Search

CN-122003805-A - Apparatus for forming induction windings on salient poles of an electric machine and related method of operation

CN122003805ACN 122003805 ACN122003805 ACN 122003805ACN-122003805-A

Abstract

An apparatus (1) for forming induction windings (C) wound on salient poles (P) of an electric machine, comprising at least one support group (2) for temporarily housing the ferromagnetic cores (R) of the electric machine in a configuration in which at least one radial salient pole (P) faces and is in proximity to at least one assembly (3), the assembly (3) rotating with respect to an axis (X) parallel to the radial direction of the respective salient pole (P), the assembly (3) being provided with at least one wire feeder (4) of at least one conductor (W), and at least one structure (5, 6) for guiding and conveying the conductor (W) at least partially insertable into at least one slot (S) for surrounding the respective salient pole (P).

Inventors

  • G. Manueli

Assignees

  • ATOP有限公司

Dates

Publication Date
20260508
Application Date
20241003
Priority Date
20231009

Claims (15)

  1. 1. An apparatus for forming induction windings (C) for an electric machine having salient poles, wherein at least one conductor (W) is wound on salient poles (P (W) of a ferromagnetic core (R) of the electric machine, wherein the salient poles (P) extend parallel to a rotation axis (Y) of the core (R), protrude radially and are spaced apart from each other, defining slots (S) between each successive salient pole (P), the apparatus comprising a rotating assembly (3) equipped with a wire feeder (4) of at least one conductor (W), a support group (2) for temporarily supporting the ferromagnetic core (R), and at least one guiding and conveying structure (5; 6) of the at least one conductor (W), the structure (5; 6) being dimensioned to be at least partially insertable into one of the slots (S) so as to surround the respective salient pole (P) and being mounted on the support group (2), wherein the rotating assembly (3) is rotatable about the rotation axis (X) with respect to the support group (2), wherein the guiding and conveying structure (5; 6) is interposed between the pair of transverse elements (11; 8; 11) and (8) and at least one pair of transverse elements (11; 12) is interposed between each other, the guiding and transporting structure (5; 6) is configured to translate along a trajectory having at least one component (dx) parallel to the rotation axis (X) of the rotating assembly (3), and is movable between a first configuration in which the pair of longitudinal (7; 8) and transversal (11; 12) elements are distanced from the ferromagnetic core (R), and a second configuration in which they surround one of the salient poles (P) to guide and transport the at least one conductor (W) supplied by the at least one wire feeder (4) to obtain ordered and regular conductor (W) coils wound around the surrounding salient pole (P); Characterized in that the transverse elements (11; 12) of the pair of transverse elements (11; 12) are configured to be movable in a longitudinal direction (dy) parallel to the axis of rotation (Y) of the ferromagnetic core (R) between reciprocal approaching and removing positions to adjust their distance such that the pair of transverse elements (11; 12) are positionable at a distance approaching the axial extension (Pa) of the respective salient pole (P).
  2. 2. Device according to claim 1, characterized in that said pair of transverse elements (11; 12) and said guiding and conveying structure (5; 6) are moved by respective linear actuators (11 a,12 e).
  3. 3. Device according to claim 2, characterized in that the linear actuator (11 a;12 e) is of the type selected from among electromechanical, hydraulic or pneumatic or electromagnetic actuators, and in that the linear actuator (11 a;12 e) is commanded by a controller (11 a ';12 e') for adjusting the mutual distance of the transverse elements (11; 12) in a longitudinal direction (dy) parallel to the rotation axis (Y) of the rotor (R) so as to adapt to the axial extension (Pa) of the respective salient pole (P) to be wound.
  4. 4. The apparatus according to at least one of the preceding claims, characterized in that the transverse elements (11; 12) comprise respective inclined surfaces (13; 14) arranged parallel to the longitudinal extension (Pl) of the pole (P) and configured to cooperate with the longitudinal elements (7; 8) to form a shape configured to guide the at least one conductor (W) during winding around the salient pole (P).
  5. 5. The apparatus according to one or more of the preceding claims, characterized in that said longitudinal elements (8) are configured to translate, by means of respective movement means, on trajectories having a component along a transversal direction (dz) substantially perpendicular to said longitudinal direction (dy), for adjusting the distance between each of said longitudinal elements (8) according to the dimensions of said respective salient pole (P).
