METHODS AND APPARATUSES FOR FORMING WOVEN UNDULATED

COIL ASSEMBLIES DESCRIPTION

Field of the invention

The present invention relates to a method and apparatus for forming coil assemblies of a known type, like woven undulated coil assemblies.

State of the art

As is known, an undulated coil has adjacent linear portions extending parallel to each other, and a plurality of turn portions for connecting the ends of adjacent linear portions to each other.

The linear portions are inserted in slots of a stator core, whilst the turn portions protrude from respective end sides of the stator core. The section of the conductor from which the coil is formed may be circular, square or rectangular. The size of the section of the conductor is usually comparable to the width of the section of the slot of the stator core. The conductors present in a slot are normally positioned one adjacent to another in a radial direction of the stator core, i.e. along an extension, which extends from a slot opening to the bottom of the same slot.

For reasons of clarity, a coil formed from one conductor having the undulated configuration will be referred to as "a coil", whilst a number of coils having the aforementioned configuration, and which are woven together, will be referred to as a coil assembly. When examining the path of a conductor along the coil assembly which has been formed according to a woven configuration, the linear portions of one conductor are alternatively positioned above and below the linear portions of another conductor. This overlapping of a conductor is repeated at a pitch distance along the coil assembly and for a certain number of undulations. The turn portions joining these linear portions are positioned to be partially above and partially below turn portions of other coils.

Solutions for producing woven coil assemblies of undulated coils have been described in US8122593, US6376961, EP1710996 and US6140735.

Stator cores wound according to these principles can be used in dynamoelectric machines; in particular as components of traction motors and energy generators of vehicles .

The woven coil assembly can be first produced as a flat coil assembly, i.e. a planar coil assembly. Successively, the coil assembly can be transformed into a cylindrical form to insert the linear portions in the slots of the core, or the linear portions can be inserted directly into the slots of the core from the planar configurations. The turn portions protrude from the ends of the core after the linear portions have been inserted in the slots.

Normally, the coil assembly thickness can be reduced by applying compression on the flat coil assembly. Prior to the compression, the linear portions and turn portions need to be positioned with high precision in view of the low allowable tolerances that exist during the successive insertion operations in the core.

Furthermore, the production of woven coil assemblies has been mostly a manual operation, or a partially automatic using time consuming and complicated operations. Scarce success in these production attempts have been due to the high rate of inaccuracy in forming the coil assembly; particularly in forming the linear portions and the turns portions according to the tolerances required in their positioning. Summary of the invention

It is therefore an object of the present invention to provide a method and an apparatus for manufacturing woven undulated coil assemblies, which overcome the drawbacks mentioned in the foregoing of the state of the art.

It is also an object of the present invention to provide a method and an apparatus for manufacturing woven undulated coil assemblies having linear portions and turn portions positioned with high precision.

It is a further scope of the invention to provide a method and an apparatus for manufacturing woven undulated coil assemblies with reduced production times with respect to the solutions of the state of the art.

It is another object of the present invention to provide a method and an apparatus for manufacturing woven undulated coil assemblies, which are highly flexible, in other words capable of manufacturing woven coils and conductors having different geometries.

It is a particular object of the present invention to provide a method and an apparatus for manufacturing woven undulated coil assemblies, which are completely automated. These and other objects are achieved using the method and the apparatus for forming woven coils as described in the independent claims.

Other characteristics of the inventions are described in the dependent claims.

Brief description of the drawings

The invention will be now shown with the following description of an exemplary embodiment, exemplifying but not limitative, with reference to the attached drawings in which :

Figure 1 is a schematic representation of portions of undulated coils;

Figure 2 is a schematic planar representation of a portion of a coil assembly formed according to the principles of the invention;

Figure 3 is a schematic perspective view illustrating devices required for forming a coil assembly according to the invention;

Figure 3a is a section view as seen from directions 3a - 3a of figure 3;

Figure 3b is a section view as seen from directions 3b - 3b of figure 3;

Figure 4 is a schematic perspective view similar to the view of figure 3 illustrating devices required for forming a coil assembly according to the invention in a certain stage of functioning;

Figure 5 is a schematic perspective view similar to the view of figure 3 illustrating devices required for forming a coil assembly according to the invention in a further stage of functioning; Figure 5a is a view as seen from directions 5a - 5a of figure 5;

Figure 5b is a view similar to that of figure 3b in a different stage of functioning;

Figures 6 to 14 are schematic views of various stages of functioning according to the principles of the invention as seen from a direction 6 of figure 3;

Figure 15 is a view similar to figure 4, although illustrating a second embodiment of the invention;

Figures 16 to 20 are views similar to those figures 6 - 14, although illustrating various stages of functioning of the second embodiment of the invention.

