Abstract: A device for modeling hairpins promoting insertion of winding sets of the hairpins on a stator or rotor to allow an increased filling of the slot space in an assembly of winding sets on the stator or rotor is provided. Application relates to electric stators or rotors, and any device using electric wires having any gauge.

Abstract: A method and a system for inserting all hairpins of a k-th crown of a stator winding into the same region of space are provided. Progressively inserted hairpins are movable along a path of geometry so that the last hairpin of the crown is always insertable as if the last hairpin were the first hairpin, without hindrance. After inserting the last hairpin the crown centers itself by removing the apparatus that allowed insertion of the hairpins into the same region of space. Inner and/or outer containments allow the hairpins to follow the required profile. Rotation of the hairpins is obtainable by cylindrical or conical pins between the legs of the hairpins. After assembling one crown, outermost crowns are progressively assembled on the system to have the winding without handling the crowns. Once assembled, the innermost crown is vertically lowered along a winding axis to leave sufficient space to assemble an adjacent crown.

Abstract: An apparatus for assembling a winding of hairpins is provided. The apparatus has a feeding section, an insertion section into a winding assembly cylinder, and a handling section having at least two arms configured so that when the end of one arm faces the feeding section, the end of the other arm faces the insertion section. Each arm has a gripper for picking and releasing a hairpin, the gripper being slidingly mounted along an extension direction of the corresponding arm. The insertion section has an assembly drum moved by a rotary mechanism, both mounted on the same axis, perpendicular to the rotation axis of the arms. The assembly drum has a series of inserts on its outer surface defining a series of radially open slots, the rotary mechanism being sized to leave free space between the arm and the slots. A method for assembling a winding of hairpins is also provided.

Abstract: An apparatus for deforming conductors of at least one winding assembly protruding from a side of a stator or rotor of an electric machine is provided. The conductors are arranged with at least one leg inserted into cavities of the stator or rotor, having at least one free end. The apparatus has at least one twisting matrix rotating about an axis and having at least one pocket for insertion of the at least one free end, a radial backing member provided close to the at least one twisting matrix, and in particular close to the at least one pocket on an insertion side of the at least one free end. The radial backing member has an inner radial backing surface for a portion of the at least one leg protruding from the side of the stator or rotor.

Abstract: An assembly for assembling a winding group of a bar winding for an electric machine is provided. The winding group includes a plurality of bar conductors, each bar conductor having a first leg, a second leg and a bridge portion connecting the first leg to the second leg, and being shaped so that the first and second legs are mutually spread by a predetermined distance. The assembly includes an annular fixture delimiting a plurality of slots, each slot receiving at least one portion of either the first leg or the second leg, a guiding device defining an annular containment housing, receiving at least partially the first and second legs of the plurality of legs of the plurality of bar conductors that are housed in the plurality of slots, forming at least one radial containment wall for the first and second legs.

Abstract: An apparatus for pre-assembling a winding for an electric machine stator or rotor includes a plurality of hairpins with two legs having non-circular cross-section, a ring including a plurality of slots and an outer containment ring acting in containment along the perimeter of the ring. An inner cam block and an outer cam block, surrounding and radially facing the inner cam block, are arranged opposite to the exit face of the ring. The cams are adapted to be crossed, in use, by the two legs when they cross the ring at the same time; the cams open into a free circular space between the two cam blocks. A method for pre-assembling a winding set for an electric machine stator or rotor is also provided. Hairpins are inserted in sequence in the slots of the apparatus. A finished winding set positioned in the free circular space is obtained by successive rotations of the ring.

Abstract: A process for making a continuous bar winding (4) for an electric machine is described, comprising: a) a step of providing a template (10) having a template axis (X) and a circular array of slots (11) extended about said template axis (X), said circular array of slots having a number of slots equal to a number of slots of the stator or of the rotor of said electric machine, each slot (11) of said circular array having a first and a second open end face (11A, 11B) which are axially spaced from one another and a third open end face (11C), said third face (11C) being a longitudinal face extended between said first and second end faces (11A, 11B) b) a step of providing a conductive bar (20); c) a step of locking a locking portion (21) of said conductive bar; d) a step of inserting the conductive bar (20) into the slots (11) of said array and shaping the conductive bar (20) so that such conductive bar (20) repeatedly passes through the slots (11) of said array from the side of the first open end faces (11A) to the

Abstract: An assembly for assembling a winding group of a bar winding for an electric machine is provided. The winding group includes a plurality of bar conductors, each bar conductor having a first leg, a second leg and a bridge portion connecting the first leg to the second leg, and being shaped so that the first and second legs are mutually spread by a predetermined distance. The assembly includes an annular fixture delimiting a plurality of slots, each slot receiving at least one portion of either the first leg or the second leg, a guiding device defining an annular containment housing, receiving at least partially the first and second legs of the plurality of legs of the plurality of bar conductors that are housed in the plurality of slots, forming at least one radial containment wall for the first and second legs.

