WO2022084754A1 - Machine de transfert et procédé de formation d'épingles à cheveux - Google Patents

Machine de transfert et procédé de formation d'épingles à cheveux Download PDF

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Publication number
WO2022084754A1
WO2022084754A1 PCT/IB2021/054504 IB2021054504W WO2022084754A1 WO 2022084754 A1 WO2022084754 A1 WO 2022084754A1 IB 2021054504 W IB2021054504 W IB 2021054504W WO 2022084754 A1 WO2022084754 A1 WO 2022084754A1
Authority
WO
WIPO (PCT)
Prior art keywords
metal filament
transfer machine
station
beveling
bending
Prior art date
Application number
PCT/IB2021/054504
Other languages
English (en)
Inventor
Jacopo VERZELETTI
Original Assignee
Progettilab S.R.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Progettilab S.R.L. filed Critical Progettilab S.R.L.
Publication of WO2022084754A1 publication Critical patent/WO2022084754A1/fr

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H02K15/0414—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils
    • H02K15/0421—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils consisting of single conductors, e.g. hairpins

Definitions

  • the present invention relates to a transfer machine for forming hairpins, and a method for making hairpins.
  • hairpin refers to a metal filament with a particular geometry obtained by a forming process and generally applicable to the stator of an electric motor to make the electromagnetic interactions underlying the operation of the above-mentioned electric motor possible.
  • the hairpins are then interconnected by welding so as to obtain the characteristic metal winding found in the stators of electric motors.
  • the present invention applies to the various fields of the art in which use is made of electric motors, for example the automotive field and the field of industrial robotics.
  • hairpins are made by feeding a forming head with a metal wire wound on a reel.
  • the metal wire is passed through a plurality of rollers configured to straighten it, thus eliminating the curved shape thereof due to storage being wound on the reel.
  • the wire is subjected to a stripping process which allows the removal of a protective, generally polymeric, surface coating.
  • the forming head then obtains a plurality of sequential bends at different points in the metal wire to create the particular geometrical shape of the hairpin.
  • the wire may be moved, generally advancing, so as to allow a bending of the wire at different portions of the wire itself.
  • a trimming head trims the portion of wire formed to allow starting a new forming portion on the portion of wire following the one formed previously.
  • the hairpins made are then collected and associated with a stator of an electric motor.
  • the duration of the forming process defines a kind of "bottleneck" in the process of making the hairpins, thus limiting the productivity and the efficiency of the entire production line.
  • the processes with limited times are to maintain the production rate dictated by the duration of the forming process.
  • the current process for making hairpins disadvantageously constrains the entire production to a predetermined hairpin shape.
  • the parameters of the entire production line are to be modified (bending, trimming, stripping, etc.), thus affecting the production process times and inevitably resulting in machine stops which affect the productivity of the entire line.
  • FIG. 1 is a perspective view of a transfer machine for forming hairpins according to the present invention
  • FIG. 2 is a side view of the transfer machine for forming hairpins in Figure 1 ;
  • FIG. 3 to 5 are detailed views of certain portions of the transfer machine for forming hairpins according to possible embodiments of the invention.
  • FIG. 6 is a sectional view of a portion of the transfer machine for forming hairpins according to a possible embodiment of the present invention.
  • reference numeral 1 indicates a transfer machine for forming hairpins, which will be indicated hereinafter as a transfer machine 1 .
  • transfer machine refers to a type of automatic machine which combines the functions of a series of separate machines in a single production unit by virtue of a plurality of working stations which operate simultaneously.
  • the transfer machine 1 comprises movement means 2 configured to move a metal filament "F" between an inlet station 3 and an outlet station 4.
  • the transfer machine 1 may comprise at least one conveyor "C” arranged close to the inlet station 3 and/or the outlet station 4, adapted to facilitate the introduction of the metal filament "F” into and/or the removal of the hairpin from the transfer machine 1 , respectively.
  • the movement means 2 comprise a rotation drum 5 which is rotatable about a preferably horizontal rotation axis "Y".
  • horizontal in the present description refers to an axis parallel to a support/resting plane of the transfer machine 1 in a regular operating condition.
  • the above-mentioned rotation axis "Y" may have a vertical or oblique extension without altering the inventive concept underlying the present invention.
  • the movement means 2 comprise a retaining device 6 configured to retain the metal filament "F", i.e. constraining the metal filament "F" to the movement means 2.
  • the retaining device 6 is mounted on the rotation drum 5 to rotate about the rotation axis "Y".
  • the retaining device 6 is configured to restrain the metal filament "F" to the movement means 2 during the movement between the inlet station 3 and the outlet station 4.
  • the retaining device 6 grasps the metal filament "F" at the inlet station 3 and retains it during the movement up to the outlet station 4.
  • the retaining device 6 may be configured to retain the metal filament "F” so that it is arranged at least partially parallel to the rotation axis "Y".
  • the transfer machine 1 allows limiting the volume caused by the metal filament "F” and by the retaining device 6. Moreover, such an embodiment allows limiting the occurrence of inertial loads induced by an uneven distribution of the mass with respect to the rotation axis "Y”.
  • the retaining device 6 comprises a first and a second gripper 7, 8 configured to grasp the metal filament "F" at respective separate intermediate portions of the metal filament "F".
  • the first and second grippers 7, 8 may constrain the metal filament "F", thus leaving free at least one of the two ends so as to allow a processing thereof in one or more operating stations (as described in detail below).
  • At least one gripper of the first gripper 7 and the second gripper 8 may be a four-finger self-centering gripper ( Figure 6), thus allowing a highly effective grasping of the metal filament "F".
  • the four self-centering fingers ensure an increased operating flexibility for the retaining device 6, thus allowing a grasping of metal filaments "F" with different geometries, for example each activating selfcentering fingers on a respective side of a metal filament "F” with quadrangular cross section or on different portions of the lateral surface of a metal filament "F” with circular or elliptical cross section.
  • the first gripper 7 and/or the second gripper 8 may be rotatable to obtain a rotation of the metal filament "F" with respect to an axis parallel to, and preferably coincident with, a main extension axis of the same metal filament "F".
  • the first and second grippers 7, 8 moreover may be mutually movable close to and away from each other.
  • first and second grippers 7, 8 allow an adjustment of the retaining device 6 in such a way as to constrain metal filaments "F" having different dimensions.
