APPARATUS AND METHOD FOR MANUFACTURING A PARTIAL NEST OR A NEST OF CONDUCTORS

Abstract

The invention is directed to an apparatus (100) and a method for manufacturing a partial nest or a nest (5) of pin conductors (1, 1.sub.i, 1.sub.o) for forming a stator. The apparatus (100) comprises a stator core template (10) with a block body (11) and radially extending ribs (12) forming slots (13) there between for insertion of legs (2, 2.sub.i, 2.sub.o) of the pin conductors (1, 1.sub.i, 1.sub.o). The apparatus (100) comprises at least one ring element (25, 33, 42) being arranged to provide an outer radial abutment face for inserted pin conductors (1, 1.sub.i, 1.sub.o).

Claims

1-26. (canceled)

27. Apparatus for manufacturing an at least partial nest of pin conductors for forming a stator, the apparatus comprising a stator core template, wherein: the stator core template comprises a block body provided with radially extending ribs, said ribs forming slots therebetween for insertion of legs of the pin conductors; and the apparatus further comprises at least one ring element arranged to provide an outer radial abutment face for inserted pin conductors.

28. An apparatus according to claim 27 wherein an upper level of the block body and an upper level of the ribs are on same axial level.

29. An apparatus according to claim 27, wherein at least a part of the block body and the ribs are machined as a single piece.

30. An apparatus according to claim 29, wherein the ribs are machined as a single piece from a steel cylinder.

31. An apparatus according to claim 27, wherein at least an upper part of the ribs has a radial length which is larger than the radial length of a lower part of the ribs, the ribs comprising a continuous transition between the upper part and the lower part.

32. An apparatus according to claim 27, wherein the ring element has an axial extension which is smaller than the axial extension of the ribs.

33. An apparatus according to claim 27, wherein the at least one ring element comprises a separate ring connected to the ribs.

34. An apparatus according to claim 33, wherein the separate ring is attached to shelf elements, which are connected to the ribs.

35. An apparatus according to claim 32, wherein an upper level of the separate ring is arranged axially below the upper level of the block body.

36. An apparatus according to claim 34, wherein the radially outward facing side of the separate ring comprises a contact surface for either (a) a bearing or (b) a drive element, to generate a rotary motion.

37. An apparatus according to claim 27, wherein the at least one ring element is formed by a support ring rotatably arranged with respect to the ribs.

38. An apparatus according to claim 27, wherein the support ring comprises a fixing flange for fastening the separate ring to a mounting frame.

39. An apparatus according to claim 37, wherein the inner radius of the support ring corresponds to an outer radius of a lower part of the ribs.

40. An apparatus according to claim 37, wherein the support ring comprises an opening for inserting a pusher element, the opening having a circumferential width of at least the maximal circumferential width of a slot formed by adjacent ribs.

41. An apparatus according to claim 40, further comprising a lower pusher element, which is arranged to be radially moveable into the opening of the support ring from the radial outside of the support ring.

42. An apparatus according to claim 27, wherein the at least one ring element comprises a hood element having a radially inner surface being arranged axially above the upper level of the ribs and having a radial inner diameter being smaller than a radial diameter of the upper level of the stator core template, being adapted to contact an upper part of at least a part of inserted pin conductors.

43. An apparatus according to claim 42, wherein the hood element is fastenable to a mounting frame and is arranged rotatably with respect to the ribs.

44. An apparatus according to claim 42, wherein the hood element has a shape of a ring segment with an open area which allows access for at least one upper pusher element for pushing inwardly the upper part of at least one inserted pin conductor.

45. An apparatus according to claim 27, wherein the apparatus comprises at least one outer positioning tool, the at least one outer positioning tool having a radially inwardly protruding pocket element providing at least one pocket for stabilizing the radial outside of an i-pin conductor.

46. An apparatus according to claim 45, wherein the at least one outer positioning tool is radially moveable.

47. An apparatus according to claim 27, wherein the apparatus comprises at least one upper pusher element for pushing inwardly the upper part of at least one inserted pin conductor.

