for in other classes
H02K 15/06 - Embedding prefabricated windings in the machines
B23P 19/02 - Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformationTools or devices therefor so far as not provided for in other classes for connecting objects by press fit or for detaching same
B60L 15/20 - Methods, circuits or devices for controlling the propulsion of electrically-propelled vehicles, e.g. their traction-motor speed, to achieve a desired performanceAdaptation of control equipment on electrically-propelled vehicles for remote actuation from a stationary place, from alternative parts of the vehicle or from alternative vehicles of the same vehicle train for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
19.
Device and method for bending hairpin winding heads
A device for modeling hairpins promoting insertion of winding sets of the hairpins on a stator or rotor to allow an increased filling of the slot space in an assembly of winding sets on the stator or rotor is provided. Application relates to electric stators or rotors, and any device using electric wires having any gauge.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
B21D 7/024 - Bending rods, profiles, or tubes over a stationary forming memberBending rods, profiles, or tubes by use of a swinging forming member or abutment by a swinging forming member
B21D 39/04 - Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by platingTube expanders of tubes with tubesApplication of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by platingTube expanders of tubes with rods
B60K 6/26 - Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the motors or the generators
H02K 3/28 - Layout of windings or of connections between windings
20.
Apparatus and method for pre-assembling winding sets of a winding bar for electric machine stator or rotor
An apparatus for pre-assembling a winding for an electric machine stator or rotor includes a plurality of hairpins with two legs having non-circular cross-section, a ring including a plurality of slots and an outer containment ring acting in containment along the perimeter of the ring. An inner cam block and an outer cam block, surrounding and radially facing the inner cam block, are arranged opposite to the exit face of the ring. The cams are adapted to be crossed, in use, by the two legs when they cross the ring at the same time; the cams open into a free circular space between the two cam blocks. A method for pre-assembling a winding set for an electric machine stator or rotor is also provided. Hairpins are inserted in sequence in the slots of the apparatus. A finished winding set positioned in the free circular space is obtained by successive rotations of the ring.
H02K 15/06 - Embedding prefabricated windings in the machines
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
21.
Machine and method for processing a continuous semi-processed product
a) configured to adjust the position of the processing unit along the feed direction (A) of the semi-processed product (W), and a control system (40) configured to read input instructions relating to a series of consecutive segments to be produced, determine the required position of the processing unit (21, 22, 23) as a function of the input instructions, and determine the required feed step as a function of the input instructions.
A switching device for an electric motor (100) provided with a plurality of phases (104, 105, 106) comprises a fixed body (2) equipped with a plurality of connection portions (3) and at least one moveable body (5, 10) that can be moved with respect to the fixed body (2) between at least a first position, in which the phases (104, 105, 106) are arranged in a first electrical configuration, and a second position, in which the phases (104, 105, 106) are arranged in a second electrical configuration. The second electrical configuration is separate from the first one due to the connection between the phase fractions (107, 108) within each phase (104, 105) and/or due to the reciprocal connection between the phases (104, 105, 106).
An apparatus (200) for deforming conductors of at least one winding assembly (100), protruding from a side of a stator or of a rotor (114) of an electric machine. The at least one winding assembly (100) comprises a plurality of basic conductors (102) comprising at least one leg inserted into cavities (115) of stator or rotor (114), each having at least one respective free or terminal end (108, 110). The apparatus (200) comprises at least one twisting matrix (202, 203) adapted to rotate about an axis (X), comprising at least one gripping element (204) adapted to grip at least one free end (108, 110) and adapted to be moved in radial direction with respect to said axis (X). The apparatus comprises at least one guide (206, 207) adapted to guide the at least one gripping element (204) along the radial direction with respect to the axis (X); and a radial actuator (208), adapted to put in motion the at least one gripping element (204) along the radial direction with respect to the axis (X).
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
24.
DEVICE AND METHOD FOR BENDING HAIRPIN WINDING HEADS
The invention relates to a device designed in order to model hairpins so as to promote the insertion of winding sets of such hairpins on a stator or rotor so as to allow an increased filling of the slot space in the assembly of winding sets on such a stator or rotor. The application of this forming not only relates to electric stators or rotors, but to any device using electric wires having any gauge.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
25.