  • the first and second grippers 7, 8 give the transfer machine 1 increased operating flexibility, thus allowing an employment thereof with metal filaments having different geometry and dimension.
  • the metal filament "F" may have a length, measured along the extension axis thereof, between 250 mm and 500 mm, preferably equal to 400 mm.
  • first gripper 7 may be activated on the metal filament "F” by sliding with respect to the second gripper 8, which is not activated on the metal filament "F", so as to obtain a sliding of the metal filament "F” with respect to the second gripper 8.
  • the first gripper 7 promotes an advancement of the metal filament "F" with respect to the second gripper 8 so as to allow an effective processing thereof in one or more operating stations, for example by a bending station.
  • the transfer machine 1 further comprises at least one bending station 9 interposed between the inlet station 3 and the outlet station 4.
  • the bending station 9 comprises at least one forming tool 10 configured to form at least one predetermined bend of the metal filament "F" to make a respective hairpin.
  • the transfer machine 1 comprises a plurality of bending stations 9 configured to obtain a sequential sequence of bends on the metal filament "F".
  • the transfer machine 1 may comprise a plurality of bending stations 9 so as to obtain a sequence of bends on the metal filament "F", each of which may make a sequence of bends so as to obtain the specific geometry of the hairpin.
  • the relative sliding between the above-mentioned first and second grippers 7, 8 advantageously ensures the possibility of obtaining bends on different portions of the metal filament "F" both at the same bending station and at different bending stations.
  • the transfer machine 1 comprises four bending stations 9 circumferentially distributed about the rotation drum 5.
  • each bending station 9 has a forming tool 10 for operating, preferably simultaneously, on a respective metal filament "F".
  • the transfer machine 1 increases the production rate as compared to the machines of the prior art by simultaneously operating on a plurality of metal filaments "F” and thus overcoming the "bottleneck” due to a single bending station for each production line.
  • the transfer machine 1 may further comprise a beveling station 11 configured to obtain a beveling of at least one end of the metal filament npn
  • the beveling station 11 may be arranged upstream of the at least one bending station 9 performing the beveling on a substantially rectilinear metal filament "F", thus allowing a simplification of the production process.
  • the beveling station 11 comprises a pair of beveling heads 12, each selectively activatable on a respective end of the metal filament "F" to obtain the beveling thereof.
  • the retaining device 6 may be interposed between the pair of beveling heads 12 during the beveling operations.
  • each of the free ends of the metal filament "F" is facing a respective beveling head 12.
  • the beveling heads 12 may be mutually movable towards and away from each other to be activated on the respective ends of the metal filament "F".
  • the beveling heads 12 may have a respective rotating portion which, by being activated on the free ends the metal filament "F", promote the beveling thereof.
  • the transfer machine 1 may comprise a stripping station 13 configured to remove a surface coating of at least one portion of the metal filament "F".
  • the stripping station 13 is arranged upstream of the at least one bending station 9 and downstream of the above-mentioned beveling station 12.
  • the stripping station 13 may have a different position or may not be provided, without altering the inventive concept underlying the present invention.
  • the stripping station 13 comprises at least one laser stripping device 14, even more preferably a pair of laser stripping devices 14 (as shown in Figure 4).
  • the laser stripping device 14 may be reversibly movable in a plurality of operating positions to irradiate at least a portion of the metal filament "F" coated by the surface coating.
  • the transfer machine 1 allows the stripping of metal filaments "F" having different dimensions and various types of coatings.
  • the present invention refers to a method for making hairpins comprising the steps of preparing a transfer machine and feeding the transfer machine with at least one metal filament "F".
  • the transfer machine is a transfer machine 1 according to what is described above.
  • the present method may comprise a step of cutting a continuous metal wire of a reel so as to obtain at least one metal filament npn
  • the cutting step precedes the feeding step of the transfer machine 1 .
  • the cutting step with increased production rates which may be performed, for example by a trimming machine, is freed from the further steps generally having lower production rates, of the process for making hairpins.
  • the cutting step may not be provided, without altering the inventive concept underlying the present invention.
  • the method comprises a step of moving the metal filament "F" between a plurality of different operating stations of the transfer machine 1.
  • the method comprises a step of bending the metal filament "F” according to a sequence of bending operations.
  • Each of the above-mentioned bending operations may comprise a substep of obtaining one or more bends on the metal filament "F" according to a predetermined sequence. Moreover, each bending operation may be obtained at a respective bending station of the transfer machine 1 in order to make the above-mentioned hairpin.
  • the method may comprise at least one step of preparing the metal filament "F" for the bending operations which may be obtained during the step of moving the metal filament "F” between a plurality of different operating stations and/or during the bending step itself.
  • the method comprises a step of beveling at least one end of the metal filament "F".
  • such a beveling step may be obtained prior to the bending step so as to overcome the need for further processing of the hairpin.
  • the beveling step may be obtained by means of a pair of beveling heads 12, each selectively activatable on a respective end of the metal filament "F".
  • the method may comprise a stripping step adapted to remove a surface coating of at least one portion of the metal filament "F".
  • the stripping step may comprise at least one sub-step of irradiating at least the surface coating of the metal filament "F" through laser device 14.
  • the stripping step may further comprise a step of moving the laser device 14 and/or the metal filament "F" so as to irradiate the entire portion of the metal filament "F" coated by the above-mentioned coating.
  • the present invention achieves the suggested objects by making a transfer machine for forming hairpins and a method for making hairpins, which are capable of increasing the efficiency of the hairpin production process by virtue of the employment of a transfer machine 1 specially made for forming hairpins and having at least one bending station comprising at least one forming tool configured to obtain at least one predetermined bend of the metal filament, thus making a respective hairpin.
  • the present machine overcomes the "bottleneck" problem due to the length of the bending procedures, thus freeing the forming process from that of trimming the wire and ensuring the possibility of simultaneously working on a plurality of metal filaments.
  • the transfer machine 1 ensures increased operating flexibility as compared to the machinery of the prior art by virtue of the possibility of adapting to filaments having various geometry and dimensions.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Wire Processing (AREA)