48. An apparatus for manufacturing an at least partial nest of pin conductors for forming a stator, the apparatus comprising a stator core template and a rim segment, wherein: the stator core block has a block body provided with radially extending ribs, said ribs forming slots therebetween for insertion of legs of the pin conductors; and the rim segment is mounted to the upper face of the block body which prevents radial inward bending or movement of at least one upper part of a pin conductor.

49. An apparatus according to claim 48, wherein the rim segment comprises a radially outwardly protruding pocket element providing at least one pocket for supporting the radial outside of an i-pin conductor.

50. An apparatus according to claim 48, wherein the apparatus comprises a lifting element, the lifting element comprising an axial contact face for a drive element to generate an axial motion, in order to push upwards an at least partial nest of inserted pin conductors.

51. An apparatus according to claim 50, wherein the lifting element comprises leg supports for receiving legs of the pin conductors, the number of leg supports corresponding to the number of slots and each leg support being arranged in a respective slot.

52. An apparatus according to claim 51, wherein each leg support comprises seats for receiving legs of different lengths.

53. An apparatus according to claim 50, wherein the lifting element comprises an annular element comprising the axial contact face, being connected to the radially inner sides of the leg supports.

54. An apparatus according to claim 53, wherein the axial length of the block body is smaller than the axial length of the ribs and the annular element is axially moveable below the block body.

55. A method for manufacturing an at least partial nest of pin conductors for forming a stator, comprising: providing an apparatus for manufacturing an at least partial nest of pin conductors for forming a stator, the apparatus comprising: a stator core template with a block body provided with radially extending ribs forming slots in between for insertion of legs of the pin conductors, and at least one ring element being arranged to provide an outer radial abutment face for the legs of inserted pin conductors; inserting at least one pin conductor into at least one of said slots of the stator core template such that said pin conductor is arranged at a first position within said slot, wherein in said first position the pin conductor is arranged differently than in the intended position in the stator core template; moving said pin conductor within said slot of said a stator core template from said first position to a second position; repeating, for at least one additional pin conductor, the providing the apparatus and the inserting at least one pin conductor into at least one of said slots of the stator core template, to form a first layer of an at least partial nest of pin conductors; and removing the at least partial nest of pin conductors from the stator core template.

56. A method according to claim 55, the removing the at least partial nest of pin conductors from the stator core template comprising axially moving a lifting element comprising leg supports for receiving legs of the of pin conductors.

57. A method according to claim 55, further comprising: inserting at least one i-pin conductor into at least one of said slots of the stator core template; preventing the lower part of the i-pin conductor from radially extending to the outside of least a lower part of the ribs by the ring element being formed as a support ring which is rotatably arranged with respect to the ribs; and radially moving inwards the leg of the i-pin conductor by a lower pusher element being radially moved into an opening of the support ring, said opening having a circumferential width which corresponds to the maximal circumferential width of a slot formed by adjacent ribs.

58. A method according to claim 57, further comprising rotating the stator core template and inserting another pin conductor into at least one of the slots.

59. A method according to claim 57, further comprising radially moving the leg of the i-pin conductor during radially inward movement of the i-pin conductor until it reaches the radial position of a respective seat being arranged on a leg support for receiving legs of pin conductors.

Description

[0118] The invention will be explained hereinafter with reference to the description of specific embodiments and the respective drawings, which show:

[0119] FIG. 1 a first perspective sectional view of an apparatus according to the invention;

[0120] FIG. 2 a second perspective sectional view of the apparatus;

[0121] FIG. 3 a first side view of the apparatus;

[0122] FIG. 4 a first perspective view of the apparatus;

[0123] FIG. 5 a sectional view of the apparatus along a longitudinal axis and an enlarged detail;

[0124] FIG. 6 a second perspective view of the apparatus;

[0125] FIG. 7 a perspective view of a rim segment;

[0126] FIG. 8 a perspective view of a part of the stator core template;

[0127] FIG. 9 a part of the stator core template in top view;

[0128] FIG. 10 a further perspective view of a part of the stator core template;

[0129] FIG. 11a a top view on outer positioning tool in a first radial position;