Detailed description of the invention

Figure 1 and 2 show the constitution of a woven coil assembly 100. Figure 1 shows two separate undulated coil portions CI and C2, which are used as a reference for explaining the woven coil assembly of figure 2 .

A coil portion CI is shown with dark shading, whilst a coil portion C2 is shown without shading. In this example, each of the coil portions CI and C2 is formed of six wire conductors .

A portion of a formed woven coil assembly 100 consisting of twelve wire conductors is shown in figure 2. Coil assembly 100 has a flat configuration, which extends parallel to the plane P of the drawing of figure 2. The result of figure 2 can be considered an interlacing of the coil portions CI and C2 of figure 1.

Considering more particularly the interlacing, in area Al of coil assembly 100, six initial linear portions LI - superimposed, on six linear portions AL7 - AL12 of coil portion C2, therefore portions AL7 - AL12 are not visible in figure 2.

The distance between two adjacent superimposed linear portions is referred to as the pitch (see PT in figure 2) .

In area A2 of coil assembly 100, six linear portions AL13- AL18 of coil portion C2 are superimposed on six linear portions L7 - L12 of coil portion CI, therefore linear portions L7 - L12 are not visible in figure 2.

The transition between the various superimpositions occurs by means of turns T, which represent the turn portions of the coil assembly as shown in figure 2 .

Adjacent turn portions T overlap each other with an orderly progression of succession. In fact, the overlap of the turn portions is such that it causes the linear portions of any of the conductors to pass between overlapping the linear portion of another conductor in area Al, to being overlapped by another linear portion of the same conductor in an adjacent area A2, as shown in figure 2.

This alternation of the linear portions being overlapped and then overlapping of the linear portions, with reference to one conductor, occurs constantly along the coil assembly for all the conductors, and represents the weaving or interlacing occurring.

In the example shown, the twelve conductors will have linear portions and turn portions positioned according to the alternation of overlapping described above.

According to the example of figures 1 and 2, the linear portions of a specific conductor are positioned along the coil assembly at distances of 6 times the pitch distance, i.e. half the number of conductors multiplied by the pitch distance PT . Therefore as a general law, at a distances equal to half the number of conductor multiplied by the pitch distance.

Area Al is adjacent to area A2 and the two areas are delimited by a separation distance SD equal to the pitch distance PT .

Areas Al and A2 are repeated a predetermined number of times along the coil assembly 100. At the end of the last of the areas Al, or A2 of the flat coil assembly 100, the conductors form leads like AL1 - AL6 respectively of coils C2, and initial leads II- 16 of coils CI, which do not overlap as shown in figure 2.

However, when inserting the coil assembly 100 in the core of the stator, each of the leads II- 16 of coil CI can overlap a respective lead AL1 - AL6 of coil C2 during their insertion in the slots of the stator core.

The core of the stator, which receives the coil assembly of figure 2, will have a number of slots proportional to the total number of linear portions that overlap. This total includes the linear portions of initial leads that overlap, as described previously. As a result, a slot of the stator core will have two linear portions that overlap accommodated on another two linear portions that overlap, and also on other linear portions that overlap, depending on the number of areas like Al and A2, which have been foreseen in the coil assembly.

With reference to figure 3, a first embodiment is shown for forming the example of a coil assembly of figure 2. More particularly, the example foresees twelve wire conductors of conductor group 12 fed through respective exits 23' of conductor supply store 23. Each conductor of the group of conductors 12 can be fed from a respective conductor supply reel (not shown) to exits 23'. Furthermore, along direction X, each of the wire conductors of group 12 passes through a respective seat of group of seats 24 of guide unit 36, as shown in figure 3. The seats of group 24 are twelve, each being aligned with a seat of conductor store exits 23. Therefore, the number of seats of group 24 is equal to the number of conductors of group 12.

