Abstract:
Apparatus and method for winding coils of at least one electric wire conductor (W) on a coil support ( 10, 11, 10′, 11 ′) comprising a coil support ( 10,11 ) wound and assembled on a pole of a core of a dynamo electric machine, or a pole ( 10′,11 ′) wound and assembled to form the core of a dynamo electric machine; comprising: a wire dispenser ( 19 ), the wire dispenser having a passage portion ( 18 ) for the wire and an exit ( 23 ′) from where the wire reaches the coil support ( 10, 11, 10′, 11 ′) during winding; means ( 31,32 ) for pressing on the wire (W) during winding to bend the wire according to a configuration of the coil; means ( 20 ) for supporting and rotating the coil support with respect to the dispenser ( 19 ) to wind the wire on the coil support ( 10,11, 10′, 11 ′); means ( 40 ) for applying tension on the wire reaching the dispenser ( 19 ); means ( 24, 24′, 25, 25′, 26, 26 ′) for moving the dispenser ( 19 ) with respect to the coil support ( 10, 11, 10′, 11 ′).

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to winding of coils of dynamoelectric machines. In particular the invention relates to winding supports for coils or single poles in which one or more electric conductors (in the following referred to as wires) are wound to form a coil of a predetermined number of turns. 
       BACKGROUND OF THE INVENTION 
       [0002]    The supports for coils are made of insulating material and become assembled on the poles of the cores after having being wound. Supports of this type have been described in WO 2009/115312. 
         [0003]    Single poles are individual portions of the laminated core that are disassembled to be wound. After winding, the single poles are assembled together, one next to the other to form the laminated core, see for example EP  1098425 . 
         [0004]    In the following, the use of the terminology “coil support” can contemplate both the supports for coils and the single poles. 
         [0005]    The wire that needs to wound may have a large cross section, therefore when bending occurs the wire becomes permanently deformed. 
         [0006]    During winding, the wire is bent to be in contact with the surface of the coil support, or to be in contact with portions of wire that have been previously wound on the coil support. 
         [0007]    The deformation process bends the wire according to a configuration that tries to copy the shape of the perimeter of the coil support where the turns need to be wound. In this way, the quantity of wire that needs to be wound in a given space of the coil support becomes maximized. 
         [0008]    Winding can occur by rotating the coil support to extract wire from the exit of a wire dispenser and by directing the wire from the wire dispenser to required positions of the coil support. 
         [0009]    In these positions of the coil support the wire is deformed against the surface of the coil support, or against turns that have been previously deposited, like is described in WO 2009/115312. 
         [0010]    Modern applications of dynamoelectric machines require that the length of wire that is wound on the coil support should be very long and precisely matching a predetermined total quantity. 
         [0011]    Furthermore, in achieving this maximum filling, the winding operations and formation of the initial and final leads of the coils should be performed automatically without damaging the wire insulation. The presence of the damages can be responsible for an early deterioration of the dynamoelectric machine. 
       SUMMARY OF THE INVENTION 
       [0012]    It is therefore an object of the present invention to position lengths of wire with precision in predetermined positions of the coil support during winding to form a coil. 
         [0013]    It is a further object of the present invention to guarantee that the wire wound on the coil support results deformed with precision in order to be positioned along predetermined trajectories of the coil support to increase the wire filling. 
         [0014]    It is also an object of the present invention to automatically accomplish the winding operations and form the initial and final leads of the coils and the stretches of wire for passage between the coils. 
         [0015]    Another object of the present invention is to position lengths of wire having desired tension in predetermined positions of the coil support during winding to form a coil. 
         [0016]    A further object of the invention of the present invention is to guarantee that the wire wound on the coil support results tensioned with precision in order to be positioned along predetermined trajectories of the coil support to increase the wire filling. 
         [0017]    It is also an object of the present invention to accomplish with required tension the winding operations and form the initial and final leads of the coils and the stretches of wire for passage between the coils. 
         [0018]    These and other objects are accomplished with the apparatuses and methods of the invention according to the independent claims. 