ASSEMBLY AND METHOD OF ASSEMBLAGE FOR A WINDING GROUP OF A BAR WINDING FOR AN ELECTRIC MACHINE
An assembly for assembling at least one winding group of a bar winding for an electric machine, said winding group (2) comprising a plurality of bar conductors (4), each bar conductor (4) of said plurality of bar conductors (4) comprising a first leg (6), a second leg (8) and a bridge portion (10) connecting said first leg (6) and said second leg (8) to each other, each of said bar conductors being shaped so that the respective legs (6, 8) are mutually spread by a predetermined distance; - said assembly comprises an annular fixture (12) delimiting a plurality of slots, each slot (16) being adapted to receive at least one portion of either said first leg (6) or said second leg (8), said assembly comprises at least one guiding device (28) which defines an annular containment housing (30), adapted to receive at least partially the legs (6, 8) of said plurality of legs (6,8) of said plurality of bar conductors (4) when they are housed in said plurality of slots (16, 16', 16"), forming at least one radial containment wall (39, 40) for said legs (6, 8).
The present invention relates to an apparatus (200) for pre-assembling a winding for electric machine stator or rotor which includes a plurality of hairpins (255) with two legs (255a, 255b) having non-circular cross- section. It comprises a ring (220,230), including a plurality of slots (222,232), as well as an outer containment ring (210) acting in containment along the perimeter of the ring (220,230). Furthermore, an inner cam block (270) and an outer cam block (280), surrounding and radially facing the inner cam block (270), are arranged opposite to the exit face of said ring (220.230). The cams are adapted to be crossed, in use, by said two legs (255a, 255b) when they cross said ring (220.230) at the same time; the cams opens into a free circular space (295) between the two cam blocks. The invention also relates to a method of pre-assembling a winding set (290) for electric machine stator or rotor, in which the hairpins are inserted in sequence in the slots of the apparatus (200), and successive rotations of the ring (220,230) are made to obtain the finished winding set (290) positioned in the free circular space.
A process for making a continuous bar winding (4) for an electric machine is described, comprising: a) a step of providing a template (10) having a template axis (X) and a circular array of slots (11) extended about said template axis (X), said circular array of slots having a number of slots equal to a number of slots of the stator or of the rotor of said electric machine, each slot (11) of said circular array having a first and a second open end face (11A, 11B) which are axially spaced from one another and a third open end face (11C), said third face (11C) being a longitudinal face extended between said first and second end faces (11A, 11B) b) a step of providing a conductive bar (20); c) a step of locking a locking portion (21) of said conductive bar; d) a step of inserting the conductive bar (20) into the slots (11) of said array and shaping the conductive bar (20) so that such conductive bar (20) repeatedly passes through the slots (11) of said array from the side of the first open end faces (11A) to the side of the second open end faces (11B) and vice versa, so that said bar (20) has a plurality of bar portions (20B, 20E, 20H) received in the slots (11) of said array and a plurality of connecting portions (20C, 20D; 20F, 20G) projecting beyond said first and second open end faces (11A, 11B), each of said connecting portions joining a pair of said bar portions (20B, 20E, 20H) received in the slots (11) of said array; in which said step d) comprises: d1) an operation of inserting a first bar portion (20B) of said plurality of bar portions into a respective slot (11) of said circular array of slots (11) through said third face (11C) of such slot (11); d2 ) an operation of shaping a first connecting portion (20C, 20D) of said plurality of connecting portions (20C, 20D; 20F, 20G); d3) an operation of inserting a second bar portion (20E) of said plurality of bar portions (20B, 20E, 20H) into a further slot (11) of said array, different from the slot (11) into which said first bar portion (20B) has been inserted, through said third face (11C) of the further slot (11); in which said first connecting portion (20C, 20D) joins said first and second bar portions (20B, 20E) projecting beyond the second end faces (11B) of the slots (11) in which said first and second bar portions (20B, 20E) have been inserted.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
28.
MACHINE AND METHOD FOR PROCESSING A CONTINUOUS SEMI-PROCESSED PRODUCT
A machine for processing a continuous semi- processed product (W), comprising a feeding unit (10), a processing unit (21, 22, 23), and a terminal cutting unit (30) past which processed segments (M) of the semi-processed product (W) are producible, which width (LI, L2, L3) is correlated to the feed step. The feeding unit (10) is automatically adjustable in the feed step. The machine further comprises actuators (21a, 22a, 23a) configured to adjust the position of the processing unit along the feed direction (A) of the semi-processed product (W), and a control system (40) configured to read input instructions relating to a series of consecutive segments to be produced, determine the required position of the processing unit (21, 22, 23) as a function of the input instructions, and determine the required feed step as a function of the input instructions.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
The present invention describes a rotor (3) for a switched (1) or assisted reluctance electric machine comprising a rotation axis (XI) and a section of rotor having a radially external edge (33), said section of rotor including a plurality of groups of flux barriers distributed around said rotation axis (XI), each group of flux barriers comprising a plurality of flux barriers (19-22) which are separate from one another in the radial direction and each of which has a barrier end (29-32), the rotor (3) comprising a plurality of peripheral bridges (25-28) each of which is defined between one of said barrier ends (29-32) and the radially external edge (33) of the section of the rotor (3), said peripheral bridges (25-28) having a variable width.