[0130] FIG. 11b a top view on outer positioning tool in a second radial position;

[0131] FIG. 12 a perspective view of a part of a further example of stator core template;

[0132] FIG. 13 a further perspective view of the part of the example of FIG. 12;

[0133] FIG. 14 a first partial perspective view of a part of the stator core template;

[0134] FIG. 15 a second partial perspective view of a part of the stator core template;

[0135] FIG. 16 a third partial perspective view of a part of the stator core template;

[0136] FIG. 17 a forth partial perspective view of a part of the stator core template;

[0137] FIG. 18 a top view on a part of the stator core template;

[0138] FIG. 19 a third perspective sectional view of an apparatus according to the invention;

[0139] FIG. 20 a side view of an i-pin conductor;

[0140] FIG. 21 a sectional view of a part of a nest in stator core template.

[0141] FIG. 1 shows a first perspective sectional view of an apparatus 100 according to the invention.

[0142] The apparatus 100 comprises a stator core template 10, comprising a block body 11 provided with radially extending ribs 12.

[0143] Said ribs 12 form slots 13 therebetween for insertion of legs 2 of the pin conductors 1 (see for example FIG. 3).

[0144] An upper part 18 of the ribs 12 has a radial length 19 which is larger than the radial length 21 of a lower part 22 of the ribs 12. The ribs 12 have a continuous transition 61 between the upper part 18 and the lower part 22, in this case formed as a step.

[0145] The apparatus 100 comprises at least two ring elements 25, 33 arranged to provide an outer radial abutment face for inserted pin conductors 1 not explicitly shown.

[0146] A first ring element is formed by a separate ring 25 being fixedly connected to the ribs 12 and has an axial extension 23.1 which is smaller than the axial extension 24 of the ribs 12.

[0147] The separate ring 25 is arranged above the transition 61. The inner radius 28 of the separate ring 25 corresponds to the outer radius 29 of the upper part 18 of the ribs 12.

[0148] A second ring element is formed by a support ring 33 rotatably arranged with respect to the ribs 12.

[0149] The support ring 33 is arranged below the separate ring 25 and below the continuous transition 61.

[0150] The support ring 33 has an axial extension 23.2 which is smaller than the axial extension 24 of the ribs 12.

[0151] The apparatus 100 further comprises a lifting element 50.

[0152] The lifting element 50 comprises leg supports 51 for receiving legs 2 of pin conductors 1 (see FIG. 5 or 13). The number of leg supports 51 corresponds to the number of slots 13. Each leg support 51 is arranged in a respective slot 13 (see also FIG. 2).

[0153] Each leg support 51 comprises seats 52, 53, 57 for receiving legs 2 of different lengths.

[0154] The lifting element 50 has an axial contact face 54 for a drive element 55 (see FIG. 5) to generate an axial motion, in order to push upwards a partial nest or a nest of inserted pin conductors 1.

[0155] The lifting element 50 comprises an annular element 58 with the axial contact face 54. The annular element 58 is connected to the radially inner sides of the leg supports 51.

[0156] The lifting element 50 provides a central opening for guiding through a rotational drive element 64, which is connected to the block body 11 (see FIG. 5) for inducing a rotational movement of the stator core template 10.

[0157] The axial length 56 of the block body 11 is smaller than the axial length 24 of the ribs 12. The annular element 58 has an outer diameter 59 which corresponds to the outer diameter 60 of the block body 11. The annular element 59 is axially moveable below the block body 11.

[0158] FIG. 2 shows a second perspective sectional view of the outside of a part of the apparatus 100.

[0159] The upper level 14 of the block body 11 and an upper level 15 of the ribs 12 essentially are on same axial level 16.

[0160] The radially outward facing side 30 of the separate ring 25 comprises a contact surface 31, especially for a bearing 32 (see also FIG. 5).

[0161] The separate ring 25 is attached to shelf elements 26, which are connected to the ribs 12.

[0162] FIG. 3 shows a first side view of the apparatus 100.

[0163] The support ring 33 comprises an annular fixing flange 34 for fastening the separate ring 33 to a mounting frame 35.