  6. 6. The apparatus according to claim 5, characterized in that the respective moving means are configured to translate the respective longitudinal element (8) between the first configuration and the second configuration, wherein in the first configuration the longitudinal element (8) is removed from the slot (S) and in the second configuration the longitudinal element (8) is at least partially inserted into the slot (S) of the side of one of the salient poles (P), and wherein the respective end edge (10) of the longitudinal element (8) faces and is close to the salient pole (P).
  7. 7. The apparatus according to any one of the preceding claims, characterized in that each transverse element (12) comprises a pair of blocks (12 a,12 b), each block (12 a,12 b) being fixed to and protruding from a respective longitudinal element (9) of the pair of longitudinal elements (8).
  8. 8. The apparatus according to the preceding claim, characterized in that the blocks (12 a,12 b) of the pair of blocks (12 a,12 b) are configured to be arranged at least partially overlapping so as to define a guide for the at least one conductor (W) provided by the at least one wire feeder (4) during winding around a salient pole (P).
  9. 9. The apparatus according to the preceding claim, characterized in that the longitudinal element (8) and the blocks (12 a,12 b) are synchronously operable to make the degree of translation of the blocks (12 a,12 b) the same.
  10. 10. The device according to any one of the preceding claims, characterized in that the longitudinal element (8) is of the sheet-like type.
  11. 11. A method for forming an induction winding (C) wound on a salient pole (P) of a ferromagnetic core (R) of an electric machine, wherein the salient pole (P) extends parallel to a rotation axis (Y) of the ferromagnetic core (R), the method comprising: -arranging (I) a ferromagnetic core (R) of the electric machine with one of its salient poles (P) facing a rotating assembly (3), wherein the rotating assembly (4) is rotatable about a rotation axis (X) substantially perpendicular to the rotation axis (Y) of the core (R); -inserting (II) a guiding and transporting structure (5; 6) between the salient poles (P) and the rotating assembly (3) for guiding at least one conductor (W) to be wound around the salient poles (P), wherein the guiding and transporting structure (5; 6) comprises a pair of longitudinal elements (7; 8) and at least one pair of transverse elements (11; 12) interposed between the longitudinal elements (7; 8) and facing each other; -surrounding (III) the salient poles (P) with the guiding and conveying structure (5; 6); -conveying (IV) said at least one conductor (W) by means of a wire feeder (4) during rotation of said rotating assembly (3), allowing said conductor (W) to slide on said guiding and conveying structure (5; 6); -translating (V) the guiding and transporting structure (5, 6) along a direction (dx) parallel to the rotation axis (X) of the rotating assembly (3) to obtain ordered and regular coils of conductors (W) wound around the surrounding salient poles (P), the method being Characterized in that it further comprises an adjustment step in which the transverse elements (11; 12) of the pair of transverse elements (11; 12) are moved in a longitudinal direction (dy) parallel to the axis of rotation (Y) of the ferromagnetic core (R) between reciprocal approaching and removing positions to adjust their distance until the pair of abutment elements (11; 12) are positioned at a distance approaching the axial extension (Pa) of the respective salient pole (P).
  12. 12. Method according to the preceding claim, characterized in that the adjustment step involves translating the pair of transverse elements (11; 12) in a longitudinal direction (dy) parallel to the rotation axis (Y) of the rotor (R) by means of a linear actuator (11 a;12 e), and in that the linear actuator (11 a;12 e) is commanded by a controller (11 a ';12 e') associated therewith.
  13. 13. Method according to claim 11 or 12, characterized in that said adjustment step comprises a translation of said longitudinal elements (8) on a trajectory having a component along a transversal direction (dz) substantially perpendicular to said longitudinal direction (dy) for adjusting the distance between each of said longitudinal elements (8) according to the dimensions of the respective salient poles (P).
  14. 14. A method according to claim 13, wherein each transverse element (13) of the pair of transverse elements (12) comprises a pair of blocks (12 a,12 b), each block (12 a,12 b) being fixed to and protruding from a respective longitudinal element (8) of the pair of longitudinal elements (8), and wherein the adjusting step further comprises adjusting the mutual distance of the pair of blocks (12 b) in the transverse direction (dz) perpendicular to the longitudinal direction (dy).
  15. 15. Method according to any one of claims 11-14, characterized in that the direction (dx) parallel to the rotation axis (X) of the rotating assembly (3) is perpendicular to the longitudinal direction (dy) parallel to the rotation axis (Y) of the core (R).

