Abstract: Methods and apparatus for twisting rectangular rotor and stator conductor ends whereby most if not all conductor ends are bent at once, radially adjacent ends being bent in opposite directions. A lost motion member may be used to bend selected conductors through lesser angles for such purposes as phase interconnection and power leads. The rectangular conductors are retained against twisting so that flat conductors will bend about an axis perpendicular to the larger dimension of the conductor cross section. Various features of the methods and apparatus are disclosed.

Abstract: An apparatus for inserting a preformed electrical bar conductor into a twisting device of the conductor, the apparatus comprising: a supply device that arranges the preformed bar conductor into a supply direction (X-X), the preformed bar conductor having two rectilinear arms that are parallel to each other and connected to each other by a curved portion; a transfer device that draws the conductor from the supply device into a grip position in which the conductor is arranged along the supply direction (X-X) and rotates it 90 degrees into an insertion position in which the conductor is arranged along an insertion direction (Y-Y), perpendicular to the supply direction (X-X) and parallel to a pocket on the twisting device; and an insertion device that inserts the conductor into the twisting device, the insertion device equipped with thrust means that move the conductor along the insertion direction (Y-Y) until the conductor is at least partially inserted in the pocket.

Abstract: A method (20) is described for making a stator (1) of an electric machine, the stator comprising a stator core (2), the stator core comprising a main body and a plurality of slots (8) which are axially extended inside the main body and are adapted to receive bar conductors. (5, 5?, 5?) of a bar stator winding. The method (20) comprises the steps of : inserting (23) at least one preshaped insulating sheet (10) inside at least one of said slots (8); hot shaping (26) said preshaped insulating sheet (10) inside the slot, along the entire axial extension of the slot (8) or along a substantial portion thereof, in order to confer form regularity and stability to said preshaped insulating sheet (10). Through the described process, it is possible to make stators with bar winding having a stator core with relatively high height and slot fill factor.

Abstract: A stator for an electric machine includes a stator core having a first and a second face and a circular row of stator slots extended between said faces and which are distributed around a stator axis; and, a winding bar comprising a plurality of basic conductors and a plurality of special conductors interconnected with one another to form the bar winding. The basic conductors each comprise two basic conductor legs and a connecting portion of basic conductor between said legs. The basic conductors are inserted into the stator slots with the free end portions protruding from said second face. The special conductors comprise a jumper of a first type having a first and a second leg of jumpers connected respectively to two of said free end portions, and one jumper connection portion between said legs of jumpers.

Abstract: A method for twisting preformed bar conductors of electric machines comprising: a) providing a twisting apparatus comprising a twisting device having at least a first and a second body extended around a twisting axis, respectively comprising a first and a second circular array of pockets with center on such axis, said bodies being relatively rotatable to each other around the twisting axis to assume a first insertion configuration in which respective pockets of the first and second array are radially aligned; loading, in a subset of said pockets, a first plurality of said preformed conductors leaving a first residual subset of pockets free; driving the first and the second body in relative rotation around said axis until a second insertion configuration is reached in which a second plurality of pockets of the first and second body of said residual subset are radially aligned with each other.

Abstract: Stripping apparatus (4) for an electrical bar conductor (8) having a metal core with two longer sides (12) and two shorter sides (16) coated with an electrically insulating coating (20). The apparatus (4) comprises a first stripping portion (24) that at least partly houses the conductor (8) arranged along a prevailing extension (X-X), so as to rest on one of said longer sides (12) cantilevered relative to a pair of supports (28). The first stripping station (24) houses a first pair of broaches (40), opposite to one another and arranged at opposite sides relative to the conductor (8), said broaches (40) being axially movable relative to a cross working direction (Y-Y) perpendicular to the prevailing extension (X-X). The broaches (40) are aligned with said stripping portion (36) relative to the prevailing extension (X-X), so as to carry out the removal of the insulating coating (20) at the stripping portion (36) comprised cantilevered between the supports (28).

Abstract: It is described a clamping system (30) of special conductors (S1, S2, S3) for a stator or rotor bar winding (U1, S1, S2, S3) for an electric machine, such as connection terminals (S1), jumpers (S2), neutrals or star points (S3), etc. The system (30) allows the special conductors (S1, S2, S3) to be clamped during a twisting step and/or a step of picking up such conductors from a twisting device (250). The system comprises a system axis (T-T), a plurality of grippers (10) aligned or able to be aligned along a circumference lying on a plane substantially perpendicular to the system axis (T-T) and actuation elements (50, 60, 70, 80, 90) of the grippers (10). Each gripper includes a pair of jaws (32, 33) mounted so as to be mobile in a plane transversal to said system axis (T-T).

Abstract: Methods for forming female connectors integral with stator winding conductors, thereby avoiding the necessity of using a separate female connector. A typical connector in accordance with the present invention has a first length of the wire adjacent an end of the wire striped of insulation, and a second length of the wire adjacent the end not greater than the first length of wire being bent in a substantially closed loop, the loop preferably being pressed flat so as to have a thickness less than the wire. Also preferably the wire bends in a first direction and then bends in a circular arc to form the loop, the center of the loop being substantially aligned with a center of the wire. Various embodiments are disclosed as are exemplary simple methods for forming the female connector.