The seats of group 24 are parallel to each other to cause conductors of group 12 to remain parallel to each other and to be separate from each other by a same pitch distance PT .

Feeding the conductors of group 12 in direction X can be seen as being a feeding of the conductors in direction X in a same plane P, which contains the twelve conductors. Orthogonal directions to X will be the Y direction, and the Z direction, as shown in figure 3. Directions X', Y' and Z' are directions opposite to directions X, Y, Z, respectively .

A first unit or holding device 37 is located down stream of guide unit 36 in the feeding direction X of the conductors. First holding unit 37 is provided with a first plate 38, or support member, having group of seats 39 which are open towards a second plate 51, or cover member. The second plate 51 covers the first plate 38 (see also figure 3a) .

The seats of group 39 are twelve and are aligned with those of guide unit 36. Furthermore, the seats of group 39 are parallel to each other, and have the same separation pitch PT . First holding unit 37 is located so that seats of group 39 are aligned with seats of group 24 in order to achieve a travel of conductors of group 12 through the seats of guide unit 36 and first holding unit 37 without bending conductors of group 12.

A second device or holding unit 55 is located down stream of first holding unit 37 in the feeding direction X of the conductors. Second holding unit 55 is provided with a first plate 56, or support member, having group of seats 59, which are open towards a second plate 58, or cover member which covers the first plate 56 (see also figure 3b) .

Seats of group 59 are parallel to each other and aligned with the same separation distance PT described in the foregoing for the seats of group 24 of guide unit 36.

Second holding unit 55 is located so that seats of group 59 are aligned with seats of group 39 of first holding unit 37 in order to achieve a travel of conductors of group 12 through the seats of first holding unit 37 and second holding unit 55 without bending conductors of group 12.

First plate 38 and second plate 51 of first holding unit 37 are assembled together to allow passage of the conductors in directions X and X' through seats of group 39 and without causing unwanted movements in transverse directions Y and Y' and Z and Z' , and also for locking the conductors in directions X and X' when required.

First plate 56 and second plate 58 of second holding unit 55 are assembled together to allow passage of the conductors in the feeding direction X to reach the ends of seats of group 59 without causing unwanted movements in directions Y and Y' and Z and Z' , and also for locking the conductors in directions X and X' once the conductors have reached a required position at the ends of the seats of group 59.

The resulting situation of conductors of group 12 which have been fed through guide unit 36, first holding unit 37, and second holding unit 55 is shown in figure 3.

A clamp device, not shown, can place the conductors on the paths and in the groups of seats described with reference to figure 3. The clamp is able to hold the ends of the conductors at the pitch distance PT . The clamp device moves in direction X to pull the conductors from the supply store 23. When the clamp device moves in direction X, a conductor is aligned with a specific seat of plate 36', plate 38 and plate 56. During this movement, plate 36' ' , plate 51 and plate 58 have been removed to allow the conductors to access the seats when the clamp is moved in direction Z' . Once the conductors are located in the seats, plate 36' ' , plate 51 and plate 58 can be relocated, as shown in figure 3.

Figure 3a shows the section view of first holding unit 37 having group of seats 39 of first plate 38, where in each seat a conductor of group of conductors 12 is located. Second plate 51 covers the first plate 38. The underside of plate 51 can be in engagement with a predetermined pressure on the conductors to exert a clamping action when holding is required. If the conductors need to move though the seats, then the pressure can be reduced.

Figure 3b shows the section view of second holding unit 55 having first plate 56 with group of seats 59, where a conductor is located in each seat, as shown.

Similarly, second plate 58 covers the first plate 56. The underside of plate 58 can be in engagement with a predetermined pressure on the conductors to exert a clamping action when holding is required. If the conductors need to move though the seats, then the pressure can be reduced.

Second plate 58 is provided with extension 58' . The width W of the extension is such that the underside 58" of the extension 58' can cover and engage half the number of conductors (six conductors in the case of the example) of group of conductors 12, at a certain stage of the forming of the coil assembly.

Figures 6 - 14 are planar representations parallel to plane P showing a sequence of steps for forming the woven coil assembly of figure 2 starting from the condition of figure 3.