         [0019]    Further characteristics of the invention are defined in the dependent claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    Further characteristics and advantages of the apparatus and the methods according to the invention will result more clearer from the description which follows of 
           [0021]      FIG. 1  is a prospective view of two coil supports that have been wound using the principles of the invention; 
           [0022]      FIG. 1   a  is a prospective view showing two single poles that have been wound using the principles of the invention; 
           [0023]      FIG. 2  is a prospective view of an embodiment of an apparatus of the invention for winding the coil supports of  FIG. 1 ; 
           [0024]      FIG. 3  is a partial view as seen from direction  3  of  FIG. 2 ; 
           [0025]      FIG. 4  is a partial section view as seen from direction  4 - 4  of  FIG. 3 ; 
           [0026]      FIG. 5  is a partial view as seen from direction  5  of  FIG. 2 ; 
           [0027]      FIG. 5   a  is a partial prospective view as seen from direction  5   a  of  FIG. 5 ; 
           [0028]      FIG. 6  is a continuation of the inferior part of of  FIG. 5 ; 
           [0029]      FIGS. 7   a - 7   e  are schematic partial views according to direction  5  of  FIG. 2  showing a sequence of winding conditions and lead formation of the coils accomplished with the solutions of the invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0030]    With reference to  FIG. 1  the coils supports  10  that need to be wound are provided with a central portion  12  and opposite flange portions  12 ′ and  12 ″. The wire W is wound around the central portion  12  for a certain number of turns  15  until flanges  12 ′ and  12 ″ are engaged by the turns as shown. 
         [0031]    Two coils supports  10  and  11  can be electrically connected by the same wire W″ like is shown in  FIG. 1 . As a sequence, first coil support  10  is wound, and successively coil support  11  is wound. In the passage of operations between winding coil support  10  and winding coil support  11  continuous wire W″ is formed, i.e. a stretch W″ is formed without interrupting wire W used for winding. 
         [0032]    The initial stretch of wire W that enters the coil of coil support  10  is referenced WI, whilst the final stretch of wire that exits coil support  11  is referenced WF. 
         [0033]    In  FIG. 1   a,  two single poles  10 ′,  11 ′ have the coils wound with wire W and result connected by means of stretch W″. Similarly to the coil supports of  FIG. 1 , the initial and final leads are respectively referenced WI and WF. 
         [0034]    With reference to  FIG. 2 , at least one wire W is delivered by wire delivery member  19 . More particularly, wire W runs through guide passage  18  (see  FIG. 4 ) which leads to wire delivery member  19 . The wire W enters wire delivery member  19  through end, or enter,  23 , after having passed through spring  120 , and leaves the wire delivery member  19  from exit  23 ′ (see  FIG. 3 ). 
         [0035]    With reference to  FIGS. 2 and 3 , the wire delivery member  19  is assembled on platform  24 , which can move when required in directions Y and Y′ by running on guides  24 ′. Guides  24 ′ are assembled on platform  25  which can move in directions X and X′ by running on guides  25 ′. Guides  25 ′ can be part of a further platform  26  which moves when required in directions Z and Z′ by movement of shaft  26 ′ of the apparatus (see  FIG. 3 ). 
         [0036]    Each of the platforms  24 , 25 , 26  are moved by means of a respective motor screw system. Each motor of a respective motor screw mechanism can be controlled by an axis control system. Therefore, wire delivery member  19  can be moved in space in the directions Z,Z′,Y,Y′,X,X′ to reach programmed positions in required times. 
         [0037]    Device  40 , which is fixed to the frame of the apparatus, is located upstream with respect to entrance  23 . Device  40  is capable of feeding wire W in directions Y and Y′, i.e. respectively feeding wire towards delivery member  19 , or withdrawing wire from delivery member  19 . 
         [0038]    Furthermore, device  40  is capable of applying a braking action on the wire when it runs in directions Y′ and Y. Device  40  is capable of accomplishing these actions in a programmable manner, as a function of the stage and winding instances. 
         [0039]    In particular, device  40  accomplishes actions of feeding, withdrawing or braking the wire as a function of the position of the delivery member  19  and the position of pressure member  32  (described in the following). 
         [0040]    Device  40  comprises two belt members  41  and  42  facing each other for a certain length portion, as shown in  FIGS. 2 and 3 . The wire W is positioned in the space existing between the portions of the belts that are facing each other, as shown in  FIGS. 2 and 3 . The group of rollers  43  push on belts  41 , whilst the group of rollers  44  react to the pressure created on belt  42 . In this way, wire W is gripped between the length portions of the belts facing each other, as shown in  FIGS. 2 and 3 , with a force that depends on the pressure achieved by the group of rollers  43  pushed by the linear actuator  43 ′. 
         [0041]    The motor (not shown) that drives belt  47  (see  FIG. 2 ) is programmed and controlled to rotate pulley wheels  45  and  46  where belts  41  and  42  are engaged to be moved. 
