The present invention relates to an apparatus and a method for manufacturing coil members for insertion into slots of the core of a dynamo-electric machine.
In the field of dynamo-electric machines, it is known to use apparatuses and methods for manufacturing coil members to be housed in respective slots formed in the cores of such machines.
Coil members can be used in stators of electric motors or electric generators. In this respect, a number of solutions have been disclosed in International Patent Application No. WO 2012/156066.
Coil members made in accordance with the present invention may have a fork-like shape or other shapes as well, e.g. they may have an undulated configuration. Generally, the electric conductor has a relatively large cross-section, which permits the formed coil member to be self-supporting, i.e. the shape of the coil member is permanently formed according to a specific geometric configuration, which will not change unless considerable bending forces are applied thereto. Fork-shaped coil members are commonly called “hairpins” in the industry. Another shape, i.e. the undulated configuration, is described in European Patent Publication EP 1 372 242.
A typical production sequence involving formed hairpins may envisage the following: inserting specific hairpins into respective slots of the core of the dynamo-electric machine, bending the end portions of the hairpins that extend beyond an end of the core of the dynamo-electric machine, welding together predetermined hairpin ends that have become adjacent to each other as a result of the previous bending operation. International Patent Application WO 2012/119691 describes operations of this kind and solutions to ensure an accurate alignment of the hairpin ends that need to be welded together.
The bending necessary for making a coil member requires repeated steps of feeding predetermined lengths of an electric conductor in alignment with a bending tool, as described in the above-mentioned International Patent Application WO 2012/156066.
During the feeding steps, a bending tool engages the electric conductor and makes some predetermined movements to cause the electric conductor to be permanently bent into a desired shape.
A cutting operations is carried out in order to remove a formed coil member from the rest of the electric conductor, so that such electric conductor can subsequently be fed for making other coil members. International Patent Application WO 2012/156066 describes operations carried out in accordance with these principles.
Furthermore, an apparatus and a method for manufacturing coil members of the above-specified type are also described in International Patent Application WO 2015/132180.
It is one object of the present invention to provide an apparatus and a method for manufacturing coil members for insertion into slots of the core of a dynamo-electric machine, which are an improvement over the prior art.
In particular, according to the present invention, higher accuracy and repeatability are attained in the bending of the conductor.
According to the present invention, this and other objects are achieved through an apparatus and a method having the technical features set out in the appended independent claims.
It is understood that the appended claims are an integral part of the technical teachings provided in the following detailed description of the present invention. In particular, the appended dependent claims define some preferred embodiments of the present invention that include some optional technical features.
Further features and advantages of the present invention will become apparent in light of the following detailed description, provided merely as a non-limiting example and referring, in particular, to the annexed drawings as summarized below.
With particular reference to
The coil member (not numbered) of
With particular reference to
The apparatus comprises feeding means of a per se known type, which are configured for feeding portions of conductor 300 having a predetermined length through an aperture 80. One example of such feeding means has been described in International Patent Application WO 2012/156066, the description of which should be considered as incorporated herein by reference. In such International patent application, the feeding means are provided in the form of a pair of motorized belts pressing on conductor 300 and, by friction, applying a pull/thrust force to conductor 300. A further example of such feeding means has been described in International Patent Application WO 2018/092022, the description of which should be considered as incorporated herein by reference. With reference to
With particular reference to
Furthermore, the apparatus comprises moving means, also of a per se known type, configured for moving engagement members 112, 112′ with respect to aperture 80 to engage a portion of conductor 300 with the engagement members in a transverse direction (designated by letters X and X′, represented in
According to the present invention, as will be described more in detail below with particular reference to the two exemplary embodiments illustrated in
Owing to these measures, it is possible to precisely and repeatedly control the engagement between conductor 300 and reaction surface 2. This results in higher accuracy and repeatability of the bending of conductor 300, which is achieved through the action of engagement members 112 and 112′. Moreover, according to a preferred aspect, the accurate control over the engagement between conductor 300 and reaction surface 2 and the consequent programmability of the forces applied to conductor 300 make it possible to use he same apparatus for bending differently sized conductors (e.g. to make the apparatus compatible with conductors having different diameters) and to obtain hairpins having different configurations.
