APPARATUS AND METHOD FOR MANUFACTURING COIL MEMBERS FOR CORES OF DYNAMO ELECTRIC MACHINES BY BENDING
20170012511 ยท 2017-01-12
Inventors
- Massimo Ponzio (Tavernelle Val di Pesa, IT)
- Rubino Corbinelli (Staggia Senese, IT)
- Maurizio Mugelli (San Gimignano, IT)
Cpc classification
H02K15/08
ELECTRICITY
Y10T29/53161
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
Abstract
Apparatuses and method for manufacturing coil members (230, 250) for insertion in slots of a core of an electric dynamo machine, wherein the coil members (230, 250) are formed by bending portions of an electric conductor (10). Portions of conductor of a predetermined length are fed through an aperture (80), where at least one engagement member (51) can move to engage and bend the conductor (10) so as to form the configuration of the coil member (230, 250).
Claims
1-22. (canceled)
23. An apparatus for manufacturing coil members for insertion in slots of a core of a dynamo electric machine wherein the coil members are formed by bending portions of an electric conductor, the apparatus comprising: means for feeding portions of conductor of predetermined length through an aperture, along a feeding axis, according to a feeding direction, adjacent to a first engagement member capable of engaging the conductor, wherein the aperture is positioned before the first engagement member in the feeding direction; means for moving the first engagement member with respect to the aperture to engage a portion of the conductor with the first engagement member in a transverse direction to the feeding axis to bend the conductor; and means for rotating the first engagement member around the feeding axis to reposition the first engagement member around the conductor.
24. The apparatus of claim 23 wherein the means for moving the first engagement member move the first engagement member for engaging the conductor against a portion of the aperture during bending.
25. The apparatus of claim 23 comprising means for moving the first engagement member parallel to the feeding axis to position the first engagement member for bending.
26. The apparatus of claim 23 comprising means for rotating the first engagement member around an axis that is perpendicular to the feeding axis.
27. The apparatus of claim 23 wherein the means for feeding feed the conductor adjacent to a second engagement member capable of engaging the conductor; the second engagement member is positioned after the first engagement member in the feeding direction; and the second engagement member is capable of engaging the conductor transversally with respect to the feeding axis.
28. The apparatus of claim 27 comprising means for rotating the first engagement member and the second engagement member around a rotation axis to engage the conductor with the first engagement member and the second engagement member transversally with respect to the feeding axis.
29. The apparatus of claim 26 comprising means for moving the first engagement member parallel to the axis that is perpendicular to the feeding axis.
30. The apparatus of claim 23 wherein the first engagement member and a second engagement member grip the conductor; and comprising means for rotating the first engagement member and the second engagement member around the feeding axis to apply torsion to the conductor.
31. The apparatus of claim 25 comprising a first support assembly rotated around the feeding axis, a second support assembly capable of translating transversally to the feeding axis; the first engagement member being supported by the second support assembly.
32. The apparatus of claim 25 comprising a first support assembly rotated around the feeding axis, a second support assembly capable of translating parallel to the feeding axis; and a third support assembly supported by the second support assembly; the first engagement member being supported by the third support assembly.
33. The apparatus of claim 31 comprising a member for passage of the conductor on a path to reach the first engagement member; wherein rotation of the first support assembly is around the member for passage of the conductor; and wherein translation of the second support assembly is supported by the member for passage of the conductor.
34. The apparatus of claim 23 wherein the means for moving the first engagement member with respect to the aperture comprises a crown gear rotated around the feeding axis.
35. The apparatus of claim 25 wherein means for moving the first engagement member parallel to the feeding axis comprises a crown gear rotated around the feeding axis.
36. The apparatus of claim 26 wherein the means for rotating the first engagement member around an axis that is perpendicular to the feeding axis comprises a crown gear rotated around the feeding axis.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other objects and advantages of the invention will become apparent from the following detailed description, which is only provided by way of non-limiting example, with reference to the annexed drawings, wherein:
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DETAILED DESCRIPTION OF THE INVENTION
[0038] With reference to
[0039] The unit 11 unwinds the conductor 10 from a conductor magazine 11, whereon the conductor was previously wound to form a reserve coil.
[0040] The cross-section of the conductor 10 in the magazine 11 may be circular, and unwinding takes place by aligning the longitudinal axis of the conductor 10 with the axis 100 of a feeding path.
[0041] The path may be straight, i.e. parallel to the axis 100, with a feeding direction 10, as shown in
[0042] The motion of the conductor 10 along the path, and therefore the feeding of the conductor 10 along the path, may occur through a push/pull action exerted onto the conductor in the unit 16, where motorized belts 16a and 16b press against the conductor in the feeding direction 10, as shown in
[0043] The unit 13 carries out the transformation of the conductor's cross-section, e.g. from a circular cross-section to a rectangular cross-section (or another cross-section with plane sides).