         [0042]    By controlling the motor that drives belt  47 , belts  41  and  42  can run in synchronism with each other in direction Y, or in opposite direction Y′. 
         [0043]    When the belts run in direction Y′, the wire is fed towards entrance  23 , whilst when the belts run in the opposite direction Y the wire is withdrawn from entrance  23 . The result is respectively to feed the wire from delivery member  19  towards the coil support being wound, or to withdraw the wire in passage  18  of delivery member  19 . 
         [0044]    Furthermore, the pressure applied on wire W by means of rollers  43  avoids that belts  41  and  42  slip on the wire when it is moving in directions Y and Y′. 
         [0045]    At the same time, a predetermined braking torque can be applied by the motor of belt  47  to produce on behalf of belts  41 ,  42  an opposite force (tension), in other words a drag on the wire, as the latter runs towards the delivery member  19  due to the pull occurring during winding in the feed direction Y′ by the rotation R of the coil support like  10 . 
         [0046]    In this situation a tension is created on the wire, which influences the positioning and bending of the turns. To optimize this result on the turns it is preferable to apply a tension generated by the motor of belt  47  as a function of the position of the delivery member  19  and the position of the pressure member  32 . 
         [0047]    The ideal tension law to be applied on the wire needs to determined and programmed as a function of the characteristics of the wire, of the coil support or the single pole which needs to be wound. 
         [0048]    Assembly  50  is provided with a series of idle rollers  51  (see  FIGS. 2 and 3 ), in between which wire W runs as it advances towards device  40 . 
         [0049]    Assembly  50  is required for straightening wire W after wire W has been extracted from the wire store  60 . 
         [0050]    In fact, in assembly  50  the wire runs in grooves existing on the circumference of the idle rollers  51 . The grooves are aligned on the rectilinear path where the wire needs to travel to reach device  40 . 
         [0051]    A wire presser  70  is present within passage  18  (see particularly  FIG. 4 ). Passage  18  extends from entrance  23  to exit  23 ′ of delivery member  19 . Wire presser  70  is pushed by linear actuator  70 ′. Wire presser  70  is capable of pressing on wire W for blocking wire W in passage  18  against possible running in directions Y and Y′, like is shown in  FIG. 4 . 
         [0052]    A spring  120  is assembled at the exit of assembly  40  and at the entrance  23  as shown in  FIGS. 2 ,  3  and  4 . Wire W runs within the interior of spring  120 . Spring  120  functions as a guiding corridor for wire W when wire W is running towards delivery member  19 . 
         [0053]    Spring  120  can extend axially and laterally when entrance  23  moves in directions X,X′,Y,Y′,Z,Z′ due to the movements of platforms  24 ,  25  and  26 . 
         [0054]    Spring  120  has an important function when a new wire needs to be fed to delivery member  19 , i.e. when a cut end of a new wire needs to pass automatically through assembly  40  and enter entrance  23 . In this situation, the platforms  24 ,  25  and  26  are moved for positioning spring  120  in alignment with assembly  40 , see  FIG. 2 . Furthermore, and as a result of this positioning, spring  120  is totally compressed to have all of its turns in contact to create a corridor that is closed laterally for guiding the end of the new wire when it runs towards entrance  23 . 
         [0055]    In this situation, assembly  40  is feeding the new wire until its end is individuated by sensor  100  (see  FIG. 3 ). Starting from this individuation calculated feeding of wire W occurs on behalf of the motor of belt  47  to achieve that a predetermined length of wire WI extends from exit  23 ′ of delivery member  19 . 
         [0056]    In summary, assembly  40  can feed a predetermined length of wire WI to have it extend from exit  23 ′ of delivery member  19 . The portion WI, which extends from exit  23 ′, can be a portion which needs to be inserted in a clamping device  52  (see  FIGS. 5 and 5   a ) to start winding the coil support  10 . 
         [0057]    A stretch of this portion of wire extending from delivery member  19  becomes positioned in groove  32 ′ of pressure member  32  and in a groove  31 ′ of member  31  (see  FIGS. 1 and 3 ). 
         [0058]    In fact, pressure member  32  and member  31  are assembled on arm  122 , which in turn is mounted integral to delivery member  19 , as shown in  FIGS. 2 and 3 . 
         [0059]    This assembly is such that alignment with exit  23 ′ occurs of channel  32 ′ of pressure member  32  and of channel of member  31 . 