With reference to
Preferably, pressing member 1 is configured to apply a force on conductor 300 in a thrust direction PR substantially transverse to feeding direction 10′ during the bending of the conductor carried out by engagement members 112 and 112′, in order to cause conductor 300 to engage reaction surface 2. More preferably, pressing member 1 is configured for assuming a selectable predetermined position along said thrust direction PR, which is substantially transverse to feeding direction 10′, to apply the force on conductor 300.
Advantageously, but not necessarily, the apparatus further comprises a distribution nozzle 191 axially including, at its end, aperture 80 through which electric conductor 300 is configured to pass. As will be described more in detail hereinafter, in such first embodiment distribution nozzle 191 is mounted movable with respect to a frame 200 (or, more generally, a supporting portion) of the apparatus.
In particular, the apparatus comprises an actuator 5 configured for causing pressing member 1 to move in the substantially transverse thrust direction PR. More particularly, actuator 5 is configured for translatably moving in feeding direction 10′.
Preferably, the apparatus further comprises a transmission mechanism 4 configured for converting a movement of actuator member 5 into a movement of pressing member 1 in the substantially transverse thrust direction PR. In particular, transmission mechanism 4 is configured for converting a translational movement of actuator 5 in thrust direction 10′ into a movement of pressing member 1 in thrust direction PR.
Still with reference to the first embodiment shown in
By way of example, as illustrated in
Preferably, distribution nozzle 191 has a transverse passage 6 through which pressing member 1 can pass. Moreover, in a position facing towards transverse passage 6, distribution nozzle 191 internally carries reaction surface 2, against which conductor 300 is configured to engage under the action of pressing member 1 as the latter passes through transverse passage 6.
In such first illustrative embodiment, with reference to
In particular, with reference to
In the first embodiment, transmission mechanism 4 is a rod - crank mechanism. In particular, transmission mechanism 4 is configured for converting the translational movement imparted by actuator member 5 (and then transferred from connection member 3 to distribution nozzle 191) into a movement, in particular a rotational or oscillating movement, of pressing member 1 in thrust direction PR. Thus, pressing member 1 - and preferably its terminal finger 1a -will move to push conductor 300.
In the first embodiment, said rod - crank mechanism comprises a rod member 4a and a crank member 4b hinged to and co-operating with each other.
Rod member 4a is hinged, on one side, to a frame 200 (or a stationary support portion) of the apparatus and, on the other side, to crank member 4b. In turn, crank member 4b hinged to rod member 4a is rotatably supported around a pivot member 7 carried by distribution nozzle 191.
More in detail, by way of example, the fixed point where rod member 4a is hinged to frame 200 is indicated by reference 8a, while the movable point where rod member 4a is hinged to crank member 4b is indicated by reference 8b. Furthermore, the movable point where crank member 4b is rotatably supported (which can move integrally with pivot member 7 of distribution nozzle 191) is indicated by reference 8c.
In particular, crank member 4b is configured for moving pressing member 1 in thrust direction PR; in particular, pressing member 1 is integral with crank member 4b, being for example carried radially thereon. Pivot member 7 is mounted to distribution nozzle 191, e.g. being a shelf fixed to (in particular, by means of screws) and protruding transversally from distribution nozzle 191.
Preferably, the position of rod member 4a relative to crank member 4b is adjustable, so that the action of pressing member 1 can be adjusted as a function of the bending to which the conductor, fed by distribution nozzle 191, is to be subjected. For example, the adjustability of the position of rod member 4a with respect to crank member 4b is obtained by changing the relative position of mutually sliding portions (e.g. telescopic ones) belonging to the rod member and including the previously described hinge points 8a and 8b.
The following will briefly describe, for completeness’ sake, an operative phase wherein the apparatus according to the first embodiment controls the engagement of conductor 300.
As actuator member 5 translates forward along feeding direction 10′ integrally with pivot member 7 (carried by distribution nozzle 191, which in turn is supported by connection member 3), pressing member 1 moves - by oscillating or rotating - closer to conductor 300 in thrust direction PR under the action of transmission mechanism 4. In particular, as movable rotational support point 8c moves, crank member 4b makes a clockwise (when viewing
In the first embodiment illustrated in
Those parts and elements which are similar to – or which perform the same function as – those of the above-described embodiment have been assigned the same reference numerals. For simplicity, the description of such parts and elements will not be repeated below, and reference should be made to the above description of the preceding embodiment.
