Methods and apparatus for twisting rotor and stator conductor ends

• US 20090302705A1
• Filed: 07/20/2007
• Published: 12/10/2009
• Est. Priority Date: 07/20/2007
• Status: Active Grant

• Current Assignee: Tecnomatic S.p.A.
• Original Assignee: Tecnomatic S.p.A.
• Inventors: Guercioni, Sante
• Granted Patent: US 8,215,000 B2
• Time in Patent Office: Days
• US Class Current: 310/216.69
• CPC Class Codes: H02K 15/0031 Shaping or compacting conductors in slots or around salient poles H02K15/005 takes precedence
• CPC Class Codes: H02K 15/0056 Manufacturing winding connections
• CPC Class Codes: H02K 15/0087 characterised by the method or apparatus for simultaneously twisting a plurality of hairpins open ends after insertion into the machine for simultaneously twisting a plurality of hairpins prior to mounting into the machine H02K15/0428
• CPC Class Codes: H02K 15/0428 characterised by the method or apparatus for simultaneously twisting a plurality of hairpins for simultaneously twisting a plurality of hairpins open ends after insertion into the machine H02K15/0087
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/53161 including deforming means

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.

Claims

1. A method of bending the free ends of rectangular motor winding conductors comprising:

providing a bending fixture having a plurality of pockets circularly distributed in one or more pairs of adjacent pocket members, each concentric with an axis of the bending fixture, at least one pocket member defining each of the pockets in one of each pair of adjacent circles being rotatable, at least through a limited angle, with respect to a pocket member defining the pockets in the other of the respective adjacent pocket members;

supporting a rotor or stator adjacent the bending fixture with free ends of the rectangular motor winding conductors extending into the pockets;

rotating at least one pocket member for each pair of adjacent pocket members to bend the free ends of the rectangular motor winding conductors.

2. The method of claim 1 wherein pocket members in each adjacent pocket members are rotated in opposite directions.

3. The method of claim 2 further comprising reducing the separation between the motor rotor or stator and the pocket members as bending progresses.

4. The method of claim 3 wherein the rotor or stator is held stationary and the pocket members are moved to change the separation.

5. The method of claim 3 wherein the separation between the motor rotor or stator and the pocket members as bending progresses is changed by a different amount for each pocket member.

6. The method of claim 5 wherein the rotor or stator is held stationary and the pocket members are moved to change the separation.

7. The method of claim 6 wherein each pocket member is moved closer to the rotor or stator as bending progresses by a respective cam responsive to the rotation of the pockets.

8. A method of bending the free ends of rectangular motor winding conductors comprising:

providing a bending fixture having a plurality of pockets circularly distributed in one or more pairs of adjacent pocket members, each concentric with an axis of the bending fixture, at least one pocket member defining each of the pockets in one of each pair of adjacent circles being rotatable, at least through a limited angle, with respect to a pocket member defining the pockets in the other of the respective adjacent pocket members, at least one of the pocket members having a lost motion member associated therewith defining at least one of the pockets in the respective circle of pockets;

supporting a rotor or stator adjacent the bending fixture with free ends of the rectangular motor winding conductors extending into the pockets;

rotating at least one pocket member for each pair of adjacent pocket members to bend the free ends of the rectangular motor winding conductors, a rectangular motor winding conductor extending into a pocket in the lost motion member being bent to a lesser amount because of the lost motion of the associated pocket.

9. The method of claim 8 wherein pocket members in each adjacent pocket members are rotated in opposite directions.

10. The method of claim 9 further comprising reducing the separation between the motor rotor or stator and the pocket members as bending progresses.

11. The method of claim 10 wherein the rotor or stator is held stationary and the pocket members are moved to change the separation.

12. The method of claim 10 wherein the separation between the motor rotor or stator and the pocket members as bending progresses is changed by a different amount for each pocket member.

13. The method of claim 12 wherein the rotor or stator is held stationary and the pocket members are moved to change the separation.

14. The method of claim 13 wherein each pocket member is moved closer to the rotor or stator as bending progresses by a respective cam responsive to the rotation of the pockets.

15. The method of claim 8 wherein a rectangular motor winding conductor of extended length for forming a motor rotor or stator lead is placed in the pocket in the lost motion member.

16. The method of claim 8 wherein a rectangular motor winding conductor for forming a phase interconnect is placed in the pocket in the lost motion member.

17. The method of claim 8 further comprising providing a plurality of pockets with lost motion and wherein at least one rectangular motor winding conductor of extended length for forming a motor rotor or stator lead is placed in a pocket in a lost motion member, and rectangular motor winding conductor for forming a phase interconnect is placed in a pocket in a lost motion member.