A reluctance electric machine (1) is described comprising a stator (2) including a stator winding (6) and a rotor (3) coaxial with the stator (2) and having a rotation axis (XI). The reluctance electric machine is characterised in that the stator winding (6) comprises a bar winding (6) including a plurality of bar conductors.
The present technology contemplates a stator or rotor of an electric machine comprising a main cylindrical body with a circular array of slots; at least one bar winding comprising a first and second plurality of basic conductors and a second plurality of special conductors. The first and second circular array comprise a first and second arc of legs of the first and second set of said conductors which are inserted as well as legs of the conductors. The present technology also contemplates electric machines and electric or hybrid drive vehicles comprising such stators of rotors.
H02K 3/28 - Layout of windings or of connections between windings
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
32.
Method and fixture for twisting end portions of bar conductors, in particular for bar windings of electric machines
A twisting method is described, for twisting free end portions of bar conductors for the stator or rotor bar winding of an electrical machine. The twisting method allows achieving a non uniform twisting of the bar conductors from the welding side of the stator or rotor core by means of a twisting fixture. The twisting fixture comprises a pocket member including a main structure provided with an arc of adjacent pockets and a secondary structure, provided with at least one further pocket, which can axially translate with respect to the main structure.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
A stator for an electric machine includes a stator core having a first and a second face and a circular row of stator slots extended between said faces and which are distributed around a stator axis; and, a winding bar comprising a plurality of basic conductors and a plurality of special conductors interconnected with one another to form the bar winding. The basic conductors each comprise two basic conductor legs and a connecting portion of basic conductor between said legs. The basic conductors are inserted into the stator slots with the free end portions protruding from said second face. The special conductors comprise a jumper of a first type having a first and a second leg of jumpers connected respectively to two of said free end portions, and one jumper connection portion between said legs of jumpers.
driving the first and the second body in relative rotation around said axis until a second insertion configuration is reached in which a second plurality of pockets of the first and second body of said residual subset are radially aligned with each other.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
H02K 3/28 - Layout of windings or of connections between windings
H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
35.
Method for twisting end portions of bar conductors, in particular for bar windings of electric machines
A twisting method is described, for twisting free end portions of bar conductors for the stator or rotor bar winding of an electrical machine. The twisting method allows achieving a non uniform twisting of the bar conductors from the welding side of the stator or rotor core by means of a twisting fixture. The twisting fixture comprises a pocket member including a main structure provided with an arc of adjacent pockets and a secondary structure, provided with at least one further pocket, which can axially translate with respect to the main structure.
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
36.
Apparatus for twisting electrical bar conductors, in particular for bar windings of electrical machines, with conductor's clamping system
A twisting apparatus (30) of preformed bar conductors (25) for bar windings of electric machines comprising a twisting device (50) having at least a first (51) and a second body (52) coaxial to one another and extending around a twisting axis (Zt-Zt) defining an axial direction and respectively comprising a first (A1) and a second (A2) circular array of pockets. The twisting device (50) comprises a system for clamping bar conductors comprising at least one sliding clamping element (72, 92) movable in a radial direction with respect to the axial direction (Zt-Zt) to take up an advanced operative position in which it has an end portion (73, 74, 93, 94) that projects inside an associated pocket and a set-back operating position.
An apparatus for inserting a preformed electrical bar conductor into a twisting device of the conductor, the apparatus comprising: a supply device that arranges the preformed bar conductor into a supply direction (X-X), the preformed bar conductor having two rectilinear arms that are parallel to each other and connected to each other by a curved portion; a transfer device that draws the conductor from the supply device into a grip position in which the conductor is arranged along the supply direction (X-X) and rotates it 90 degrees into an insertion position in which the conductor is arranged along an insertion direction (Y-Y), perpendicular to the supply direction (X-X) and parallel to a pocket on the twisting device; and an insertion device that inserts the conductor into the twisting device, the insertion device equipped with thrust means that move the conductor along the insertion direction (Y-Y) until the conductor is at least partially inserted in the pocket.
B23P 19/00 - Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformationTools or devices therefor so far as not provided for in other classes
B65H 1/00 - Supports or magazines for piles from which articles are to be separated
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
H02K 15/06 - Embedding prefabricated windings in the machines
38.