Abstract: An assembly for assembling a winding group of a bar winding for an electric machine is provided. The winding group includes a plurality of bar conductors, each bar conductor having a first leg, a second leg and a bridge portion connecting the first leg to the second leg, and being shaped so that the first and second legs are mutually spread by a predetermined distance. The assembly includes an annular fixture delimiting a plurality of slots, each slot receiving at least one portion of either the first leg or the second leg, a guiding device defining an annular containment housing, receiving at least partially the first and second legs of the plurality of legs of the plurality of bar conductors that are housed in the plurality of slots, forming at least one radial containment wall for the first and second legs.

Abstract: An apparatus (200) for deforming conductors of at least one winding assembly (100), protruding from a side of a stator or of a rotor (114) of an electric machine. The at least one winding assembly (100) comprises a plurality of basic conductors (102) comprising at least one leg inserted into cavities (115) of stator or rotor (114), each having at least one respective free or terminal end (108, 110). The apparatus (200) comprises at least one twisting matrix (202, 203) adapted to rotate about an axis (X), comprising at least one gripping element (204) adapted to grip at least one free end (108, 110) and adapted to be moved in radial direction with respect to said axis (X). The apparatus comprises at least one guide (206, 207) adapted to guide the at least one gripping element (204) along the radial direction with respect to the axis (X); and a radial actuator (208), adapted to put in motion the at least one gripping element (204) along the radial direction with respect to the axis (X).

Abstract: A process for making a continuous bar winding (4) for an electric machine is described, comprising: a) a step of providing a template (10) having a template axis (X) and a circular array of slots (11) extended about said template axis (X), said circular array of slots having a number of slots equal to a number of slots of the stator or of the rotor of said electric machine, each slot (11) of said circular array having a first and a second open end face (11A, 11B) which are axially spaced from one another and a third open end face (11C), said third face (11C) being a longitudinal face extended between said first and second end faces (11A, 11B) b) a step of providing a conductive bar (20); c) a step of locking a locking portion (21) of said conductive bar; d) a step of inserting the conductive bar (20) into the slots (11) of said array and shaping the conductive bar (20) so that such conductive bar (20) repeatedly passes through the slots (11) of said array from the side of the first open end faces (11A) to the

Abstract: An assembly for assembling a winding group of a bar winding for an electric machine is provided. The winding group includes a plurality of bar conductors, each bar conductor having a first leg, a second leg and a bridge portion connecting the first leg to the second leg, and being shaped so that the first and second legs are mutually spread by a predetermined distance. The assembly includes an annular fixture delimiting a plurality of slots, each slot receiving at least one portion of either the first leg or the second leg, a guiding device defining an annular containment housing, receiving at least partially the first and second legs of the plurality of legs of the plurality of bar conductors that are housed in the plurality of slots, forming at least one radial containment wall for the first and second legs.

Abstract: A device for modeling hairpins promoting insertion of winding sets of the hairpins on a stator or rotor to allow an increased filling of the slot space in an assembly of winding sets on the stator or rotor is provided. Application relates to electric stators or rotors, and any device using electric wires having any gauge.

Abstract: An apparatus for pre-assembling a winding for an electric machine stator or rotor includes a plurality of hairpins with two legs having non-circular cross-section, a ring including a plurality of slots and an outer containment ring acting in containment along the perimeter of the ring. An inner cam block and an outer cam block, surrounding and radially facing the inner cam block, are arranged opposite to the exit face of the ring. The cams are adapted to be crossed, in use, by the two legs when they cross the ring at the same time; the cams open into a free circular space between the two cam blocks. A method for pre-assembling a winding set for an electric machine stator or rotor is also provided. Hairpins are inserted in sequence in the slots of the apparatus. A finished winding set positioned in the free circular space is obtained by successive rotations of the ring.