[0044] Upstream of the station 13 there is a station 12 for straightening the conductor 10, where the conductor is forced to slide along the feeding path 100.
[0045] In the station 12, the conductor 10 slides through idle rollers 12, whose surfaces engage the conductor to force it to follow the feeding path.
[0046] More in detail, while passing through the rollers 12 the conductor 10 engages those surfaces of the rollers 12 which are arranged laterally and tangential with respect to the feeding path, as shown in the elevation view of
[0047] In the unit 13 there are a series of pairs of rollers 13a, 13b, 13c, 13d. Each roller of one pair is shaped in accordance with the deformation print to be created on one side of the conductor. The print is created by engaging the roller on the side with a certain predetermined pressure. Engagement occurs in a direction transversal to the axis 100 of the feeding path.
[0048] The rollers of one pair 13a, 13b, 13c, 13d rotate with respect to each other in a synchronous and opposite manner. Moreover, the rotation of the rollers can be synchronized with the rotation of the belts 16a and 16b through the controller 15.
[0049] The transversal pressure applied by the rollers deforms the cross-section of the conductor 10, from circular to rectangular in the case shown in
[0050] More specifically, the roller pairs 13a, 13b, 13c, 13d are mutually arranged at 90, so that their profiles are oriented according to a succession of deformations in the following order: the conductor's sides are deformed for a first time by the pair 13a; then the conductor's top and bottom are deformed for a first time by the pair 13b; subsequently the conductor's sides are deformed for a second time by the pair 13c; finally, the conductor's top and bottom are deformed for a second time by the pair 13d.
[0051] The unit 14 downstream of the unit 13 along the feeding path is capable of providing information useful for measuring the conductor length being fed from the moment when a conductor's cut end passes by the photocell 17 positioned after the unit 14. In fact, the photocell 17 can signal the presence of a cut end of the conductor 10, and can therefore start the counting of the length of the conductor being fed to the bending unit 18. The counting is done by the control system 15, which uses the length passage information transmitted by the measurement wheels in the unit 14 and the count start signal transmitted by the photocell 17.
[0052] The bending unit 18 is capable of bending the conductor in order to have it take the desired coil member configuration, e.g. the coil members shown in
[0053]
[0054] With reference to
[0055] The feeding axis AC is a theoretical reference that can be considered to coincide with the axis of the feeding path 100 of the conductor 10, as shown in
[0056] The crown gear 31 is mounted integral with one end of the support member 20, as shown in
[0057] With reference to
[0058] The central perforated part of the support member 20 houses the tube 21. The slide bushings 21 are interposed between the tube 21 and the slide member 22. In this way, the slide member 22 is supported by the tube 21 and can move on the bushes 21 in the directions T or T, i.e. parallel to the axis AC and to the axis 100, with respect to the tube 21 when the screw portion 29 is turned by the motor/pinion 200.
[0059] The tube 21 is secured to the frame 30 by means of the fastening plate 25. As shown in
[0060] The bearings 21 are mounted between the support member 20 and the tube 21 to allow the rotations R and R of the support member 20 around the axis AC with respect to the tube 21, which is secured to the frame 30 through the plate 25.
[0061] A second slide member 23 is adapted to slide on the slide member 22 (see
[0062] The motion in the directions X and X takes place through .the rotation of the gear 41, which meshes with the rack 37 secured to the second slide member 23, as shown in
[0063] The member 38 is movable in the directions X and X on the second slide member 23. The member 38 comprises a first rack portion 38 and a second rack portion 38 (see
[0064] The motion of the member 38 in the directions X and X takes place through the rotation of the gear 45, which meshes with the rack portion 38. The gear 45 is fitted to the end of the shaft 65, which is adapted to rotate on the slide element 22. The shaft 65 receives the shaft 66 in a bore 65 at its end, as shown in
[0065] The conductor bending tool 50 (see
[0066] As shown in
[0067] The shaft 54 is slideable in the directions Z and Z in the central perforated part of the member 56, which is integral with the second slide member 23, and is therefore slideable in the directions Z and Z with respect to the second slide member 23. The directions Z and Z are perpendicular to the axis AC, as shown in
[0068] The member 56 is supported on the bearings 55 mounted in the support bell 57 (see
[0069] The movements of the member 38 on the second slide member 23 in the directions X and X as described above cause the shaft 54 to rotate, bringing along the pins 51 and 52 of the rotation RO, or of the opposite rotation RO, on the second slide member 23, i.e. around an axis RZ (see
[0070] In fact, the key 60 on the shaft 54 engages a seat 60 in the central perforated part of the member 56. The seat 60 is parallel to the axis 54. Therefore, rotation is transmitted from the member 56 to the shaft 54, and the shaft 54 is allowed to slide parallel to the axis RZ.
