DE102017124859A1 - Method for producing an electric coil and winding device - Google Patents

Abstract

The invention relates to a method for producing an electrical coil (10), in which an electrical conductor (20) is wound onto a carrier (12). It is proposed that the conductor (20) is plastically deformed in such a way in the direction of a longitudinal axis (L) of the coil (10) before emergence onto the carrier (12) that a resulting deformation (38) of the conductor (22) is desired The invention further relates to a winding device (30) for producing an electrical coil (10), wherein the winding device (30) is adapted to wind an electrical conductor (20) on a support (12), in particular for Carrying out the method: The winding device (30) comprises a forming device (32) which is designed to plastically close the conductor (20) in a direction of a longitudinal axis (L) of the coil (10) prior to running on the carrier (12) deforming that a resulting deformation (38) of the conductor (20) corresponds to a desired winding jump (22).

Description

The present invention relates to a method of manufacturing an electrical coil, in which an electrical conductor is wound onto a carrier. The invention further relates to a winding device.

STATE OF THE ART

Demand for high-performance electric motors is increasing in many technical areas, for example in the area of drive technology for vehicles or in plant engineering. The advantages of electric motors are the good torque behavior over the whole speed range as well as the high efficiency.

A major component of electric motors are electric coils. In order to increase the torque generated by the electric motor and its efficiency, the use of coils with the highest possible filling factor is sought. The fill factor quantitatively indicates how well the available winding space of a coil is filled with electrical conductors. If the fill factor can be increased, so also amplifies the electric field generated by the coil, whereby at the same space, the torque and thus the achievable power of an electric motor can be increased.

The electrical coil is produced by winding one or more electrical conductors onto a carrier, the carrier being, for example, a winding mandrel which is removed from the coil after winding or is designed as a coil former which remains in the coil. The winding is carried out by a relative movement between the carrier and a feed device, which leads the wound electrical conductor from a supply roll or the like to the carrier.

The specific embodiment of this relative movement is referred to as a winding method, wherein generally different types of winding methods are known. By way of example, the linear winding method is mentioned, in which the support to be wound is rotated about its longitudinal axis and the supply of the electrical conductor via a wire guide tube (also referred to as Drahtführdüse), which can be moved relative to the rotating support in one or more directions. Another exemplary winding method is the needle winding method, with the aid of which, for example, closely spaced pole pieces of an electronically commutated multi-pole three-phase motor can be directly wound. Since in this case the electrical conductor is pulled at an angle of 90 ° from the wire guide nozzle, a targeted placement of the conductor is only possible to a limited extent. Another known winding method is the Flyerwickelverfahren.

Significant influence on the filling factor has in particular the winding geometry. With a winding structure as an orthocyclic winding, an optimum fill factor can be generated, in particular for conductors with a round cross section. In an orthocyclic winding, the aim is to deposit the turns of an upper winding in the valleys of an under winding, so that the centers of each three directly adjacent conductors define an isosceles triangle. This can be accomplished by having a majority of the conductors of the coil perpendicular to the longitudinal axis of the coil, i. H. lie in planes that are perpendicular to the longitudinal axis of the coil. For optimum space utilization, the aim is to wind the largest possible peripheral portion of a respective turn within these orthogonal planes. If a winding hits the previously run-in conductor, the conductor must make a winding jump in the size of the conductor diameter. This Windungssprung, which is also referred to as a series jump or Windungsschritt, depending on the conductor diameter and coil diameter and especially the winding width z. B. spread over an angular range of up to 60 ° of the circumference of a round coil or rectangular coils over a rectangular side on the winding base in the first winding layer.

In order to ensure that the electrical conductor or wire occupies the desired orthocyclic position, carriers are used which, on their winding ground, i. H. have on their peripheral side, embossed grooves or depressions corresponding to the desired Windungsverlauf the first winding layer. When storing the second or further winding layers, however, a reliable wire guide, in particular in the region of the winding jump, no longer exists.

In the case of orthocyclically wound coils, it is desirable for the winding transition region to always be more or less at the same angular position for different layers. Since due to the reversal of the winding direction, the conductors in the winding jump region of two adjacent layers intersect, this leads to an increase in the winding height, d. H. in a round coil to a hump-shaped shape. In the design of electric motors is intended that these areas of greater winding height are in positions where sufficient space is available, so that the performance and / or efficiency of the electric motor is not or only slightly affected.

