Device and method for bending hairpin winding heads

A method for modeling one or more die-pressed hairpins prior to assembly thereof in a winding set, wherein each die-pressed hairpin has an insulating coating and comprises two or more legs having corresponding pitches such that they are insertable into a stator or rotor core, and a bridge-like head portion, said two or more legs including respective one or more free ends opposite to said bridge-like head portion, wherein an angle between a first plane passing through at least three points of said two or more legs and a second plane passing through ends of the bridge-like head portion and through at least one point of the bridge-like head portion takes a predetermined value (γ), the method comprising the following steps:

• S1. providing a device for modeling one or more die-pressed hairpins prior to assembly thereof in a winding set, the device comprising:
• one frame which includes one or more respective housing portions configured to partially house said one or more die-pressed hairpins having said corresponding pitches, each housing portion being integrally connected to or formed in said one frame;
• and
• one or more respective deformation elements for deformation of said one or more die-pressed hairpins;
• wherein:
• said one or more respective housing portions are configured so that when said one or more die-pressed hairpins are a plurality of die-pressed hairpins, they are housable so as to be spaced apart from one another;
• and
• when said one or more respective deformation elements are a plurality of deformation elements, they are mounted at a fixed distance from one another;
• wherein:
• each deformation element of said one or more respective deformation elements of said one or more die-pressed hairpins is rotationally mounted with respect to at least one of said one or more respective housing portions so as to rotate with respect to a pre-defined axis parallel to said first or second plane;
• said one or more respective deformation elements are integral with one another and respective pushing elements are mounted on said one or more respective deformation elements, the respective pushing elements being configured and adapted to push either said bridge-like head portion or said two or more legs;
• and
• said one or more respective deformation elements are configured and adapted to move from an initial position, in which they do not apply any action on said one or more die-pressed hairpins, to a final deformation position of said one or more die-pressed hairpins, wherein said angle takes a value (γ+x) different from said predetermined value (γ);
• S2. inserting the two or more legs of said one or more die-pressed hairpins into said one or more respective housing portions, so that, when a plurality of die-pressed hairpins is used, the bridge-like head portion and the two or more legs of any one of said one or more die-pressed hairpins are not in contact with a respective bridge-like head portion and legs of any other of said one or more die-pressed hairpins in said initial position;
• and
• S3. moving said one or more deformation elements from said initial position to said final deformation position so that the bridge-like head portion and the two or more legs of any one of said one or more die-pressed hairpins are not in contact with the bridge-like head portion and legs of any other of said one or more die-pressed hairpins, in all states up to the final deformation position.