         [0060]    Therefore, by feeding wire W from delivery member  19  a stretch of the portion of wire, which extends from exit  23 ′ becomes positioned in channel  32 ′ of pressure member  32  and in the channel of member  31 , as shown in  FIGS. 1-3 . 
         [0061]    The purpose of pressure member  32  and member  31  is to bend the wire on the coil support  10  during winding, like has been described in application WO 2009/115312. The presence of pressure member  31  is not always necessary and depends on the characteristics of the wire and the coil support or single pole that are wound. 
         [0062]    With reference to  FIGS. 5 ,  5   a  and  6 , a gripper assembly  20  grips and rotates the coil supports  10 ,  11  with rotation R around axis  13  to achieve winding. Although not shown, assembly  20  with certain modifications can grip and rotate the single poles shown in  FIG. 1   a.    
         [0063]    In the embodiments of  FIGS. 5 and 6  the two coil supports  10  and  11  are grasped inside the central part  12  so that the coil supports result adjacent and aligned on axis  13 , as shown in  FIG. 5 . In this respect, assembly  20  comprises an expandable gripper member  21 , which becomes inserted in the hollow portion of coil supports  10  and  11 . A mechanism with an inclined plane of know type is present support body  22  for expanding and closing the grasping member  21 . 
         [0064]    The rotation of the support body  22  around axis  13  presents wire W exiting delivery member  19  in alignment with positions of the coils support  10  and  11  where wire W becomes bent by members  32  and  31  to form the turns of the coils. 
         [0065]    Clamp  52  and deflector  54  are assembled on body  22  to move in directions C and C′ parallel to axis  13  as shown in  FIGS. 5 and 7   a - 7   e.    
         [0066]    Tube  55  supports clamp  52  and is capable of running on body  22  in directions C and C′ for achieving movement of clamp  52  in directions C and C′, as shown in the sequences of  FIGS. 7   a - 7   e.    
         [0067]    Shaft  56  within tube  55 , if made to move in directions C and C′, opens and closes clamp  52  when it is necessary to clamp or release stretch of wire WI. 
         [0068]    Tube  57  supports deflector  54  and is capable of moving on body  22  in directions C and C′ to obtain that deflector  54  moves in directions C and C′, as shown in the sequences of  FIGS. 7   a - 7   e.    
         [0069]    Body  22  receives shaft  71  (see  FIG. 5 ) in a manner that is easily dismountable to facilitate the substitution of assembly  20  for processing coil supports of different dimensions, or if necessary to use other clamps like  52  or deflectors like  54  that are configured differently. 
         [0070]    Shaft  71  is mounted on arm  73  to rotate support body  22  with rotation R around axis  13 . 
         [0071]    More precisely, shaft  71  is assembled on bearing assembly  72 , which in turn is assembled on arm  73 . 
         [0072]    Arm  73  is integral to tube  79  (see  FIG. 6 ) which becomes rotated around axis  13  by a motor (not shown) for achieving rotation R of body  22  around axis  13  for winding. 
         [0073]    Shaft  71  can be rotated by belt  74 , which is rotated by pinion  76  which engages crown  77  of tube  78 . Tube  78  is rotated around axis  13  by a motor (not shown) for achieving rotation of the clamp assembly  20  around an axis that is perpendicular to axis  13 , in order to bring body  22  with the coil supports out of the plane of  FIG. 5 . The rotation can be necessary when the wire passes from one turn to another on the coil support. In this passage, which normally occurs on the short side of the coil support, the wire is wound on an inclined path due to the fact that the rotation axis  13  is out of the plane of  FIG. 5 . 
         [0074]    Plates  82  and  83  are integral to ends respectively of tubes  84  and  85 . Tubes  84  and  85  are assembled coaxial to axis  13  and are capable of moving in directions C and C′ in specific moments of the operational sequences of the winding apparatus, as shown in the following with reference to  FIGS. 7   a - 7   e.    
         [0075]    Shaft  86  is assembled to move within tube  85  in directions C and C′ when required. When shaft  86  moves in direction C it engages member  87  (see  FIG. 5 ) of the inclined plane mechanism present within support body  22 . 
         [0076]    A movement of member  87  in direction C, following the engagement and pushing of shaft  86  causes a contraction of member  21 , which releases gripping on coil supports  10  and  11 . The movement of member  87  in direction C′ to grip the coils supports  10  and  11  is caused by the simultaneous detachment of shaft  86  and by the action of a recall spring belonging to the inclined mechanism present in body  22 . 