A machine for winding orthocyclic coils is, for example, in US Pat. No. 1,504,005 A described. The wire guide is here not moved continuously but cyclically in the axial direction to realize the winding jump. A similar machine is in DE 1 151 321 B described. In WO 2011/045016 A2 a winding method and a corresponding device is described in which the incoming wire in the radial direction with respect to the longitudinal axis of the coil, ie, transverse to a direction of the wire, is pre-bent. This avoids that when winding a non-circular support body, such as a coil with a rectangular cross-section, the wire does not fully applied to the surface to be wound of the carrier body. Such an upset results from the fact that in the region of the corners of the carrier body, the wire must be wound with a very narrow radius, whereby alone by the wire feeder, no sufficient plastic deformation can be achieved. Since the wire tends to at least partially return to its original position, this leads to a lifting of the carrier body between two adjacent bending points.

It is the object of the present invention to specify a method for producing an electrical coil and a corresponding winding device, which improves the production of electrical coils, in particular of electric coils with orthocyclic winding.

DISCLOSURE OF THE INVENTION

The object is achieved by a method having the features of claim 1 and by a winding device having the features of claim 10. Advantageous embodiments of the method or the winding device are specified in the dependent claims, wherein advantageous embodiments of the method mutatis mutandis as advantageous embodiments the winding device and vice versa can be provided.

It is proposed that the conductor is plastically deformed in such a way in the direction of a longitudinal axis of the coil prior to emergence on the carrier that a resulting deformation of the conductor corresponds to a desired winding jump. The electrical wire or wire so the Windungssprung is permanently impressed before winding on the carrier by the plastic deformation, so that a precise, well controllable winding structure can be achieved. In comparison to conventional winding methods, in which the wire guide and the laying of the wire on the carrier or the already wound coil is done alone by the feeder, which deforms the incoming wire usually only elastically, in particular slipping of the wire and thus a Forming a wild winding avoided.

Furthermore, a correct positioning of the conductor on the coil in the region of the front sides of the carrier can be achieved. In conventional carriers is due to the frontal flanges that limit the necessary axial deflection of the incoming conductor, a correct concern of the incoming wire to the flange or the end faces near already wound turns not guaranteed. This disadvantage is avoided by preforming the conductor.

The feature according to which the conductor is deformed in such a way that a resulting deformation of the conductor corresponds to a desired winding jump is to be understood such that the resulting deformation does not necessarily correspond exactly to the desired winding jump, such as the wire diameter, but the plastic deformation in particular also somewhat may be greater than the winding pitch to compensate for plastic or elastic recovery due to a longitudinal tensile stress on the conductor.

The desired winding jump can also amount to a multiple of the conductor diameter. Thus, coils can be wound, in which the layers to the outside, d. H. with increasing number of layers, fewer and fewer turns. In this way, for. B. coils are made, which are not rectangular for better utilization of an existing installation space in longitudinal section, but run to one end conical or trapezoidal.

In addition to being deformed in the direction of a longitudinal axis of the coil, the conductor can also be plastically deformed transversely to the longitudinal axis such that the resulting deformation of the conductor corresponds to a desired positional jump.

The carrier may be formed as a winding mandrel, which may be removed after winding the coil or be formed by a bobbin, which remains in the coil and in particular at its end faces flanges for limiting and fixing the coil in the axial direction.

According to an advantageous embodiment, the coil is constructed as an orthocyclic winding. In the case of such a winding geometry, the method according to the invention has proved to be particularly advantageous since, in the case of orthocyclically wound coils, a precise shaping of the winding jump further optimizes the achievable fill factor. The risk of slippage of turns, especially at higher winding layers, here Again, especially in the area of crossing ladder adjacent layers is significantly reduced.

Advantageously, the carrier has a groove-free lateral surface. Such groove-free carriers, which have no depressions or elevations which guide the wound wire, can be universally, d. H. be used for different conductor diameters. When changing the conductor diameter, therefore, no new winding mandrel or bobbin must be designed and manufactured.

According to an advantageous embodiment, the deformation is performed such that the two conductor sections, which are located immediately before and behind the deformation, parallel to each other and in the direction of the longitudinal axis of the coil. The conductor is thus deformed approximately S-shaped. Thus, the course of the conductor before winding the unwinding of the wound coil corresponds.

In this context, it has proven to be advantageous if the deformation is further carried out such that between the two parallel mutually offset conductor portions, a straight transition portion is formed, which is inclined by a transition angle to the two mutually parallel offset conductor portions. Such a straight transition section has proved to be particularly advantageous for the formation of an orthocyclic winding. The extent of the winding jump is essentially determined by the transition angle and the length of the transition section, but also the bending radii between the transition section and the two parallel mutually offset conductor sections exert a certain influence. The transition angle may for example be between 5 ° and 60 °, in particular between 10 ° and 40 °.

