Atop S.p.a.

Axis Usa, Inc.

Massimo Ponzio

Rubino Corbinelli

Maurizio Mugelli

Sabatino Luciani

Gianfranco Stratico

Massimo Lombardi

Fabrizio Cresti

Daniele Nocciolini

Stefano Niccolini

Giovanni Manuelli

Antonio Lumini

Roberto Giachetti

Davide Chesi

Federico Rossi

Paolo Nesti

Graziano Quirini

Gianfranco Stratico'

Maurizio Nugelli

Andrea Migliorini

Massimo Cugnigni

Embodiments of the present invention are directed to an apparatus for inserting an undulated coil assembly in a plurality of slots of a hollow core of a stator of a dynamoelectric machine. In some embodiments, the hollow core includes a hollow core central rotation axis, the undulated coil assembly is formed by a plurality of undulated coils, and each of the plurality of undulated coils including adjacent superimposed linear portions (LI). At least three of the plurality of undulated coils extend parallel to each other and a plurality of turn portions (T) connecting the adjacent linear portions (LI) thereof. The apparatus includes, inter alia, a support member, a first guide device aligned with respect to each of the end faces and the plurality of slots of the hollow core, a passage associated with the first guide device which includes at least one guide surface, a feeder that feeds the first coil portion, and moving means for relatively moving the hollow core with respect to the first guide device to position the plurality of slots of the hollow core for receiving the superimposed linear portions (LI).

Apparatus for inserting an undulated coil assembly in slots of a core of a stator of a dynamoelectric machine

The invention relates to a stator () which may be used within an electric rotating machine, an electric machine, an apparatus for preparing a stator and a method for preparing a stator. The stator () comprises a stator core () having a plurality of slots () arranged in a circumferential direction (C) of the stator core (). At least a first conductor () and at least a second conductor () are arranged along a radial direction (R) of one slot (). Axial end sections () of the conductors () are electrically connectable or connected and the axial end sections () of radially adjacent conductors () are distanced from each other. The distance () between the proximal end () of the axial end section () of a first conductor () and the stator core () is longer than the distance () between the distal end () of the axial end section () of a second conductor () and the stator core ().

Stator, electric machine, apparatus and method for preparing a stator

The invention relates to a stator which may be used within an electric rotating machine and a method for manufacturing a stator. The stator () comprises a stator core () having a plurality of slots () arranged in circumferential direction (C) of the stator core (), a plurality of conductors () forming a stator winding, wherein at least a radially outer conductor () and a radially inner conductor () are arranged along a radial direction (R) of each slot (). At least one pair of a radially outer conductor () of a first slot () and a radially inner conductor () of a second slot () circumferentially spaced from the first slot () is electrically connected by a connection bridge (). The connection bridge () comprises a first base element () and a second base element () connected to a respective conductor () and a top element () being connected to the base elements () and preferably arranged in a larger distance from the stator core () than the first base element () and second base element ().

Stator, electric machine, connection bridge and method for manufacturing a stator

The invention relates to a stator () which may be used within an electric rotating machine, an apparatus for preparing pre-shaped insulators and a method for preparing a pre-shaped insulator. The stator () comprises a stator core () which has a plurality of axially extending slots () arranged in a circumferential direction (C) of the stator core () and at least two conductors () arranged along a radial direction (R) of the same slot (). Each conductor () is peripherally wrapped by an individual insulator () which extends around the outer circumference () of the conductor (), such that in circumferential direction the insulator () comprises a one-layer-section () and an overlapping section () which extend along the complete axial length () of the insulator ().

Stator, apparatus and method for peparing a pre-shaped insulator

A device for positioning the ends of at least first pair of legs of hairpin conductors extending from a stator core with respect to a welder tool includes a first clamping element and a second clamping element that are independently moveable radially. The first clamping element has a first clamping surface and said second clamping element has a second clamping surface, wherein the clamping surfaces radially face each other. The clamping elements form a first radially inner receiving section between the first clamping surface and the second clamping surface, having a first radial width dimensioned to axially receive and clamp a first pair of legs during welding, and a second radially outer receiving section inside the first and second clamping elements, having a second radial width dimensioned to receive at least a further pair of legs during welding of the first pair of legs.

Device for positioning ends of at least first pair of legs of hairpin conductors

A device for widening ends of legs of hairpin conductors, arranged in slots of a stator core, includes at least one finger, for radially moving the ends of legs of hairpin conductors. The at least one finger includes at least one radially extending arm and a separation member arranged adjacent to an end of the arm. The separation member is designed to be positioned between two ends of radially neighboring legs of pairs of hairpin conductors. The finger has a first section adjacent to the separation member. The first section is adapted for moving the pair of ends of legs when the finger is radially moved. The finger has a second section, which does not overlap with the first section. The second section is dimensioned to receive at least one pair of legs without moving, when the finger is radially moved.

Device and method for widening ends of legs of hairpin conductors

The invention is directed to an apparatus () and a method for manufacturing a partial nest or a nest () of pin conductors () for forming a stator. The apparatus () comprises a stator core template () with a block body () and radially extending ribs () forming slots () there between for insertion of legs () of the pin conductors (). The apparatus () comprises at least one ring element () being arranged to provide an outer radial abutment face for inserted pin conductors ().

