Manufacturing process for stator and/or rotor windings of an electric motor including a number of cavities distributed along a cylindrical internal surface of the stator and/or a cylindrical external surface of the rotor, respectively, each having a first lateral mouth provided on a first side (A) of the stator and/or the rotor, respectively, a second lateral mouth provided on an opposite side (B) of the stator and/or of the rotor, respectively, and an internal mouth provided on the cylindrical internal surface of the stator and/or along the cylindrical external surface of the rotor, respectively, and further including:
- A supporting shaft (2) for the stator (1) and/or the rotor, respectively, capable of rotating around its axis, which happens to coincide with the axis of the cylindrical internal surface of the supported stator and/or the axis of the cylindrical external surface of the supported rotor, respectively;
- A first (3) and a second (3′) working station respectively allocated on a position opposite to the sides (A, B) of the stator and/or the rotor, respectively, next to the outlet area of one of the first and second lateral mouths, respectively,
- A first (4) and a second (4′) carriers, allocated on the first and the second working station, respectively, used for sliding and dragging the wire (f) destined to form the windings in an opposite cavity at the moment processed,
- A first (5) and a second (5′) clamp, present on the first and the second working station, respectively, capable of grasping and moving the tip of the wire (f) of the winding in processing phase,
- A first (6) and a second (6′) sensor, present on the first and the second working station, respectively, capable of detecting arrival of the extremity of the wire (f) that has crossed a cavity in a processing phase, and comprising the following processing phases aimed at obtaining the progressive passing of the wire in an alternate direction and subsequently, within an established orderly series of cavities:
- 1. Positioning of the shaft (2) so as to bring a lateral mouth of a first cavity of the series of cavities into a position opposite the first and second carriers (4, 4′);
- 2. Introducing the tip of the wire, by the first clamp (5), into a first carrier (4) and subsequently introducing the tip, by the action of the first carrier, into the first lateral mouth of the first cavity, and sliding the wire within the first cavity and exiting from a second lateral mouth, until the wire has passed through the second carrier (4′) and is detected by the second sensor (6′);
- 3. Actuating the second clamp (5′), which after grasping the wire next to its tip moves a certain distance in the forward direction of the wire and rotates its tip until orienting it into an opposite direction, either in this phase or in one of the phase 4, 5 and 6 outlined below;
- 4. Continuing the exit of the wire from the second lateral mouth, until the length of the exited wire has reached a value adequate for completing the passing of the wire into the mentioned series of cavities;
- 5. Arresting the dragging action of the first (4) and the second (4′) carrier and starting the action of a third clamp (7) in the first working station, which blocks the tail of the wire near the first lateral mouth of the first cavity of the series of cavities;
- 6. Disengaging the wire from the first and second carrier and rotating the shaft (2), together with the mentioned third clamp (7), until the lateral mouths of the second cavity of the mentioned series of cavities are brought to a position opposite the mentioned carriers;
- 7. Repeating the previous processing phases 2 and 3, while interpreting the same substituting the terms “first clamp (5)”, “first carrier (4)”, “first mouth of the first cavity”, “second mouth”, “second carrier (4′)” and “second sensor (6′)”, with the terms “second clamp (5′)”, “second carrier (4′)”, “second mouth of the second cavity”, “first mouth”, “first carrier (4)” and “first sensor (6)”, respectively;
- 8. Continuing the exit of the wire from the first lateral mouth of the second cavity of the mentioned series of cavities, until the wire has disengaged from the second carrier and the length of the wire connecting the second lateral mouth of the first cavity of the series of cavities to the second lateral mouth of the second cavity has been reduced by a certain value slightly exceeding the distance between the internal mouths of the first and second cavities;
- 9. Disengaging the wire from the first carrier and rotating the shaft (2) until the lateral mouths of a third cavity of the series of cavities are brought to a position opposite the first and second carriers;
- 10. Repeating, mutatis mutandis, the previous operations from 7 to 9 for all the remaining cavities of the series of cavities, until the tip of the wire exits from one of the lateral mouths of the last cavity of the series of cavities.