         [0077]    By rotating body  22  and moving tube  84  in direction C it is possible to align and engage the ends  55 ′ and  57 ′, respectively of tube  56  and tube  57 , with the slots  82 ′ of plate  82 . In this situation movement of tube  84  in directions C and C′ accomplishes motion of gripper  52  or deflector  64  in directions C and C′, as is required in the sequence of  FIGS. 7   a - 7   e.    
         [0078]    Similarly, it is possible to engage the end of shaft  56  in slots  83 ′ of plate  83 , and by moving tube  85  in directions C and C′ it is possible to open and close clamp  52 , as is required in the sequence of  FIGS. 7   a - 7   e.    
         [0079]    With reference to the sequence of operations illustrated in  FIGS. 7   a - 7   e ,  FIG. 7   a  shows a portion of wire WI extending from delivery member  19  and located in groove  32 ′ of pressure member  32  and in the groove of member  31 . Such a portion of wire has been produced by actuating belts  41  and  42  to turn towards direction Y′ and therefore feed wire through passage  18  up to the beam of sensor  100 . The interception with the beam initiates a calculated feed on behalf of the motor of belt  47  that drives belts  41  and  42 . The calculated feed occurs by position controlling the motor of belt  47  to guarantee that the portion of wire that passes sensor  100  achieves stretch WI which extends from delivery member  19  for a predetermined length. When the predetermined length is reached, presser  70  is actuated to block the wire portion WI (see  FIG. 4 ). This is necessary during the movements that follow of delivery member  19 , for example during the movement in direction Y′ for becoming near to the coil support (see  FIGS. 7   a - 7   b ) and for being with portion WI in alignment with gripper  52 . 
         [0080]    Blocking the wire W with presser  70  during the movements of delivery member  19  achieves that the length of stretch WI does not change, but at the same time accomplishes recalling variable lengths of wire, which extend from entrance  23  to the exit of assembly  40  and which that run within extendible spring  120 . 
         [0081]    In the positions of being near to the coil support  10 , as shown in  FIGS. 7   a  and  7   b , the presser is released and belts  41  and  42  feed a further length of wire in the direction Y′. This further length of wire is in alignment with pressure members  32  and  31 . At the end of the feed, the wire reaches gripper  52  where it is clamped (see condition represented with the dash line in  FIG. 7   b  and with full line in  FIG. 5   a ) by moving shaft  56 . 
         [0082]    Following the situation of the wire being present and clamped in gripper  52 , gripper assembly  20  can start rotation R around axis  13  to pull wire through delivery member  19  and thereby form the first coil around coil support  10 . During the rotation around axis  13 , delivery member  19  moves in direction Z′ (parallel to direction C′) to stratify the turns (see  FIG. 7C ) 
         [0083]      FIG. 7   d  shows the start of the sequence for passage of the wire from the coil of coil support  10  to the coil of coil support  11 . Clamp  52  in the meantime is moved in direction C′ (by moving shaft  55 ) to avoid interference with the stretch of wire that is being wound, whilst deflector  54  has been moved in direction C to be aligned with wire W that extends to delivery member  19 . Successively, further rotation around axis  13  continues to wind wire W around deflector  54  and forms passage stretch W″ which is outside of coil supports  10  and  11  (see  FIG. 7   e ). Once the stretch W″ has been formed, deflector  54  is moved in direction C′ to be removed from the passage stretch W″ (condition of  FIG. 7   e ) and for avoiding interference during winding of the successive turns. 
         [0084]    Once the required number of turns have been wound on coil support  11 , wire W is cut by a cutter to leave a final stretch WF of the coil. The stretch of wire that has been cut and that extends from delivery member  19  can be of undefined length. This stretch of wire can be withdrawn through passage  18  until its cut end intercepts the beam of sensor  100 . In this situation the calculated feeding in direction Y′ can then be accomplished on behalf of the motor that drives belts  41  and  42  to guarantee that a portion of wire passing the beam of sensor  100  in direction Y′ achieves the stretch WI extending from exit  23 ′ for a predetermined length. 
         [0085]    The foregoing description of a specific embodiment will so fully reveal the invention according to the conceptual point of view, so that others, by applying current knowledge, will be able to modify and/or adapt for various applications such an embodiment without further research and without parting from the invention, and it is therefore to be understood that such adaptations and modifications will have to be considered as equivalent to the specific embodiment. The means and the materials to realise the different functions described herein could have a different nature without, for this reason, departing from the field of the invention. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.