Advantageously, the length of the transition section and / or the transition angle are variable. As a result, the configuration of the winding jump can be adapted to the already achieved winding height or layer number.

According to an advantageous embodiment, the electrical conductor is a wire. Such conductor wire is particularly suitable for the intended plastic deformation.

Advantageously, the conductor is deformed at predetermined longitudinal positions, wherein the longitudinal positions are predetermined in dependence on an already wound number of turns and in particular are equidistant at least for a predetermined number of turns. For example, the distance between the longitudinal positions can be kept constant for all turns of a respective layer and adapted for a subsequent position in accordance with the circumferential enlargement of the coil caused by the layer jump.

Advantageously, the distance of the longitudinal positions in dependence on the number of already wound turns and / or layers is variable.

The invention further relates to a winding device for producing an electrical coil, wherein the winding device is adapted to wind an electrical conductor on a support, in particular for carrying out the method according to one of the embodiments described above. The winding device comprises a forming device, which is designed to plastically deform the conductor in such a way in the direction of a longitudinal axis of the coil before it comes to rest on the carrier that a resulting deformation of the conductor corresponds to a desired winding step. With such a winding device, the advantages described with respect to the method according to the invention can also be achieved.

According to an advantageous embodiment, the forming device comprises at least one cooperating with the conductor, transverse to a longitudinal extension of the conductor in the direction of a longitudinal axis of the coil displaceable first forming element. By the first forming element necessary for deforming the conductor transverse forces are applied. Advantageously, two first forming elements are provided, which are designed such that they can deform the conductor in mutually opposite directions.

Advantageously, the forming device further comprises at least one cooperating with the conductor second forming element, which is spaced in the direction of the longitudinal extent of the conductor of the first forming element. The one or more second forming elements are preferably not displaceable, d. H. they are only passively involved in the deformation process. They fix the conductor at one end of the transition gate while the first forming elements actively effect the deformation. However, the second forming element or elements can be adjustable in their position. They are preferably arranged in the feed direction of the conductor above the first forming elements.

According to a particularly advantageous embodiment, the forming device comprises two transverse to the longitudinal extent of the conductor spaced from each other first Umformelemente and two spaced transversely to the longitudinal extent of the conductor second Umformelemente, wherein in particular, the distance between the first forming elements to each other and / or the distance between the second forming elements to each other and / or the distance between the first forming elements and the second forming elements is variable. By changing the distance of the first forming elements to each other or the distance of the second forming elements to each other, the respective gap between the first and the second forming elements, through which the tapered conductor is passed, be adapted to the cross section of the conductor, so that a precise Guiding the conductor during forming is guaranteed. By changing the distance between the first and the second forming elements, the length of the transition section can be influenced, wherein this change can be made in particular depending on the already wound layer number.

According to a further advantageous embodiment, the winding device has a feed device for the conductor, wherein the forming device is adapted to offset the forming element in dependence on a relative angular position between the feed device and the coil. This can be ensured, for example, that the deformation always comes to rest at a desired, in particular always the same angular position of the coil.

list of figures

• 1 eine schematische und nicht maßstäbliche Seitenansicht einer orthozyklisch gewickelten elektrischen Spule gemäß dem Stand der Technik; und
• 2 und 3 schematische und nicht maßstäbliche Ansichten einer Wickelvorrichtung gemäß einem Ausführungsbeispiel.

Further advantages emerge from the drawing and the associated description of the drawing. In the drawings, embodiments of the invention are shown. The drawing, the description and the claims contain numerous features in combination. The person skilled in the art will expediently also consider these features individually and combine them into meaningful further combinations. Show it:

• 1 a schematic and not to scale side view of an orthocyclic wound electrical coil according to the prior art; and
• 2 and 3 schematic and not to scale views of a winding device according to an embodiment.

In the figures, the same or similar components are numbered with the same reference numerals.

1 shows a partially wound electrical coil 10 with an orthocyclic winding structure. The sink 10 comprises a carrier, which in the embodiment as a bobbin 12 is configured, which has a lateral surface 14 which extends along a longitudinal axis L extends. The bobbin 12 is frontally of two flanges 16 limited, which the lateral surface 14 projecting in the radial direction on all sides. The flanges 16 extend in planes perpendicular to the longitudinal axis L run.

The bobbin 12 is built groove-free, ie, the lateral surface 14 is free of depressions or elevations, which are required in conventional manufacturing processes for orthocyclic wound coils.