Methods and apparatus for twisting rotor and stator conductor ends
Methods and apparatus for twisting rectangular rotor and stator conductor ends whereby most if not all conductor ends are bent at once, radially adjacent ends being bent in opposite directions. A lost motion member may be used to bend selected conductors through lesser angles for such purposes as phase interconnection and power leads. The rectangular conductors are retained against twisting so that flat conductors will bend about an axis perpendicular to the larger dimension of the conductor cross section. Various features of the methods and apparatus are disclosed.
H02K 15/085 - Forming windings by laying conductors into or around core parts by laying conductors into slotted stators
H02K 15/09 - Forming windings by laying conductors into or around core parts by laying conductors into slotted rotors
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
39.
Clamping system of special conductors for a stator or rotor bar winding for an electric machine
It is described a clamping system (30) of special conductors (S1, S2, S3) for a stator or rotor bar winding (U1, S1, S2, S3) for an electric machine, such as connection terminals (S1), jumpers (S2), neutrals or star points (S3), etc. The system (30) allows the special conductors (S1, S2, S3) to be clamped during a twisting step and/or a step of picking up such conductors from a twisting device (250). The system comprises a system axis (T-T), a plurality of grippers (10) aligned or able to be aligned along a circumference lying on a plane substantially perpendicular to the system axis (T-T) and actuation elements (50, 60, 70, 80, 90) of the grippers (10). Each gripper includes a pair of jaws (32, 33) mounted so as to be mobile in a plane transversal to said system axis (T-T).
Stripping apparatus (4) for an electrical bar conductor (8) having a metal core with two longer sides (12) and two shorter sides (16) coated with an electrically insulating coating (20). The apparatus (4) comprises a first stripping portion (24) that at least partly houses the conductor (8) arranged along a prevailing extension (X-X), so as to rest on one of said longer sides (12) cantilevered relative to a pair of supports (28). The first stripping station (24) houses a first pair of broaches (40), opposite to one another and arranged at opposite sides relative to the conductor (8), said broaches (40) being axially movable relative to a cross working direction (Y-Y) perpendicular to the prevailing extension (X-X). The broaches (40) are aligned with said stripping portion (36) relative to the prevailing extension (X-X), so as to carry out the removal of the insulating coating (20) at the stripping portion (36) comprised cantilevered between the supports (28).
B23P 23/00 - Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass
41.
Twisting device adapted to simultaneously twist a plurality of electric bar conductors for making a stator or rotor winding for an electric machine and an extractor assembly suitable for cooperating with said twisting device
A twisting device (10) is described adapted to simultaneously twist a plurality of bar electric conductors (11) for making a stator or rotor winding for an electric machine, comprising: at least one first body (12) extending around a twisting axis (Z-Z) and comprising a first circular array of channels (15) having center on such an axis (Z-Z); and—at least one second body (13), extending around and coaxial with the first body (12), comprising a second circular array of channels (16) with center on the twisting axis (Z-Z); associated with each of the channels (15) of at least one of said first and second arrays, a channel extension groove (15A) extending longitudinally in a direction parallel to the twisting axis (Z-Z) and projecting from the respective channel (15) in a direction (CC) circumferential with respect to said axis (Z-Z).
H02K 15/02 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
42.
Apparatus for pre-forming electrical bar conductors, in particular for bar windings of electrical machines
A pre-forming apparatus (4) for an electrical bar conductor (8), comprising a punch (12) provided with moving members for exerting a thrust on the conductor (8) during the relative pre-forming, the punch (12) being axially sliding along a pre-forming direction (X-X) and being provided with a cursor (20) and with a pre-forming head (24) suitable for engaging with the conductor (8). The apparatus (4) comprises a first pre-forming chamber (44) suitable for being crossed by the conductor (8) and by the punch (12) during the forward movement of the punch (12) for the pre-forming operation.