In the second illustrative embodiment, pressing member 1 is configured to apply said force on two sides of the cross-section of said conductor 300. In particular, such sides are adjacent.
Unlike the first embodiment illustrated herein, distribution nozzle 191 is mounted substantially stationary with respect to frame 200 of the apparatus and is not movable under the action of actuator member 5. In fact, as will be described more in detail below, connection member 3 (e.g. its flange 193) is slidably mounted in distribution nozzle 191, so as to cause the displacement of pressing member 1 via the associated transmission mechanism 4.
As visible in
In particular, with reference to
In the second embodiment, movable body 1c comprises a pair of internal thrust faces 1d, 1e adjacent to each other, which form the sides whereon said force is applied. Accordingly, reaction surface 2 carried by distribution nozzle 191 defines an associated pair of internal reaction faces 2d, 2e adjacent to each other and transversally facing towards internal thrust faces 1d, 1e. In operation, as conductor 300 is fed through the cavity of distribution nozzle 191 in the section upstream of aperture 80, it becomes surrounded by internal thrust faces 1d, 1e and by internal reaction faces 2d, 2e. In particular, owing to transmission mechanism 4, an axial or longitudinal displacement of connection member 3 in feeding direction 10′ corresponds to an associated transverse displacement of movable body 1c, so that internal thrust faces 1d, 1e will apply, in a controlled manner, a transverse force on two adjacent sides of conductor 300 against reaction surface 2 defined by internal reaction faces 2d, 2e.
In the second embodiment, transmission mechanism 4 is a cam mechanism. In particular, transmission mechanism 4 is configured for converting the translational motion in feeding direction 10′ imparted to connection member 3 into a translation of pressing member 1 in thrust direction PR, thus causing internal thrust faces 1d, 1e to move and push conductor 300. For example, said cam mechanism comprises an elongated hole 4c formed in pressing member 1, which is inclined relative to the feeding direction; moreover, the cam mechanism comprises also a slider 4d integral with connection member 3, which can slide in the elongated hole 4c. In particular, pressing member 1 acts as a follower, since it is moved due to the axial movement of slider 4d of connection member 3 that transversally pushes elongated hole 4c.
With particular reference to
In particular, as shown by way of example in
Also in the second embodiment, with reference to the representation shown in
In the second embodiment, therefore, differently from
In the second embodiment, with particular reference to
Advantageously, the quick-coupling mechanism is configured to permit a releasable and restorable coupling between connection member 3 (e.g. flange 193) and actuator member 5 (e.g. shaft 190). This makes it possible to reversibly separate said assembly from the rest of the apparatus. The apparatus can thus be adapted for processing conductors 300 of different sizes and cross-sectional shapes and/or for different types of bends of the hairpins to be manufactured, simply by using different types of such assemblies depending on the desired operating conditions of the apparatus.
In the second embodiment illustrated in
The following will describe some preferred aspects of both embodiments illustrated herein, in regards to the application of the force by pressing member 1 in thrust direction PR.
Preferably, the force by means of which pressing member 1 engages conductor 300 is reduced during the feeding of conductor 300 towards engagement members 112, 112′.
Preferably, the force by means of which pressing member 1 engages conductor 300 is increased during the transverse movement and engagement of conductor 300 against engagement members 112, 112′. This results in the bending of the portions of electric conductor 300 intended to form coil members 20.
Preferably, the force by means of which pressing member 1 engages conductor 300 is kept substantially constant during the feeding of conductor 300 and the simultaneous transverse engagement of conductor 300 against engagement members 112, 112′, without said engagement members 112, 112′ being moved. This creates a curvature of the portions of electric conductor 300 intended to form said coil members 20.
Of course, without prejudice to the principle of the invention, the forms of embodiment and the implementation details may be extensively varied from those described and illustrated herein by way of non-limiting example, without however departing from the scope of the present invention as set out in the appended claims.
For example, in the illustrated embodiments the apparatus comprises a plurality, in particular a pair, of engagement members 112, 112′. However, in further implementation variants the apparatus may include just one engagement member.
Furthermore, the technical characteristics that differentiate the various embodiments and variants thereof described and illustrated herein are freely interchangeable, whenever compatible.
Number | Date | Country | Kind |
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102020000019003 | Aug 2020 | IT | national |
Filing Document | Filing Date | Country | Kind |
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PCT/IB2021/056859 | 7/28/2021 | WO |