Figure 6 shows the situation of figure 3

A successive step of the coil forming solution is shown in figure 7, where second holding unit 55 has moved in directions Y of plane P to cause conductors of group 12 to become inclined between second holding unit 55 and first holding unit 37. In particular, during the movement of the second holding unit 55 a first portion IP' of conductors 12 (see figure 6) is bent.

For the example shown, the distance of the movement in direction Y is equal to six times the pitch PT .During the movement of second holding unit 55 in direction Y, guide unit 36 and first holding unit 37 can be moved in direction X to avoid excessive strain on the conductors of group 12. This step of figure 7 results in the formation of the inclined portion IC1 of portion IP' of conductors of group 12 located between second holding unit 55 and first holding unit 37.

A successive step of the coil forming solution is shown in figure 4 and figure 8, where second holding unit 55 has moved further in directions Y of plane P, and at the same time first holding unit 37, which is holding a second portion of conductors 2P' , is moved in direction Y for the same distance. This distance is equal to six times the pitch PT . The further movement in direction Y causes conductors of group 12 to become inclined between first holding unit 37 and guide unit 36, i.e. of a third portion of conductors 3P' , thereby forming second inclined portion IC2 as shown in figure 8. Guide unit 36, which is positioned upstream of portion 3P' , positions a fourth portion 4P' . Guide unit 36 is moved in direction X to avoid straining the conductors of group 12, when second holding unit 55 and first holding unit 37 are moved in direction Y.

In addition, as shown in figure 4 and figure 8, a bending plate 80 is positioned between first holding unit 37 and second holding unit 55. Preferably, bending plate 80 is located proximate to second plate 51 of first holding unit 37, with bending edge 80' positioned transverse and perpendicular to feeding direction X, as shown in figures 4 and 8.

More particularly, bending edge 80' can be in engagement with the inclined portion IC1 of conductors of group 12 located between first holding unit 37 and second holding unit 58. Preferably, the engagement can occur approximately at the middle of the inclined portion IC1, as shown in figures 4 and 8.

The next stage of the coil forming solution is shown in figure 9, where plate 56 of second holding unit 55 has been rotated according to arrow A around bending edge 80' . Bending edge 80' is aligned with axis A' and orthogonal to the feeding direction X. Prior to the rotation, in this stage around axis A' , plates 51 and 58 are respectively removed from the first holding unit 37 and the second holding unit 55. Possible solutions for rotations around bending edge 80' can be either that plate 56 is rotated itself around bending edge 80' , or that plate 56 is rotated around a middle axis R - R of second holding unit 55 (see figure 4) for rotation A, and at the same time plate 38 moves in direction X and direction Z' . This second combination of motions achieves that bending edge 80' remains in engagement with the middle of the inclined portion IC1 during the rotation A around the middle axis R - R of plate 56.

This combination of motions results in a rotation around the bending edge 80' .

At a predetermined position of the rotation around bending edge 80' , bending plate 80 is removed to allow plate 56 to become close to plate 38, and at the same time to be located over plate 38, as shown in figures 5 and figure 9.

With reference to figure 1, 2 and 5a, the resulting situation is that leads AL1 - AL6 of the coil assembly have been formed together with area Al consisting of linear portions L1-L6 overlapping linear portions AL7- AL12, and also linear portions L7 - L12. This result is visible in figure 5 and 5a, where linear portions L7- L12 remain uncovered and positioned on one side of plate 56.

Successively, as shown in figure 10, guide unit 36 and overlapping plates 56 and 38 can be moved in direction X simultaneously and for same amounts to draw further lengths of conductors of group 12 from their respective wire conductor supply stores. This also obtains that inclined portion IC2 becomes aligned with the position where bending plate 80 is applied, as shown in figure 8.

In figure 11 , plate 38 has been moved in direction

Z' to become free from the conductors and has been translated in direction Y' to return to the position in alignment with guide unit 36. In this way plate 38 can return to form first holding unit 37 with plate 51 repositioned as shown in figure 12.

In figure 12, guide unit 36 and first holding unit 37 have been moved in direction X' along the conductors of group 12 to reach the position of figure 7.