Description

Apparatus for forming induction windings on salient poles of an electric machine and related method of operation Technical Field The present invention relates to a device for forming induction windings on salient poles of an electric machine, in particular for providing windings on the rotor of an electric machine (of any type and therefore also suitable for automotive use) and/or of a generator (in particular a direct current generator or an alternator). The invention also relates to a method for implementing the above specified induction winding. Background Salient poles are part of a ferromagnetic core that generally protrudes in the radial direction and is made up of a stack of laminations (laminations are employed to reduce eddy current losses). The induction winding is constituted by one or more conductors (typically constituted by a metal wire coated with a layer of dielectric material) arranged to constitute a plurality of coils around respective magnetic cores (salient poles in this case). The automation of providing induction windings on salient poles is particularly complex and requires the use of rotating assemblies responsible for the conductor feeding, which are commonly identified by the term flyer (flyer). However, this assembly does not allow an optimal distribution of the conductor coils, which may overlap at will, affecting the proper functioning of the winding. It is known to use conductor transport structures designed to precisely define the position of each conductor coil routed by a rotating assembly (flyer). Application number WO2021205279 (claiming priority from italian patent 102020000007288) in the name of the same applicant shows a device for realising (or providing) windings of this type, provided with a particularly efficient transport structure. However, the structure described in the above patent document has some key problems. First, the entire conveying structure must be replaced whenever it is necessary to change the form (format) of the salient poles on which the windings are to be implemented. This means that each time the form is changed, a production downtime is required for the time required for the operator to perform the transport structure changing operation. Secondly, it is necessary to provide a conveying structure for each type of salient pole form on which the windings are implemented, which results in a significant increase in procurement costs and requires an area dedicated to their storage when they are not in use (with consequent logistical problems and costs). According to application number WO2021205279, the transport structure needs to be replaced each time the form is changed, which requires the presence of trained personnel for these activities, resulting in an increase in the costs attributable to the equipment. Disclosure of Invention The object of the present invention is to solve the above-mentioned problems by providing an apparatus for forming an induction winding on a salient pole of an electric machine, which does not require replacement of the conveying structure when a change of the form of the salient pole of the winding is effected thereon. Within the scope of this aim, an object of the present invention is to provide a device for forming induction windings on salient poles of an electric machine at an operating cost lower than that expected with prior art solutions in the field. It is another object of the present invention to provide an apparatus for forming induction windings on salient poles of an electric machine that does not require a storage area for replacement parts to be serviced to ensure proper operation. Another object of the present invention is to provide a device for forming induction windings on salient poles of an electric machine that does not require supervision and intervention by a professional operator in the form-altering operation. Another object of the present invention is to devise a method for forming induction windings on salient poles of an electric machine, which is suitable for operating on different types of rotors of electric machines having a wide range of variable dimensions. Another object of the present invention is to devise a method for forming induction windings on salient poles of an electric machine which, when operated in form-changing, provides short downtime, which is in any case shorter than the downtime currently provided in the background art. Another object of the present invention is to provide an apparatus and a method for forming induction windings on salient poles of an electric machine, which are low in cost, relatively simple to put into practice, and guaranteed in application. This object and these objects are achieved by an apparatus for forming induction windings on salient poles of an electric machine according to claim 1. This object and these objects are also achieved by means of a method of forming induction windings on salient poles of an electric machine according to claim 10