B23P 19/00 - Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformationTools or devices therefor so far as not provided for in other classes
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
There is described a stator (1) for an electric machine comprising: a stator core (2) having a first and a second face opposite to one another (3, 4) and a circular array of stator slots (5) extending between said faces (3, 4) and that are distributed around a stator axis (Z-Z); and a bar winding (10) comprising a plurality of basic conductors (11) and a plurality of special conductors (12, 13, 14, 15, 16, 17) interconnected to one another for forming the bar winding (10). Each basic conductor (11) comprises two basic conductor legs (11A, 11B) and a basic conductor connecting portion (11C) between said legs (11A, 11B). Each basic conductor leg (11A, 11B) has an end portion connected to the basic conductor connecting portion (11C) and an opposite free end portion (11F). The basic conductors (11) are inserted into the stator slots (5) with the free end portions (11F) protruding from said second face (4). The free end portions (11F) define a plurality of circular conductor layers (LI, L2, L3, L4) concentric to one another comprising a radially outer circular end layer (LI) and a radially inner circular end layer (L4). The special conductors (12, 13, 14, 15, 16, 17) comprise a jumper (12; 13) of a first type having a first and a second jumper arm (12A, 12B; 13A, 13B) respectively connected to two of said free end portions (11F), and a jumper jointing portion (12C; 13C) between said jumper arms (12A, 12B; 13A, 13B). The stator (1) is characterised in that the jumper of said first type (12; 13) is arranged so that: the two' free end portions (11F) whereto the first and the second jumper arm (12A, 12B; 13A, 13B) are connected respectively belong to two of said conductor layers (LI, L2, L3, L4) separate from one another; the jumper jointing portion (12C; 13C) extends radially outer relative to the radially outer end layer (LI), or radially inner relative to the radially inner end layer (L4), for passing around at least one of the free end portions (11F) respectively of the radially outer end layer (LI) or of the radially inner end layer (L4); and at least one between the first and the second jumper arm (12A, 12B; 13A, 13B) extends in a respective passage defined in said conductor layers (LI, L2, L3, L4) for connecting to the respective free end portion (11F).
A method (20) is described for making a stator (1) of an electric machine, the stator comprising a stator core (2), the stator core comprising a main body and a plurality of slots (8) which are axially extended inside the main body and are adapted to receive bar conductors. (5, 5′, 5″) of a bar stator winding. The method (20) comprises the steps of : inserting (23) at least one preshaped insulating sheet (10) inside at least one of said slots (8); hot shaping (26) said preshaped insulating sheet (10) inside the slot, along the entire axial extension of the slot (8) or along a substantial portion thereof, in order to confer form regularity and stability to said preshaped insulating sheet (10). Through the described process, it is possible to make stators with bar winding having a stator core with relatively high height and slot fill factor.
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
H02K 3/34 - Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
H02K 15/10 - Applying solid insulation to windings, stators or rotors, e.g. applying insulating tapes
H02K 15/12 - Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines
45.
Apparatus and method for making pre-shaped insulating sheets intended to be inserted into stator or rotor slots
Apparatus (30) for making pre-shaped insulating sheets (10) for use in a stator or in a rotor comprising shaping elements (40-44) such to produce, starting from a continuous strip (15) made of electrically insulating material having a flat or substantially flat cross section, a strip portion having a cross section comprising a central septum (20) and two lateral portions (21-23, 21′-23′) joined to a respective end portion of the central septum (20), each of the lateral portions comprising a first section (21,21′) joined to the central septum (20), a second section (22,22′) joined and perpendicular, or essentially perpendicular, to the first section (21,21′), a third section (23, 23′) joined to the second section (22,22′) and inclined with respect to the latter towards the central septum (20). The apparatus (30) further comprises a pair of opposite rollers (46,47) having a transverse shaping profile comprising a projecting appendage (56, 57) suitable to be interfaced having a respective portion of the strip (15) facing the central septum (20) and operatively interposable between the central septum (20) and the third inclined section (23,23′).
B65H 35/00 - Delivering articles from cutting or line-perforating machinesArticle or web delivery apparatus incorporating cutting or line-perforating devices, e.g. adhesive tape dispensers
H02K 3/34 - Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
46.
METHOD AND FIXTURE FOR TWISTING END PORTIONS OF BAR CONDUCTORS, IN PARTICULAR FOR BAR WINDINGS OF ELECTRIC MACHINES
A twisting method (100) and a twisting fixture (10) is described, for twisting free end portions (2A, 3A, 2A', 3A') of bar conductors (1, 1') for the stator or rotor bar winding of an electrical machine which comprises The twisting fixture (10) comprises at least a pocket member (11) including a main structure (11A) provided with an arc (R1) of adjacent pockets (11A') and a secondary structure (11B) comprising further pockets (11B') and which is axially movably mounted with respect to main structure (11A). Some but not all of free ends (2A, 3A, 2A', 3A') of bar conductors are arranged in said adjacent pockets (11A'). The main structure is then rotated to twist said free ends (2A, 3A, 2A', 3A') partly. Then the secondary structure (11B) is axially moved such that the remaining free ends (2A, 3A, 2A', 3A') of bar conductors are inserted in the pockets (11b') therein. Thereafter both the main structure (11A) and the secondary structure (11B) are rotated simultaneously to twist all free ends (2A, 2A') further.
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
47.