[0164] The apparatus 100 further comprises a third ring element being formed by a hood element 42 (see also FIG. 6).

[0165] FIG. 4 shows a first perspective view of a part of the apparatus 100.

[0166] The support ring 33 comprises an axially extending opening 38 for inserting a lower pusher element 41 (see FIGS. 3 and 5). The opening 38 has a circumferential width 39 which corresponds to at least the maximal circumferential width 40 of a slot 13 formed by adjacent ribs 12 (see FIG. 2).

[0167] FIG. 5 shows a sectional view of the apparatus 100.

[0168] The inner radius 36 of the support ring 33 corresponds to an outer radius 37 of the lower part 22 of the ribs 12.

[0169] A radially innermost seat 52 and a radially outermost seat 53 are lower than the other seats 57 for receiving a longer leg 4. The longer leg 4 is inwardly pushed by the lower pusher element 41 to reach a respective innermost lower seat 52.

[0170] FIG. 6 shows a second perspective view on the topside of the apparatus 100.

[0171] The hood element 42 has a radially inner surface 43 arranged axially above the upper level 15 of the ribs 12. The radially inner surface 43 has an inner diameter 44 smaller than an outer diameter 45 of the upper level 16 of the stator core template 10 (see FIG. 4). Hence, the radially inner surface 43 is adapted to contact an upper part of at least a part of inserted pin conductors 1.

[0172] The hood element 42 has a shape of a ring segment with an open area 46 which allows access for at least one upper pusher element 47 for pushing inwardly the upper part an inserted pin conductor 1.

[0173] The apparatus 100 further comprises a rim segment 48 which is mounted to the upper face 49 of the block body 11.

[0174] The rim segment 48 prevents radial inward tilting or movement of at the upper parts 3 of pin conductors 1 (see FIG. 5 or 13).

[0175] FIG. 7 shows a perspective view of a rim segment 48.

[0176] The rim segment 48 comprises a body part 81 with a flange 82 to be mounted on the upper face 49 of a block body 11 (see FIG. 8) and a wall 83. The wall 83 extends in an axial direction A and in a circumferential direction C.

[0177] On the radially outer surface 84 of the wall 83 a pocket element 85 is mounted to the rim segment 48.

[0178] The pocket element 85 comprises a railing 86 and separating members 87. The railing 86 is connected to the wall 83 by the separating members 87. The separating members 87 form a number of pockets 88 on the radial inside of the railing 86 which are delimited by the railing 86, the wall 83 and the separating members 87.

[0179] FIG. 8 shows a perspective view of a part of the stator core template 10.

[0180] The rim segment 48 is mounted at the radially inward end of the ribs 12.

[0181] The flange 82 comprises mounting holes 89 for fixing the rim segment 48 to the top surface 49 of the block body 11.

[0182] The pockets 88 are aligned with slots 13 formed by the ribs 12.

[0183] FIG. 9 shows a part of the stator core template 10 in a top view.

[0184] The circumferential distance 90 between two adjacent separating members 87 corresponds to the circumferential distance 91 between the radially innermost parts of respective lateral walls 92 of adjacent ribs 12. Thus, the pockets 88 are precisely aligned with the slots 13.

[0185] The opening 93 for inserting i-pins are each delimited by a radially innermost part of respective lateral walls 92, by the wall 83, by the railing 86 and by a separating member 87.

[0186] FIG. 10 shows a further perspective view of a part of the stator core template 10 during removal of the nest (not completely shown).

[0187] For the sake of clarity FIG. 10 only shows the innermost layer of conductors 1.

[0188] Each i-pin conductor 1.sub.i of the innermost layer is positioned in a respective pocket 88.

[0189] Each i-pin conductor 1.sub.i of the innermost layer is supported by the rim segment 48.

[0190] The wall 83 prevents radially inward tilting of the i-pin conductor. The railing 86 prevents radially outward tilting. The separation members 87 and the radially innermost part of respective lateral walls 92 prevent rotation of the i-pin conductors 1.sub.i around an axis in axial direction A.