Abstract

Machine de transfert (1) destinée à former des épingles à cheveux, comprenant un moyen de déplacement (2) conçu pour déplacer un filament métallique (F) entre une station d'entrée (3) et une station de sortie (4) et comprenant un dispositif de retenue (6) conçu pour retenir le filament métallique (F). La machine de transfert (1) comprend au moins une station de courbure (9) interposée entre la station d'entrée (3) et la station de sortie (4). La station de courbure (9) comprend au moins un outil de formation (10) conçu pour former au moins une courbure prédéterminée du filament métallique (F), ce qui permet de fabriquer une épingle à cheveux respective.
PCT/IB2021/054504 2020-10-21 2021-05-25 Machine de transfert et procédé de formation d'épingles à cheveux WO2022084754A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT202000024805 2020-10-21
IT102020000024805 2020-10-21

Publications (1)

Publication Number Publication Date
WO2022084754A1 true WO2022084754A1 (fr) 2022-04-28

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2021/054504 WO2022084754A1 (fr) 2020-10-21 2021-05-25 Machine de transfert et procédé de formation d'épingles à cheveux

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WO (1) WO2022084754A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7480987B1 (en) * 2007-03-22 2009-01-27 Tecnomatic, S.P.A. Method for pre-forming conductors for motor rotors and stators
WO2012156066A2 (fr) * 2011-05-16 2012-11-22 Atop S.P.A. Appareil et procédé de fabrication d'éléments de bobine pour des noyaux de machines dynamo-électriques par pliage.
EP3240161A1 (fr) * 2014-12-26 2017-11-01 Hitachi Automotive Systems, Ltd. Dispositif de formation de bobine, et bobine d'un dispositif électrique tournant
WO2018092022A1 (fr) * 2016-11-16 2018-05-24 Atop Spa Procédé et appareil de fabrication d'un stator d'une machine dynamoélectrique
DE102018114580A1 (de) * 2018-06-18 2019-12-19 copperING S.r.l. Verfahren und Vorrichtung zum Formen eines Wicklungselements

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7480987B1 (en) * 2007-03-22 2009-01-27 Tecnomatic, S.P.A. Method for pre-forming conductors for motor rotors and stators
WO2012156066A2 (fr) * 2011-05-16 2012-11-22 Atop S.P.A. Appareil et procédé de fabrication d'éléments de bobine pour des noyaux de machines dynamo-électriques par pliage.
EP3240161A1 (fr) * 2014-12-26 2017-11-01 Hitachi Automotive Systems, Ltd. Dispositif de formation de bobine, et bobine d'un dispositif électrique tournant
WO2018092022A1 (fr) * 2016-11-16 2018-05-24 Atop Spa Procédé et appareil de fabrication d'un stator d'une machine dynamoélectrique
DE102018114580A1 (de) * 2018-06-18 2019-12-19 copperING S.r.l. Verfahren und Vorrichtung zum Formen eines Wicklungselements

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