APPARATUS FOR TWISTING ELECTRICAL BAR CONDUCTORS, IN PARTICULAR FOR BAR WINDINGS OF ELECTRICAL MACHINES, WITH CONDUCTOR' S CLAMPING SYSTEM
A twisting apparatus (30) of preformed bar conductors (25) for bar windings of electric machines is described, each of said conductors (25) comprising one or more legs (5), the twisting apparatus (30) comprising a twisting device (50) having at least a first (51) and a second body (52) coaxial to one another and extending around a twisting axis (Zt-Zt) defining an axial direction and respectively comprising a first (Al) and a second (A2) circular array of pockets with centre on such an axis (Zt-Zt), the pockets being suitable for receiving legs (5) of the preformed bar conductors, the bodies (51, 52) being rotatable relative to one another around the twisting axis. The twisting device (50) comprises a system for clamping bar conductors comprising at least one sliding clamping element (72, 92) movable in a radial direction with respect to the axial direction (Zt-Zt) to take up an advanced operative position in which it has an end portion (73, 74, 93, 94) that projects inside an associated pocket and a set-back operating position, the advanced and set-back operative positions corresponding respectively to an operative state clamping the conductor and to an operative state releasing the conductor.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
48.
"CLAMPING SYSTEM OF SPECIAL CONDUCTORS FOR A STATOR OR ROTOR BAR WINDING FOR AN ELECTRIC MACHINE"
It is described a clamping system (30) of special conductors (S1, S2, S3) for a stator or rotor bar winding (U1, S1, S2, S3) for an electric machine, such as connection terminals (S1), jumpers (S2), neutrals or star points (S3), etc. The system (30) allows the special conductors (S1, S2, S3) to be clamped during a twisting step and/or a step of picking up such conductors from a twisting device (250). The system comprises a system axis (T-T), a plurality of grippers (10) aligned or able to be aligned along a circumference lying on a plane substantially perpendicular to the system axis (T-T) and actuation elements (50, 60, 70, 80, 90) of the grippers (10). Each gripper includes a pair of jaws (32, 33) mounted so as to be mobile in a plane transversal to said system axis (T-T).
H02K 15/06 - Embedding prefabricated windings in the machines
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
49.
"APPARATUS AND METHOD FOR INSERTING PREFORMED ELECTRICAL BAR CONDUCTORS IN A TWISTING DEVICE"
An apparatus (4) for inserting preformed electrical bar conductors (8) into an associable twisting device (12), comprising a supply device (28) of conductors (8), which are bent in a manner so as to have two substantially- rectilinear arms (16), parallel to each other, connected to each other by a curved portion (20), said electrical bar conductors (8) being arranged according to a supply direction (X-X). The apparatus (4) also comprises a transfer device (32) which draws a conductor (8) from the supply device (28) and rotates it 90 degrees into an insertion position in which it is arranged according to an insertion direction (Y-Y), perpendicular to said supply direction (X-X) and parallel to pockets (24) of an associable twisting device (12) of the conductors (8). The apparatus (4) comprises a device (36) for inserting the conductor (8) into the twisting device (12), equipped with thrust means (40) which translate the conductor (8) along the insertion direction (Y-Y) until it is at least partially inserted into said pockets (24).
H02K 15/06 - Embedding prefabricated windings in the machines
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
50.
METHOD AND APPARATUS FOR TWISTING BAR CONDUCTORS, IN PARTICULAR FOR BAR WINDINGS OF ELECTRIC MACHINES
A method (100) is described for twisting preformed bar conductors (25) of electric machines, said conductors (25) comprising a first and a second leg (5) joined together by a connection portion (15). The method (100) comprises the steps of: a) providing (101) a twisting apparatus (30) comprising a twisting device (50) having at least a first (51) and a second body (52) coaxial with each other and extended around a twisting axis (Zt-Zt), respectively comprising a first Al and a second A2 circular array of pockets with center on such axis (Z-Z), b) loading (102), in a subset of said pockets, a first plurality of said preformed conductors (25) the loading step (102) being such to leave a1 first residual subset of pockets free; c) driving (103) the first (51) and the second (52) body in relative rotation around said axis (Zt-Zt), in order to distance such legs (5) from each other by a first pre-established twisting pitch; d) loading (104), in a second subset of said second plurality of pockets, a second plurality of preformed conductors (25; e) driving (106) the first (51) and the second (52) body in relative rotation around said axis (Zt - Zt), in order to distance the legs (5) of the conductors of the second plurality of conductors from each other by a second pre-established twisting pitch and to further distance the legs of the second plurality of conductors from each other by said second pre-established twisting pitch.
H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
H02K 3/28 - Layout of windings or of connections between windings
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
51.