Instead of the bobbin shown here 12 can also be used as a carrier winding mandrel, from which the coil after winding and, where appropriate, a subsequent caking of the turns, can be removed as a cantilever coil. The mandrel is advantageously also formed groove-free.

On the bobbin 12 is an electrical conductor or wire 20 in several turns 18 wound. The individual turns 18 lie in planes that are parallel to the flanges except for a certain angle range 16 and thus perpendicular to the longitudinal axis L run. In the areas where the turns 18 not parallel to the flanges 16 The wire goes 20 from one turn to the next. This area is called a winding jump 22 designated. When winding the coil 10 , the wire can by means of a feeder (in 1 not shown) to the bobbin 12 be introduced. After winding a complete turn 18 , the feeding device is moved by an amount corresponding to the wire diameter in a direction parallel to the longitudinal axis L extending direction of departure A added.

Having a layer of the coil 10 is wound, the direction of departure becomes A vice versa.

An orthocyclic wound coil 10 can have a maximum mechanical fill factor of 91%, but only for the part of the coil 10 applies, in which the turns 18 are aligned orthocyclically. In a transition area in which the winding jump 22 is present, the fill factor is lower due to the intersecting conductor adjacent turns.

In 2 and 3 is an exemplary winding device 30 for producing an electrical coil, in particular an orthocyclically wound coil 10 according to 1 , shown. In the embodiment, the winding device 30 work according to the linear winding method. For this purpose, the bobbin 12 around its longitudinal axis L be rotated, wherein a feeding device (not shown) the wire 20 according to the winding progress in the direction of the respective direction of departure A can move continuously or in discrete steps.

The winding device 30 includes a forming device 32 in which the wire coming from a supply reel (not shown) is in a feed direction Z enters and the forming device 32 in the direction of the coil 10 leaves.

The forming device 32 has a pair of first displaceable forming elements 36A . 36B as well as one of them counter to the feeding direction Z spaced pair of second fixed forming elements 34A . 34B on. The wire 20 runs between the forming elements 34A . 34B or. 36A . 36B therethrough. The distance between the fixed forming elements 34A . 34B and between the displaceable forming elements 36A . 36B can be adjustable to ensure adaptation to different wire thicknesses.

The displaceable forming elements 36A . 36B are located in 2 in its neutral position, in which the gap between the forming elements 36A . 36B with the gap between the fixed forming elements 34A . 34B flees. The displaceable forming elements 36A . 36B can by means of suitable drive devices, such as pneumatic cylinders, in a displacement direction V , which are parallel to the longitudinal axis L the coil and transversely, in particular perpendicular to the feed direction Z of the wire 20 runs, be offset. The displacement can be in positions on both sides of the in 2 shown neutral position, wherein in 3 only the move to the left position is shown.

The displacement of the displaceable forming elements 36A . 36B takes place in the same direction, with the distance or gap between the displaceable forming elements 36A . 36B essentially preserved. However, it may also be provided a slight reduction in distance to the wire 20 to clamp during the forming process.

Using the forming device 32 becomes the wire 20 deformed such that the deformation of a straight transition section 40 has, which is inclined to the two mutually parallel offset, adjacent conductor sections. The bending radii between the transition section 40 and the mutually offset parallel conductor sections are preferably selected as narrow as it allows the wire material used to achieve the most compact possible winding in which the winding jump 22 only over the smallest possible angular range of a respective turn 18 extends.

By moving the forming elements 36A . 36B gets in the incoming wire 20 an approximately S-shaped deformation 38 generated, which the desired Windungssprung 22 the coil 10 equivalent. The wire 20 is through the forming elements 34A . 34B . 36A . 36B not only plastically deformed, but also elastic, so the measure of the offset of the deformation 38 after being released by the forming elements 34A . 34B . 36A . 36B or after leaving the forming device 32 due to the elastic restoring forces again slightly smaller than it is the adjustment of the displaceable forming elements 36A . 36B would correspond. To compensate for this return effect, the adjustment of the displaceable forming elements 36A . 36B about the degree of the desired winding jump 22 increase. At this increase may possibly also a further recovery of the wire 20 be taken into account, which is caused by a wire brake (not shown), which above the forming device 32 may be provided to provide a suitable winding tension on the incoming wire 20 exercise.

The forming or deformation of the wire 20 , may be in certain longitudinal distances of the wire 20 take place, these distances from the scope of the respective turns 18 result. The forming device 32 is always pressed when the wire 20 has reached a corresponding longitudinal position, said longitudinal position directly by measuring the continuous wire length or indirectly in response to a respective angular position of the rotating coil 10 can be determined.