Apparatus and method for manufacturing a partial nest or a nest of conductors

A method and an apparatus are provided for manufacturing a stator with a plurality of hairpin conductors. For inserting the hairpin conductors () into the slots () of a stator core () a stator core template () is provided. Hairpin conductors () are axially inserted into slots () of the stator core template () such that the hairpin conductor () is arranged at a first position (P) within said slot (). The hairpin conductor () is then moved within said slot () to a different position (P). A complete nest () of hairpin conductors () formed within the stator core template () is then transferred to the stator core ().

Method for manufacturing a stator

Methods and apparatuses for forming a woven coil assembly (), the coil assembly having adjacent superimposed linear portions (LI-LAL-ALI) extending parallel to each other in a first area (A) of the coil assembly, and adjacent superimposed linear portions (L-LAL-AL) extending parallel to each other in a second area (A) of the coil assembly, wherein a plurality of head portions (T) connect the linear portions of the first area (AI) to the linear portions of the second area (A).

Apparatuses for forming woven undulated coil assemblies

Embodiments of the currently claimed disclosure are directed to methods for inserting an undulated coil assembly in the slots of a hollow core of a dynamoelectric machine. In some embodiments, the method can include positioning at least a first coil portion of the coil assembly around a support member, aligning a guide device with respect to end faces and the slots of the core, feeding the first coil portion from the drum support member along the guide device to insert adjacent superimposed linear portions (LI) of the coil assembly in the slots, engaging the superimposed linear portions (LI) along at least one guide surface during the feeding, and relatively moving the core with respect to the guide assembly device to position the slots for receiving the superimposed linear portions (LI).

Method for inserting undulated coil assemblies in slots of cores of dynamoelectric machines

An apparatus for forming pre-shaped insulating sheets comprises a first bending station and a second bending station. The first bending station is used for bending a flat sheet of insulating material into a Z-shaped sheet (). The second bending station is used for bending the Z-shaped sheet into an S-shape. The first and second bending stations comprise pairs of first () and second bending operators for creating bending movements.

Apparatus and a method for forming pre-shaped insulating sheets

The method and apparatus comprise the following features: &#x2014;forming coil members () by bending an electric conductor () externally coated with an outer insulation ('); wherein the bending is made at predetermined lengths from a reference position (&#x2032;), and wherein each one of the coil members (), when formed, comprises at least one head portion (&#x2032;) and leg portions (&#x2033;) extending from said at least one head portion (&#x2032;); &#x2014;feeding the electric conductor () to accomplish the bending; &#x2014;cutting the electric conductor () to detach a formed coil member () from said electric conductor (); &#x2014;inserting the leg portions (&#x2033;) of the coil members () into slots of the stator, so that parts of said leg portions (&#x2033;) extend from one end of the stator and the head portions (&#x2032;) extend from an opposite end of the stator; &#x2014;arranging at least one laser beam () to remove the insulation (&#x2032;) from predetermined areas () of the electric conductor (); &#x2014;radiating the surface of the electric conductor () with said at least one laser beam () situated at a predetermined position (IP,P) with respect to the reference position (&#x2032;) along the length of the electric conductor () being fed, and at a predetermined stage of the bending of a coil member ().

Method and apparatus for manufacturing a stator of a dynamo-electric machine

Methods and apparatuses for forming a woven coil assembly (), the coil assembly having adjacent superimposed linear portions (LI-L, AL-ALI) extending parallel to each other in a first area (Al) of the coil assembly, and adjacent superimposed linear portions (L-L, AL-AL) extending parallel to each other in a second area (A) of the coil assembly, wherein a plurality of head portions (T) connect the linear portions of the first area (AI) to the linear portions of the second area (A).

Methods for forming woven undulated coil assemblies

The apparatus and process relate to aligning ends of wire conductors extending from coil members inserted in slots of a core () of a dynamo electric machine to join the ends of at least two wire conductors (EP, EP, EP, EP, EP) by means of a welding operation; wherein the ends to be joined are aligned along radiuses (R, R) of the core (), and wherein spacing (S, S) exists between two adjacent radiuses (R, R) of the core (). This apparatus and this process provide for a first alignment unit () to which the following steps are made to be performed: positioning a first member () in a first spacing (S) existing on one side of a first radius (R) of said core (); positioning a first abutment portion (') at a first position situated radially between a first group of ends (EP) to be joined and a second group of ends (E) to be joined, said first and second group of ends being aligned along said first radius (R); positioning a second member () in a second spacing (S) existing on the opposite side of the first radius (R); positioning a second abutment portion (&#x2032;) at a second position situated radially between said first group of ends (EP) to be joined and said second group of ends (E) to be joined; positioning a first pusher () at a radially outer position relative to said core () for pushing said first group of ends (EP) to be joined against said first abutment portion (&#x2032;); positioning a second pusher () at a radially inner position relative to said core () for pushing said second group of ends (EP) to be joined against said second abutment portion (&#x2032;); arranging first means () configured for relatively moving the first member (), the second member (), the first abutment portion (&#x2032;) and the second abutment portion (&#x2032;) in an axial direction (Z, Z&#x2032;) of the core (); arranging second means () configured for relatively moving the first radial pusher () and the second radial pusher () in the radial direction (R, R&#x2032;) of the core (); arranging third means () configured for moving the first member () and the second member () one towards the other in a circumferential direction (CS, CS&#x2032;) of the core ().

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Florence, Italy

Massimo Ponzio