Abstract: A pre-forming apparatus (4) for an electrical bar conductor (8), comprising a punch (12) provided with moving members for exerting a thrust on the conductor (8) during the relative pre-forming, the punch (12) being axially sliding along a pre-forming direction (X-X) and being provided with a cursor (20) and with a pre-forming head (24) suitable for engaging with the conductor (8). The apparatus (4) comprises a first pre-forming chamber (44) suitable for being crossed by the conductor (8) and by the punch (12) during the forward movement of the punch (12) for the pre-forming operation.

Abstract: A twisting apparatus (30) of preformed bar conductors (25) for bar windings of electric machines comprising a twisting device (50) having at least a first (51) and a second body (52) coaxial to one another and extending around a twisting axis (Zt-Zt) defining an axial direction and respectively comprising a first (A1) and a second (A2) circular array of pockets. The twisting device (50) comprises a system for clamping bar conductors comprising at least one sliding clamping element (72, 92) movable in a radial direction with respect to the axial direction (Zt-Zt) to take up an advanced operative position in which it has an end portion (73, 74, 93, 94) that projects inside an associated pocket and a set-back operating position.

Abstract: A method (100) is described for twisting preformed bar conductors (25) of electric machines, said conductors (25) comprising a first and a second leg (5) joined together by a connection portion (15).

Abstract: Apparatus (30) for making pre-shaped insulating sheets (10) for use in a stator or in a rotor comprising shaping elements (40-44) such to produce, starting from a continuous strip (15) made of electrically insulating material having a flat or substantially flat cross section, a strip portion having a cross section comprising a central septum (20) and two lateral portions (21-23, 21?-23?) joined to a respective end portion of the central septum (20), each of the lateral portions comprising a first section (21,21?) joined to the central septum (20), a second section (22,22?) joined and perpendicular, or essentially perpendicular, to the first section (21,21?), a third section (23, 23?) joined to the second section (22,22?) and inclined with respect to the latter towards the central septum (20).

Abstract: A twisting device (10) is described adapted to simultaneously twist a plurality of bar electric conductors (11) for making a stator or rotor winding for an electric machine, comprising: at least one first body (12) extending around a twisting axis (Z-Z) and comprising a first circular array of channels (15) having center on such an axis (Z-Z); and—at least one second body (13), extending around and coaxial with the first body (12), comprising a second circular array of channels (16) with center on the twisting axis (Z-Z); associated with each of the channels (15) of at least one of said first and second arrays, a channel extension groove (15A) extending longitudinally in a direction parallel to the twisting axis (Z-Z) and projecting from the respective channel (15) in a direction (CC) circumferential with respect to said axis (Z-Z).

Abstract: Stripping apparatus (4) for an electrical bar conductor (8) having a metal core with two longer sides (12) and two shorter sides (16) coated with an electrically insulating coating (20). The apparatus (4) comprises a first stripping portion (24) that at least partly houses the conductor (8) arranged along a prevailing extension (X-X), so as to rest on one of said longer sides (12) cantilevered relative to a pair of supports (28). The first stripping station (24) houses a first pair of broaches (40), opposite to one another and arranged at opposite sides relative to the conductor (8), said broaches (40) being axially movable relative to a cross working direction (Y-Y) perpendicular to the prevailing extension (X-X). The broaches (40) are aligned with said stripping portion (36) relative to the prevailing extension (X-X), so as to carry out the removal of the insulating coating (20) at the stripping portion (36) comprised cantilevered between the supports (28).

Abstract: Methods and apparatus for twisting rectangular rotor and stator conductor ends whereby most if not all conductor ends are bent at once, radially adjacent ends being bent in opposite directions. A lost motion member may be used to bend selected conductors through lesser angles for such purposes as phase interconnection and power leads. The rectangular conductors are retained against twisting so that flat conductors will bend about an axis perpendicular to the larger dimension of the conductor cross section. Various features of the methods and apparatus are disclosed.

Abstract: Method for removing winding conductors from a twisting machine and placing them in a rotor or stator stack. For a plurality of rectangular winding conductors each having a pair of legs separated by an amount equal to the distance between a predetermined number of rotor or stator slots in which they will be inserted, moving a plurality of fingers of a clamping assembly between the legs of a plurality of winding conductors in a twisting fixture to retain the winding conductors, moving the clamping assembly away from the twisting fixture to withdraw the winding conductors from the twisting fixture, providing relative movement of the clamping assembly and a rotor or stator to insert free ends of the winding conductors into a rotor or stator, and moving the fingers of a clamping assembly from between the legs of a plurality of winding conductors. A preferred embodiment of the method is disclosed.

Abstract: Method and apparatus for forming motor winding conductors rectangular conductor wire.

Abstract: Method and apparatus for insertion of preformed rotor and stator conductors into a twisting machine for forming hairpin shaped conductors of rectangular wire into stator conductors.

Abstract: Method and apparatus for pre-forming insulated conductors for motor rotors and stators for use in a next process in forming motor rotors and stators. In accordance with the full exemplary process, insulated rectangular cross-section wire is received from a spool, straightened, stripped over a predetermined length, fed to a bender, cut to length and then bent into the desired hairpin shape and placed on a feeder for the next process. The method and apparatus may be fully automatic, including automatically adjusting itself as required to make hairpin shaped conductors of different lengths, each length having its free ends stripped over a desired length. The method and apparatus for bending, as well as other methods and apparatus disclosed, may be used alone or in other combinations.