When a winding layer has been completely wound, the direction of deflection is reversed A , At the same time, the offset direction V changed, so that the deformation 38 has a mirror image. In the in the 2 and 3 The arrangement shown extend the direction of deposition A of the wire 20 on the spool 10 and the displacement direction of the displaceable forming elements 36A . 36B in the opposite direction.

In the linear winding method shown here is a separate feed device for the wire 20 not shown. The function of a feed device can also be achieved by a linear displacement of the shaping device 32 in the direction of the direction of departure A be fulfilled, this displacement continuously or stepwise, z. B. synchronous with the emergence of the deformation on the bobbin 12 , can be done. For moving the forming device 32 may be provided an adjusting device, not shown.

By the winding device according to the invention 10 and by the method performed therewith for producing an electrical coil 10 It is possible, in particular to produce orthocyclically wound coils, which have a defined, by the plastic deformation 38 in the ladder 20 embossed winding jump 22 respectively. By the impression of the winding jump 22 , becomes a Slippage of individual turns and thus avoid unwanted generation of wild windings, which significantly reduce the fill factor. Thus, a precise winding of the coil 10 with maximum fill factor.

LIST OF REFERENCE NUMBERS

10

Kitchen sink

12

Carrier, bobbin

14

lateral surface

16

flange

18

convolution

20

Ladder, wire

22

Windungssprung

30

winder

32

reshaping

34A, 34B

fixed forming element

36A, 36B

displaceable forming element

38

deformation

40

Transition section

A

discharge direction

L

longitudinal axis

V

offset direction

Z

feed

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• US 1504005 A [0009]
• DE 1151321 B [0009]
• WO 2011/045016 A2 [0009]

Claims (13)

Method for producing an electrical coil (10), in which an electrical conductor (20) is wound onto a carrier (12), characterized in that the conductor (20) is guided in the direction of a longitudinal axis (FIG. L) of the coil (10) is plastically deformed such that a resulting deformation (38) of the conductor (22) corresponds to a desired winding step (22). Method according to Claim 1 , characterized in that the coil (10) is constructed as an orthocyclic winding. Method according to Claim 1 or 2 , characterized in that the carrier (12) has a groove-free formed lateral surface. Method according to one of the preceding claims, characterized in that the deformation is carried out such that the two conductor sections, which are located immediately before and behind the deformation (38) parallel to and extend in the direction of the longitudinal axis of the coil (10) to each other , Method according to Claim 4 , characterized in that the deformation is further carried out such that between the two parallel mutually offset conductor portions, a straight transition portion (40) is formed, which is inclined by a transition angle to the two mutually parallel offset conductor portions. Method according to Claim 5 , characterized in that the length of the transition section (40) and / or the transition angle are variable. Method according to one of the preceding claims, characterized in that the electrical conductor (20) is a wire. Method according to one of the preceding claims, characterized in that the conductor (20) is deformed at predetermined longitudinal positions, wherein the longitudinal positions in dependence on an already wound number of turns (18) are predetermined and in particular at least for a predetermined number of turns (18 ) are equidistant. Method according to Claim 8 , characterized in that the distance of the longitudinal positions in dependence on the number of already wound turns (18) and / or layers is variable. Winding device (30) for producing an electrical coil (10), wherein the winding device (30) is adapted to wind an electrical conductor (20) on a support (12), in particular for carrying out the method according to one of the preceding claims, characterized by a forming device (32) which is designed to plastically deform the conductor (20) in such a way that it protrudes onto the carrier (12) in the direction of a longitudinal axis (L) of the coil (10) in such a way that a resulting deformation (38) of the Ladder (20) corresponds to a desired winding jump (22). Winding device (30) after Claim 10 , characterized in that the forming device (32) at least one with the conductor (20) cooperating, transverse to a longitudinal extension of the conductor (20) in the direction of a longitudinal axis of the coil (10) displaceable first forming element (36A, 36B). Winding device (30) after Claim 11 , characterized in that the forming device (32) further comprises at least one with the conductor (20) cooperating second forming element (34A, 34B), which in the direction of the longitudinal extension of the conductor (20) from the first forming element (36A, 36B) is spaced , Winding device (30) after Claim 11 and 12 , characterized in that the forming device (20) has two transverse to the longitudinal extent of the conductor spaced from each other first Umformelemente (36A, 36B) and two transversely to the longitudinal extent of the conductor (20) spaced from each other second Umformelemente (34A, 34B), in particular the distance of the first forming elements (36A, 36B) from each other and / or the distance of the second forming elements (34A, 34B) from each other and / or the distance between the first forming elements (36A, 36B) and the second forming elements (34A, 34B) is variable ,

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