Methods and apparatuses for forming woven undulated coil assemblies

A method for forming a woven coil assembly, the coil assembly having adjacent superimposed linear portions extending parallel to each other in a first area of the coil assembly, and adjacent superimposed linear portions extending parallel to each other in a second area of the coil assembly, wherein a plurality of head portions connect the linear portions of the first area to the linear portions of the second area, the method comprising:

• feeding a plurality of conductors for a predetermined length in a feeding direction parallel to each other and substantially parallel to a plane;
• bending a first portion of the length of the plurality of conductors according to a predetermined orientation such that the plurality of conductors of the first portion are parallel to each other, oriented according to an angle of orientation, and positioned in the feeding direction downstream of a second portion of the length of the plurality of conductors that have not been bent;
• bending a third portion of the length of the plurality of conductors according to the predetermined orientation such that the plurality of conductors of the third portion are parallel to each other, oriented according to the angle of orientation, and positioned in the feeding direction downstream of a fourth portion of the length of the plurality of conductors that have not been bent, the fourth portion positioned in the feeding direction upstream of the first portion;
• and
• prior to bending a further portion according to the predetermined orientation of the length of the plurality of conductors, rotating a portion of the first portion about an axis positioned substantially midway along the first portion and perpendicular to the feeding direction such that the rotated portion of the first portion of conductors are parallel to each other in a direction opposite to the feeding direction.

A method for forming a woven coil assembly, the coil assembly having adjacent superimposed linear portions extending parallel to each other in a first area of the coil assembly, and adjacent superimposed linear portions extending parallel to each other in a second area of the coil assembly, wherein a plurality of turn portions connect the linear portions of the first area to the linear portions of the second area, the method comprising:

• feeding a plurality of conductors for a first predetermined length in a feeding direction and substantially parallel to a plane through a guide unit;
• holding each of the conductors in a respective seat of a first holding device located at a first position of the predetermined length;
• holding each of the conductors in respective seats of a second holding device located at a second position of the predetermined length;
• moving the second holding device in a transverse direction with respect to the first holding device to form inclined portions of the conductors between the first holding device and the second holding device;
• moving the first holding device in a transverse direction with respect to the guide unit to form second inclined portions of the conductors between the first holding device and the guide unit;
• and
• rotating the portion of the conductors supported by the second holding device about a rotation axis in a rotation direction, the rotation axis being perpendicular to the feeding direction to engage the inclined portions transversely and perpendicularly to the feeding direction.

An Apparatus for forming a woven coil assembly, the coil assembly having adjacent superimposed linear portions extending parallel to each other in a first area of the coil assembly, and adjacent superimposed linear portions extending parallel to each other in a second area of the coil assembly, wherein a plurality of turn portions connect the linear portions of the first area to the linear portions of the second area, the apparatus comprising:

• a first holding device located at a first position along a feeding direction of a plurality of conductors, the first holding device being arranged to hold the conductors in a plurality of seats, each of the plurality of seats receiving a respective conductor;
• a second holding device located at a second position along a feeding direction of a plurality of conductors, the second holding device is arranged to hold the conductors in a plurality of seats, each of the plurality of seats receiving a respective conductor, wherein the second holding device is configured for moving in a transverse direction with respect to the first holding device to form inclined portions of conductors between the first holding device and the second holding device;
• and
• a plate for bending provided with a bending edge positioned transversally and perpendicularly to the feeding direction, wherein the second holding device is configured for rotating a portion of conductors around the bending edge in a rotation direction, and wherein during the rotation, the bending edge engages the inclined portions transversally and perpendicularly to the feeding direction.

A method for forming a woven coil assembly, the coil assembly having adjacent superimposed linear portions extending parallel to each other in a first area of the coil assembly, and adjacent superimposed linear portions extending parallel to each other in a second area of the coil assembly, wherein a plurality of head portions connect the linear portions of the first area to the linear portions of the second area, the method comprising performing:

• a first step of feeding a plurality of conductors for a predetermined length in a feeding direction parallel to each other and substantially parallel to a plane;
• a second step of bending a first portion of the length of the plurality of conductors according to a predetermined orientation, the plurality of conductors of the first portion after bending being parallel to each other, oriented according to an angle of orientation, and positioned in the feeding direction downstream of a second portion of the length of the plurality of conductors that have not been bent;
• a third step of rotating a portion of the first portion about an axis positioned substantially midway along the first portion and perpendicular to the feeding direction, the rotating positioning the rotated portion of the first portion of conductors parallel to each other in a direction opposite to the feeding direction;
• a fourth step of feeding the plurality of conductors for a predetermined length in a feeding direction parallel to each other and substantially parallel to a plane;
• a fifth step of bending a third portion of the length of the plurality of conductors according to a predetermined orientation, the plurality of conductors of the third portion after bending being parallel to each other, oriented according to an angle of orientation, and positioned in the feeding direction downstream of a fourth portion of the length of the plurality of conductors that have not been bent;
• and
• a sixth step of rotating a portion of the third portion about the axis positioned substantially midway along the third portion and perpendicular to the feeding direction, the rotating positioning the rotated portion of the third portion of conductors parallel to each other in a direction opposite to the feeding direction.

A method for forming a woven coil assembly, the coil assembly having adjacent superimposed linear portions extending parallel to each other in a first area of the coil assembly, and adjacent superimposed linear portions extending parallel to each other in a second area of the coil assembly, wherein a plurality of turn portions connecting the linear portions of the first area to the linear portions of the second area, the method comprising:

• feeding a plurality of conductors for a first predetermined length in a feeding direction and substantially parallel to a plane;
• holding each of the conductors in respective seats of a first holding device located at a first position of the predetermined length;
• holding each of the conductors in respective seats of a second holding device located at a second position of the predetermined length;
• moving the second holding device in a transverse direction with respect to the first holding device to form inclined portions of the conductors between the first holding device and the second holding device;
• and
• rotating the portion of the conductors supported by the second holding device about a rotation axis in a rotation direction, the rotation axis being perpendicular to the feeding direction to engage the inclined portions transversely and perpendicularly to the feeding direction.

An apparatus for forming a woven coil assembly, the coil assembly having adjacent superimposed linear portions extending parallel to each other in a first area of the coil assembly, and adjacent superimposed linear portions extending parallel to each other in a second area of the coil assembly, wherein a plurality of turn portions connect the linear portions of the first area to the linear portions of the second area, the apparatus comprising:

• a first holding device located at a first position along a feeding direction of a plurality of conductors, the first holding device is arranged to hold the conductors in a plurality of seats, each of the plurality of seats receiving a respective conductor, wherein the first holding device is configured for moving in a transverse direction with respect to the guide unit to form inclined portions of conductors between the first holding device and the guide unit;
• a second holding device located at a second position along a feeding direction of a plurality of conductors, the second holding device is arranged to hold the conductors in a plurality of seats, each of the plurality of seats receiving a respective conductor, wherein the second holding device is configured for moving in a transverse direction with respect to the first holding device to form inclined portions of conductors between the first holding device and the second holding device;
• and
• a plate for bending provided with a bending edge positioned transversally and perpendicularly to the feeding direction, wherein the second holding device is configured for rotating a portion of conductors around the bending edge in a rotation direction, and wherein during the rotation, the bending edge engages the inclined portions transversally and perpendicularly to the feeding direction.