[0191] In the embodiment shown in FIGS. 11a, 11b, 12 and 13 the stator core template 10 comprises a hood element 42 with two outer positioning tools 75 which are radially moveable with respect to the ribs 12.

[0192] FIG. 11a shows a top view of an outer positioning tool 75 in a first radial position, FIG. 11b in a second radial position.

[0193] Each outer positioning tool 75 comprises a radially inwardly protruding pocket element 76 providing a number of pockets 77.

[0194] The pocket element 76 comprises a railing 101 and separating members 102. The railing 101 is connected to a radially inward facing wall 103 of the positioning tool 76 by the separating members 102. The separating members 102 form a number of pockets 77 on the radial outside of the railing 101 which are delimited by the railing 101, the wall 103 and the separating members 102.

[0195] The pocket element 76 is arranged at the radially inner end of radially moveable arms 78 (FIG. 12). The hood element 42 comprises a rim segment 79, providing a radially inner surface 43 (FIG. 11a). The rim segment 79 has a recess 80 extending along a circumferential length 99 corresponding to the sum of the circumferential lengths of the pocket elements 76 of the positioning tools 75, such that the pocket elements 76 are arranged within the recess 80.

[0196] In the radially outer position (see FIG. 11a) the radially inner side of the railing 101 is axially aligned with the inner surface 43 of the rim segment 79.

[0197] Thus the complete pocket element 76 is arranged outside the intended position of the outermost layer of the nest.

[0198] The outer positioning tool 75 may be pushed radially inwards into a radially inner position (see FIG. 11b).

[0199] The radial inward movement ends, when the circumferentially adjacent edges 104, 105 of the pocket elements 76 abut.

[0200] FIG. 12 shows a perspective view of a part of an example of stator core template 10 with two outer positioning tools 75.

[0201] The pockets 77 are aligned with slots 13 formed by the ribs 12. The separating members 102 have a radial length 106 which corresponds to the radial width of the i-pin conductors 1.sub.o such that each pocket 77 receives only one i-pin conductor and prevents axial rotation of the i-pin conductors 1.sub.o (see FIG. 13).

[0202] FIG. 13 shows a further perspective view of the part of the example of FIG. 12 having two outer positioning tools 75 when the forming of the nest 5 in the stator core template 10 is almost finished.

[0203] The i-pin conductors 1.sub.o of the outermost layer have been introduced in the pockets 77 of the outer positioning tools 75. The outer positioning tools 75 are still in the radially outer position as shown in FIG. 11a. Hence the legs of the i-pin conductors 1.sub.o positioned in the pockets 77 do not get in contact with the legs of the other conductors, which are arranged radially more inwardly.

[0204] Once all i-pin hairpins have been inserted and are radially properly arranged, for example by the upper pusher elements 47, the outer positioning tools 76 may be moved inwardly to move the upper portions of the i-pin conductors 1.sub.o towards the inner layers of the nest.

[0205] The pockets prevent radial outward and inward tilting or movement of the upper portions of the i-pin conductors 1.sub.o.

[0206] The i-pin conductors 1.sub.o are moved from a position outside the nest 5 to the outermost layer of the nest 5.

[0207] FIG. 14 shows a second perspective view of a part of the stator core template 10.

[0208] Each rib 12 has a male projection 62.

[0209] The male projections 62 of the ribs 12 are inserted in respective female recesses 63 arranged within the lower part 17.1 of the block body 11 to form a positive connection.

[0210] FIG. 15 shows a first perspective view of a part of the stator core template 10.

[0211] The block body 11 comprises a lower part 17.1 and a fixing plate 17.2. arranged above the lower part 17.1.

[0212] The form fit connections between the male projections 62 of the ribs 12 and the female recesses 63 (see FIG. 14) are secured by the fixing plate 17.2 of the block body 11, which prevents the male projections 62 from leaving the female recesses 63.

[0213] FIGS. 16 and 17 show a third partial perspective view and a forth partial perspective view of a part of the stator core template 10 to explain the fixation of the shelf elements 26 to the ribs 12.

[0214] The shelf elements 26 comprise securing holes 74 for fixation of the separate ring 25 (see FIG. 1).