[0071] The axis RZ can be considered to be a reference axis perpendicular to the axis AC. The axis of the shaft 54 is parallel to the axis RZ and can be considered to coincide with the axis 54, as shown in
[0072] The drive cylinder 61 is secured to the surface 23, as shown in
[0073] When the cylinder 61 is actuated, the shaft 54 is therefore moved in the directions Z and Z, parallel to the axis RZ, and as a result also the pins 51 and 52 can move in the directions Z and Z, parallel to the axis RZ.
[0074] The movements of the member 38 on the second slide member 23 in the directions X and X cause the shaft 54 to rotate, bringing along the pins 51 and 52 on the second slide member 23, around the axis RZ on the second slide member 23. Therefore, the pins 51 and 52 are supported on the second slide member 23 to rotate around the axis RZ of the rotations RO and RO.
[0075] The possible movements of the pins 51 and 52 are summarized in
[0076] Through movements T and T of the slide member 22 generated by the motor/pinion 200, the axis RZ translates perpendicular to the plane containing
[0077] Through the movements of the second slide member 23 in the directions X and X with respect to the slide member 22, generated by the motor/pinion 400, the axis RZ translates transversally to the axis AC. Consequently, the same translation movement is made by the pins 51 and 52.
[0078] Through the rotations of the support member 20 around the feeding axis 100, generated by the motor/pinion 500, the axis RZ rotates around the axis AC of the opposite rotations R or R, in that the surface 23 rotates in the same manner around the axis AC. Consequently, the same rotational movement R or R is made by the pins 51 and 52.
[0079] Through the actuation of the cylinder 61, the pins 51 and 52 are moved perpendicularly towards or away from the axis AC. In this case, the pins 51 and 52 translate parallel to the axis RZ.
[0080] Through the movement of the member 38 on the second slide member 23 in the directions X and X, generated by the motor/pinion 300, the pins 51 and 52 perform rotations RO or RO around the axis RZ.
[0081]
[0082] For clarity and simplicity, in
[0083]
[0084] With reference to
[0085] To reach this position, the pins have been rotated by the rotations RO or RO around the axis RZ, translated in the direction X, and rotated around the axis AC by a rotation R with respect to the position of
[0086] The bending of
[0087] This bending movement of the pins 51 and 52 is obtained by using a combination of rotation RO around the axis RZ and movement of the pins 51 and 52 in the direction X. During these movements, the pins apply a transversal force onto the conductor 10 in order to bend it as indicated by the continuous line of the conductor 10 in
[0088] The bending shown in
[0089] The bending of
[0090] The bending of
[0091] In summary, the pins 51 and 52 have been translated in the direction T, translated in the direction X, rotated by the rotation RO around the axis RZ, and rotated by the rotation R around the axis AC.
[0092] The bending shown in
[0093] The torsion bending of
[0094] The coil member of
[0095] The bending unit 18 creates the bend that characterizes the hairpins of
[0096] For the hairpin of
[0097] In a second step the bend portion 131 is made, which consists of a curve and a torsion obtained, for example, by applying the principles of
[0098] In a third step the bend portion 132 is made, which consists of a gentler curve obtained, for example, by applying the principles of
[0099] In a fourth step the bend portion 133 is made, which consists of a curve and a torsion obtained, for example, by applying the principles of
[0100] The other portions 134, 135, 136 and 130 that complete the hairpin are made in a similar manner through an appropriate combination of the bending operations of
[0101] Finally, a robot's manipulator (not shown) may grasp the hairpin to remove the end portion of the leg 130 from the nozzle 80 after the cutting operation has been performed by the unit 101.
[0102] As regards the coil member of
[0103] In one embodiment of the present invention, the bending tool 50 comprises only one pin 51 or 52 for performing the bending operations described with reference to
[0104] Furthermore, simpler coil configurations may only require a bending obtained through the movement of at least one of the pins 51 and 52 in the direction X and X; in this case, the solution will be limited to the transmission from the motor 400, i.e. crown gear 33, gear 36, shaft 44, gear 41, rack 37 and guide 39 for the member 23, whereas the members 22 and 23 will be integral with each other without having to mutually rotate or translate.
[0105] Other coil configurations may require the addition of the rotation R and R of the support 20 through the motor 500 and the crown gear 31.
[0106] Further configurations may require the addition of the translation T and T of the member 22 through the motor 200 and the screw portion 29.
[0107] The above description of one specific embodiment has illustrated the invention from a conceptual viewpoint, so that others, by using prior-art techniques, will be able to modify and/or adapt said specific embodiment to various applications without further research and without departing from the inventive concept. It is therefore understood that any such modifications and adaptations will be considered to be equivalent to the exemplary embodiment described herein. The means and materials necessary for implementing the various functions described herein may vary without departing from the scope of the invention. It is understood that the expressions and terminology used herein are merely descriptive and hence non-limiting.