Also with reference to figure 12, plate 56 has been rotated with rotation B to pass from being above the portion of formed coil assembly to being below as shown. In addition, plate 56 has been moved in direction Y' for 6 pitch distances to the original alignment position of figure 7.

When plate 56 is below the coil assembly and in alignment with the linear portions as shown in figure 12, plate 56 can be moved in direction Z to receive the aligned linear portions of the coil assembly.

More particularly, with reference to figure 12, 13 and 5b, plate 56 has moved in direction Z to receive area Al consisting of linear portions AL7- AL12, overlapped by linear portions LI- L6, and linear portions L7 - L12, whilst leads AL1 - AL6 of the coil assembly extend beyond plate 56.

In a comparison between figure 5a and figure 5b, it is to be noted that in figure 5b there has been a displacement of plate 56 in direction Y' for 6 pitch distances

Figure 13 and 5b show that plate 58 has been repositioned over plate 56 and that the resulting situation can be a successive start condition similar to that of figure 7.

A following series of stages like those of figures 8 - 12 can be accomplished to continue forming the coil assembly. The end result will be that of figure 14, where bending has occurred once again around bending edge 80' for second inclined portion IC2.

Figure 14 is a situation like that of Figure 9, although with a further portion of the coil assembly that has been formed.

In fact, in the situation of figure 14 and with reference to figure 2, linear portions AL13- AL18 overlap linear portions L7- L12 to form area A2 and linear portions L 13 - L18 will be seated in seats of plate 38 without being overlapped.

Linear portions L13 - L18 will later be overlapped by linear portions AL19 - AL24 as a result of rotating with the engagement edge 80' engaged against inclined portion IC3.

It will be appreciated that the coil assembly can be completed by creating further inclined portions like ICl, IC2, IC3 and rotating against edge 80', like has been described in the foregoing sequence.

A second embodiment of the invention for forming the coil assembly of figure 2 is shown in figure 15, where group of conductors 12 reach first holding unit 37 without passing through a guide unit like 36. In the second embodiment, second holding unit 55 is present and has functions similar to those of the second holding unit 55 of the first embodiment.

Figures 16 - 20 are stages similar those of figures 6 , 7 and 9 to form the result of the coil assembly which has been described with reference to figure 9.

In the second embodiment a second inclined portion has not been formed prior to bending the first inclined portion IC1 around bending edge 80' , like has been described previously for the first embodiment with reference to figure 8.

In particular, in this embodiment, during bending of portion IP of conductors 12 which forms the inclined portion IC1, the portion 2P, which is upstream along the feeding direction X, is positioned and being held in the holding device 37. As shown schematically in figure 19, the rotation of the portion of the first portion IP occurs around an axis A" placed substantially in the middle of the first portion IP, and perpendicular to the feeding direction X.

Successively, there is feeding of the conductors in the feeding direction X, which achieves a third portion 3P of the conductors positioned between the holding device 37 and the plate 56 (figure 20) .

In particular, the third portion 3P of the conductors is located downstream of a fourth portion 4P of the conductors, positioned in the holding device 37 in figure 20. The third portion is thus bent and the bent portion is successively rotated around axis A", which obtains a rotated portion of conductors oriented in a direction opposite to the feed direction X.

Figure 21 is a successive stage after a second rotation around a second inclined portion. The portion of the coil assembly formed in figure 21 is like that of figure 14. Figure 21 show that portion Tl of the formed coil portion bears on straight portion ST1 of group of conductors 12. This will maintain portion Tl above plane P and with a certain incline.

Portion Tl can be repositioned in plane P after a successive series of steps which form the next extra portion of the coil assembly. In this situation, portion Tl will have been shifted to an area, where portion Tl is no longer bearing on group of conductors 12. In this condition of portion Tl, portion Tl can be pressed to return it into plane P

The foregoing description exemplary embodiments of the invention will so fully reveal the invention according to the conceptual point of view, so that others, by applying current knowledge, will be able to modify and/or adapt for various applications such embodiment without further research and without parting from the invention, and, accordingly, it is therefore to be understood that such adaptations and modifications will have to be considered as equivalent to the specific embodiments. The means and the materials to realise the different functions described herein could have a different nature without, for this reason, departing from the field of the invention. It is to be understood that the phraseology or terminology that is employed herein is for the purpose of description and not of limitation.