APPARATUS AND METHOD FOR STRIPPING ELECTRICAL BAR CONDUCTORS, IN PARTICULAR FOR BAR WINDINGS OF ELECTRICAL MACHINES
Stripping apparatus (4) for an electrical bar conductor (8) having a metal core with two longer sides (12) and two shorter sides (16) coated with an electrically insulating coating (20). The apparatus (4) comprises a first stripping portion (24) that at least partly houses the conductor (8) arranged along a prevailing extension (X-X), so as to rest on one of said longer sides (12) cantilevered relative to a pair of supports (28). The first stripping station (24) houses a first pair of broaches (40), opposite to one another and arranged at opposite sides relative to the conductor (8), said broaches (40) being axially movable relative to a cross working direction (Y-Y) perpendicular to the prevailing extension (X-X). The broaches (40) are aligned with said stripping portion (36) relative to the prevailing extension (X-X), so as to carry out the removal of the insulating coating (20) at the stripping portion (36) comprised cantilevered between the supports (28).
H02G 1/12 - Methods or apparatus specially adapted for installing, maintaining, repairing, or dismantling electric cables or lines for removing insulation or armouring from cables, e.g. from the end thereof
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
52.
TWISTING DEVICE ADAPTED TO SIMULTANEOUSLY TWIST A PLURALITY OF ELECTRIC BAR CONDUCTORS FOR MAKING A STATOR OR ROTOR WINDING FOR AN ELECTRIC MACHINE AND AN EXTRACTOR ASSEMBLY SUITABLE FOR COOPERATING WITH SAID TWISTING DEVICE
A twisting device (10) is described adapted to simultaneously twist a plurality of bar electric conductors (11) for making a stator or rotor winding for an electric machine, comprising: at least one first body (12) extending around a twisting axis (Z-Z) and comprising a first circular array of channels (15) having centre on such an axis (Z-Z); and - at least one second body (13), extending around and coaxial with the first body (12), comprising a second circular array of channels (16) with centre on the twisting axis (Z-Z); associated with each of the channels (15) of at least one of said first and second arrays, a channel extension groove (15A) extending longitudinally in a direction parallel to the twisting axis (Z-Z) and projecting from the respective channel (15) in a direction (CC) circumferential with respect to said axis (Z-Z).
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
53.
APPARATUS AND METHOD FOR PRE-FORMING ELECTRICAL BAR CONDUCTORS, IN PARTICULAR FOR BAR WINDINGS OF ELECTRICAL MACHINES
A pre-forming apparatus (4) for an electrical bar conductor (8), comprising a punch (12) provided with moving members for exerting a thrust on the conductor (8) during the relative pre-forming, the punch (12) being axially sliding along a pre-forming direction (X-X) and being provided with a cursor (20) and with a pre-forming head (24) suitable for engaging with the conductor (8). The apparatus (4) comprises a first pre-forming chamber (44) suitable for being crossed by the conductor (8) and by the punch (12) during the forward movement of the punch (12) for the pre-forming operation.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
54.
APPARATUS AND METHOD FOR MAKING PRE-SHAPED INSULATING SHEETS INTENDED TO BE INSERTED INTO STATOR OR ROTOR SLOTS
Apparatus (30) for making pre-shaped insulating sheets (10) for use in a stator or in a rotor comprising shaping elements (40-44) such to produce, starting from a continuous strip (15) made of electrically insulating material having a flat or substantially flat cross section, a strip portion having a cross section comprising a central septum (20) and two lateral portions (21-23, 21' -23' ) joined to a respective end portion of the central septum (20), each of the lateral portions comprising a first section (21,21') joined to the central septum (20), a second section (22,22') joined and perpendicular, or essentially perpendicular, to the first section (21,21'), a third section (23, 23') joined to the second section (22,22') and inclined with respect to the latter towards the central septum (20). The apparatus (30) further comprises a pair of opposite rollers (46,47) having a transverse shaping profile comprising a projecting appendage (56, 57) suitable to be interfaced having a respective portion of the strip (15) facing the central septum (20) and operatively interposable between the central septum (20) and the third inclined section (23,23').
H02K 3/34 - Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
H02K 15/10 - Applying solid insulation to windings, stators or rotors, e.g. applying insulating tapes
B29C 53/04 - Bending or folding of plates or sheets
55.
METHOD AND APPARATUS FOR MAKING A STATOR FOR AN ELECTRIC MACHINE AND ELECTRIC MACHINE STATOR WITH HIGH FILL FACTOR
A method (20) is described for making a stator (1) of an electric machine, the stator comprising a stator core (2), the stator core comprising a main body and a plurality of slots (8) which are axially extended inside the main body and are adapted to receive bar conductors. (5, 5', 5'') of a bar stator winding. The method (20) comprises the steps of : - inserting (23) at least one preshaped insulating sheet (10) inside at least one of said slots (8); - hot shaping (26) said preshaped insulating sheet (10) inside the slot, along the entire axial extension of the slot (8) or along a substantial portion thereof, in order to confer form regularity and stability to said preshaped insulating sheet (10). Through the described process, it is possible to make stators with bar winding having a stator core with relatively high height and slot fill factor.