[0215] Some of adjacent pairs of ribs 12 comprise extensions 70 on their outer radial surface 68. The extensions 70 may be inserted into respective recesses 69 of shelf element 26.

[0216] As can be seen best in FIG. 17, after having inserted the extensions 70 in to the recesses 69 of shelf element 26 the convection is secured by bolts 71. Alternatively, for example also screws can be used.

[0217] The bolts 71 are inserted in to respective bolt holes 72 in the shelf element 26 and bolt holes 72 in the extensions 70 (see FIG. 16).

[0218] As can be seen in FIG. 18, showing a top view on a part of the stator core template 10, the ribs 12 may be machined parts with a varying thickness along the radial extension.

[0219] FIG. 19 shows a third perspective sectional drawing of an apparatus 100 according to the invention.

[0220] The apparatus comprises a first drive motor 65 for inducing a rotational motion of a rotational drive element 64.

[0221] The apparatus comprises a second drive motor 66 for inducing a axial motion of a axial drive element 55 via a lifting platform 67.

[0222] FIG. 20 shows a side view of pin conductor 1, in this case an i-pin conductor. The i-pin conductor 1 comprises only one leg 2. Usually the upper part 3 of the i-pin conductor 1 is pre bended.

[0223] As the i-pin conductor 1 only comprises one leg 2, there is no self-stabilization of the pin conductor, unlike for example hairpin conductors, which have two legs arranged in different slots (not explicitly shown in the figures).

[0224] Hence i-pin conductors need a specific handling when inserted in a stator core template 10.

[0225] When an i-pin conductor 1 is inserted into a slot 13 of the stator core template 10 the lower part of the i-pin conductor is prevented from radially moving to the outside of least a lower part 22 of the ribs 12 by the support ring 33, as can be seen for example in FIG. 5.

[0226] The upper part of the slots 13 is radially confined by the separate ring 25.

[0227] The leg 2 of an internal i-pin conductor 1 of a nest is radially moved inwards by the lower pusher element 41 being radially moved into the opening 38 of the support ring 33.

[0228] The i-pin conductor 1 is then radially aligned with the respective seat 52 and may fall down on the leg support 51 of the lifting element 50 into the respective seat 52.

[0229] The upper parts 3 of the internal i-pin conductors 1 are stabilized by the rim element 48.

[0230] Similarly, an external i-pin conductor of a nest is radially held in a respective seat 53 and is prevented from moving out of the stator core template through the opening 38 by the lower pusher element 41.

[0231] For insertion the i-pin conductor 1 hence does not need to be placed exactly in a specific radial position. The i-pin conductor 1 may be inserted anywhere in the slot 13, in particular in a radially outer region, where the slot 13 has a bigger circumferential width 40 (see FIG. 2). After having been inserted in the slot 13, the i-pin conductor 1 may be pushed into the intended radial position. As the leg 2 of the i-pin conductor 1 cannot escape from the respective seat 52, 53, the radial position of the i-pin conductor 1 remains fixed.

[0232] After insertion of a the i-pin conductor 1 the stator core template 10 is rotated by means of the driving motor 65 and the rotational driving element 64 (see FIG. 18).

[0233] Another pin conductor 1 is then inserted into at least one of the slots, and the steps of radially moving the pin conductors and positioning the pin conductors by an upper pusher element 47 and/or a lower pusher element 41 are repeated.

[0234] Once all pin conductors necessary for forming the partial nest or the nest 5 are properly positioned, the nest may be pushed upwards by axially moving the lift 50 element via a drive element 55.

[0235] The partial nest or the nest 5 may then be removed from the stator core template 10.

[0236] A final position of the nest 5 in the stator core template 10 may be seen in FIG. 21 showing a schematic drawing of a sectional view of a part of a nest in stator core template.

[0237] The i-pins 1.sub.i in the innermost layer of nest 5 and the i-pins 1.sub.o in the outermost layer of nest 5 are longer than rest of the nest 5. The respective legs 2.sub.i and 2.sub.o accordingly are positioned in seats 52, 53 which are axially lower than the other seats 57.