# US 2022/0278596 A1 · Twisting Device and Method for a Hairpin Winding

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- Number: US 2022/0278596 A1
- Document ID: US20220278596A1
- Status: Published application
- Kind: A1
- Application number: 17/632,787
- Filed: 2020-07-24
- Published: 2022-09-01
- Earliest claimed: 2019-08-05
- Assignees: ZF Friedrichshafen AG
- Applicants: Zf Friedrichshafen AG
- Inventors: Matthias EBERT; Bernhard BYZIO; Jürgen TRÖSTER; Michael WEIGEL
- Web page: https://patentgrep.com/patent/US20220278596A1

## CPC

- H02K 15/36: Processes or apparatus for simultaneously twisting two or more open ends of hairpins after their insertion into the machine (for simultaneously twisting two or more hairpins prior to mounting into the machine H02K15/0428)
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})

## Abstract

A device for twisting hairpin ends of a coil formed from hairpins for an electric machine includes: a plurality of coaxially arranged twisting rings having: two outer twisting rings and, therebetween, at least at least two inner twisting rings. The twisting rings have, in each instance, at an axial end facing hairpin ends, a plurality of pockets distributed over a circumference for receiving a hairpin end, respectively. The twisting rings are twistable in opposite directions relative to one another, the twisting rings having couplings by which twisting rings with like rotational direction are connectable.

## Claims

### Claim at position 1

1-14. (canceled)

### Claim 15

A device (1) for twisting hairpin ends of a coil formed from hairpins for an electric machine, the device comprising:
a plurality of coaxially arranged twisting rings (2.1; 2.2; 3) comprising:
two outer twisting rings (2.1; 2.2) and, therebetween,
at least at least two inner twisting rings (3),
wherein the twisting rings (2.1; 2.2; 3) have, in each instance, at an axial end facing hairpin ends, a plurality of pockets (6; 6.1; 6.2) distributed over a circumference for receiving a hairpin end, respectively, and
wherein the twisting rings (2.1; 2.2; 3) are twistable in opposite directions relative to one another, wherein the twisting rings (2.1; 2.2; 3) have couplings (4.1; 4.2) by which twisting rings (2.1; 2.2; 3) with like rotational direction are connectable.

### Claim 16 (depends on 15)

The device (1) according to claim 15, wherein directly adjacent twisting rings (2.1; 2.2; 3) are twistable in opposite directions.

### Claim 17 (depends on 16)

The device (1) according to claim 16, wherein at least the inner twisting rings (3) have a passage (5.1; 5.2) for the couplings (4.1; 4.2) of the twisting rings (2.1; 2.2; 3) with a different rotational direction.

### Claim 18 (depends on 17)

The device (1) according to claim 17, wherein the passage (5.1; 5.2) is configured as an elongated hole extending over a portion of the circumference.

### Claim 19 (depends on 15)

The device (1) according to claim 15, wherein the twisting rings (2.1; 2.2; 3) have in each instance at least two couplings (4.1; 4.2) which are distributed, preferably symmetrically, over the circumference.

### Claim 20 (depends on 15)

The device (1) according to claim 15, wherein the couplings (4.1; 4.2) are each configured as an alignment pin receivable in corresponding receptacles at the twisting rings (2.1; 2.2; 3).

### Claim 21 (depends on 20)

The device (1) according to claim 20, wherein at least one of the twisting rings (2.1; 2.2; 3) have receptacles which, in a movement direction, have a clearance relative to the alignment pin in the initial position in order to move the twisting ring (2.1; 2.2; 3) by a rotational angle that is smaller than the alignment pin by an amount corresponding to the clearance.

### Claim 22 (depends on 15)

The device (1) according to claim 15, wherein the quantity of twisting rings (2.1; 2.2; 3) corresponds to the quantity of layers of the coil.

### Claim 23 (depends on 15)

The device (1) according to claim 15, wherein the quantity of pockets (6; 6.1; 6.2) per twisting ring (2.1; 2.2; 3) corresponds to the quantity of slots of the coil.

### Claim 24 (depends on 15)

The device (1) according to claim 15, wherein the pockets (6; 6.1; 6.2) are configured to be open on one side in radial direction, wherein the pockets (6; 6.1; 6.2) of the outer twisting rings (2.1; 2.2) are configured in each instance to open in direction of the further twisting rings (2.1; 2.2; 3), and in that the pockets (6; 6.1; 6.2) of the inner twisting rings (3) are configured in each instance to open toward the open side of the pockets (6; 6.1; 6.2) of a directly adjacent twisting ring (2.1; 2.2; 3).

### Claim 25 (depends on 15)

The device (1) according to claim 15, wherein the pockets (6; 6.1; 6.2) have at least a depth in axial direction corresponding to an uninsulated length of the hairpin ends.

### Claim 26 (depends on 15)

The device (1) according to claim 15, wherein the outer twisting rings (2.1; 2.2) have fasteners (7) by which the device (1) is connectable to drives (8) for the rotational movements.

### Claim 27 (depends on 15)

A method for twisting hairpin ends of a coil for an electric machine by the device (1) according to claim 15, the method comprising:
fitting the device (1) on the hairpin ends, wherein at least the uninsulated hairpin ends are received in pockets (6; 6.1; 6.2) of the twisting rings (2.1; 2.2; 3);
rotating the twisting rings (2.1; 2.2; 3) in opposite directions, wherein twisting rings (2.1; 2.2; 3) which are connected to one another via couplings (4.2; 4.2) are rotated in the same direction; and
removing the coil with shaped hairpin ends from the device (1).

### Claim 28 (depends on 27)

An electric machine with a coil which is formed from hairpins and which is produced by the method according to claim 27.