H02K 3/34 - Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
H02K 15/12 - Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines
56.
Methods for forming female connectors integral with the stator winding conductors
Methods for forming female connectors integral with stator winding conductors, thereby avoiding the necessity of using a separate female connector. A typical connector in accordance with the present invention has a first length of the wire adjacent an end of the wire striped of insulation, and a second length of the wire adjacent the end not greater than the first length of wire being bent in a substantially closed loop, the loop preferably being pressed flat so as to have a thickness less than the wire. Also preferably the wire bends in a first direction and then bends in a circular arc to form the loop, the center of the loop being substantially aligned with a center of the wire. Various embodiments are disclosed as are exemplary simple methods for forming the female connector.
Methods and apparatus for twisting rectangular rotor and stator conductor ends whereby most if not all conductor ends are bent at once, radially adjacent ends being bent in opposite directions. A lost motion member may be used to bend selected conductors through lesser angles for such purposes as phase interconnection and power leads. The rectangular conductors are retained against twisting so that flat conductors will bend about an axis perpendicular to the larger dimension of the conductor cross section. Various features of the methods and apparatus are disclosed.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
58.
Method for inserting of preformed hairpin conductors into a rotor or stator
Method and apparatus for insertion of preformed rotor and stator conductors into a twisting machine for forming hairpin shaped conductors of rectangular wire into stator conductors. The method comprises providing a forming fixture having a plurality of pockets distributed in equal number in an even number of adjacent circles concentric with a center of the forming fixture, receiving hairpin conductors positioned side by side from a feeder and feeding the hairpins, one by one, into a hairpin insertion assembly oriented above the forming fixture so that the legs are side by side along a line passing through the center and disposed adjacent a pair of pockets in first and second adjacent circles, and with the forming fixture angularly indexed relative to the hairpin insertion assembly, pushing a hairpin conductor down so that the legs thereof extend into a respective pair of pockets, and indexing the forming fixture about the center to align an additional pair of pockets with a hairpin in the hairpin insertion assembly and repeating until the forming fixture is substantially populated with hairpin conductors.
H02K 15/00 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
H01R 43/04 - Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
59.
Method for removing winding conductors from a twisting machine and placing them in a rotor stator stack
Method for removing winding conductors from a twisting machine and placing them in a rotor or stator stack. For a plurality of rectangular winding conductors each having a pair of legs separated by an amount equal to the distance between a predetermined number of rotor or stator slots in which they will be inserted, moving a plurality of fingers of a clamping assembly between the legs of a plurality of winding conductors in a twisting fixture to retain the winding conductors, moving the clamping assembly away from the twisting fixture to withdraw the winding conductors from the twisting fixture, providing relative movement of the clamping assembly and a rotor or stator to insert free ends of the winding conductors into a rotor or stator, and moving the fingers of a clamping assembly from between the legs of a plurality of winding conductors. A preferred embodiment of the method is disclosed.
Method and apparatus for forming motor winding conductors rectangular conductor wire. The method comprises populating with hairpin shaped conductors, most of a forming fixture having a plurality of pockets distributed in equal number in one or more pairs of adjacent circles, each concentric with a center of the forming fixture, at least one member defining each of the pockets in one of each pair of adjacent circles being rotatable, at least through a limited angle, with respect to a member defining the pockets in the other of the respective pair of adjacent circles, the hairpin conductors each having first and second legs integrally joined by a loop at one end thereof, with one leg of each hairpin conductor in a respective one of the pockets in a pair of adjacent circles, and rotating in a first direction, relative to each other, the members defining the pockets in each pair of circles through a predetermined angle, to permanently separate the two legs of each hairpin conductor without substantial rotation of each leg of the hairpin conductors relative to its respective pocket. Various additional features are disclosed.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
61.
Method for pre-forming conductors for motor rotors and stators
Method and apparatus for pre-forming insulated conductors for motor rotors and stators for use in a next process in forming motor rotors and stators. In accordance with the full exemplary process, insulated rectangular cross-section wire is received from a spool, straightened, stripped over a predetermined length, fed to a bender, cut to length and then bent into the desired hairpin shape and placed on a feeder for the next process. The method and apparatus may be fully automatic, including automatically adjusting itself as required to make hairpin shaped conductors of different lengths, each length having its free ends stripped over a desired length. The method and apparatus for bending, as well as other methods and apparatus disclosed, may be used alone or in other combinations.
H01R 43/00 - Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
patents
