DE102017211034A1 - Casting tool for cast electro-technical coils - Google Patents

Abstract

A casting tool (1) for producing molded electrical coils (30), the cast coil (30) having a plurality of spaced turns (31) about a hollow core portion (32), the casting tool (1) comprising: at least two relative to each other a demolding device (4) movable mold sides (2, 3) for forming a plurality of mold cavities (5), wherein in each case a mold cavity (5) for a coil (30) is shaping, and for forming a casting run with a casting run center point (8), lead from the runner arms (9) to the individual mold cavities (5), and per mold cavity (5) a slide (6) which can be moved in the slide direction (11), shaping the respective coil (30), wherein in a direction of demolding (4) an auxiliary straight line (12) through a coil center (13) of the respective mold cavity (5) and the casting center (8) is defined, wherein an angle α between the slide direction (11) of the respective mold cavity (5) and the H Auxiliary straight line (12) is not 90 °.

Description

The present invention relates to a casting tool for simultaneously casting a plurality of electrotechnical coils in a tool. The coils are cast from an electrically conductive material and used in an electrical machine. Furthermore, the invention relates to a method for producing the electrical coils and the cast electro-technical coil.

The publication DE 10 2013 000 899 A1 shows a prior art electrotechnical coil that can be produced by casting.

It is an object of the present invention to provide a casting tool with which electrical coils can be cast as efficiently as possible. In particular, the coils should be able to be produced as quickly as possible, with sufficient quality and the lowest possible use of materials.

The object is achieved by a casting tool for producing cast electro-technical coils. The casting tool is preferably designed to cast the coil of a metal, in particular aluminum or an aluminum alloy. Preferably, the casting tool is a permanent mold. The "permanent mold" can be used for multiple casting operations and does not require lost moldings or cores. The cast coil is designed for use in an electrical machine. The electric machine can be operated by electric motor and / or generator. In particular, the electric machines are slowly rotating electric motors which are used in vehicles as servomotors or servomotors. The coil to be produced with the casting tool has a plurality of spaced-apart turns. The turns extend around a hollow core region of the coil. After casting the coil, the individual windings may be coated with an electrically insulating material, or an insulating material is otherwise introduced between the windings.

The casting tool comprises at least two casting mold sides. The two casting mold sides are relatively movable in a demolding direction relative to one another. It is also possible that one of the two mold sides is fixed when opening and closing the casting tool and the other mold side is moved. The two sides of the mold form a large number of mold cavities. The individual mold cavities are spaced apart from each other and are each shaping a coil.

Furthermore, a casting run is formed in the casting mold sides. In particular, this casting run comprises a sprue section through which the liquid material forming the spools can be filled into the casting tool. The sprue section leads, in particular without a branch, to a center of gravity. From this central pouring point sprinkler branches branch off to the individual mold cavities. In particular, a separate Gießlaufarm is provided for each mold nest, which branches off from Gießlaufzentralpunkt. Particularly preferably, the sprue section is formed directly in front of the center of gravity of the runner so that the liquid material runs parallel to the demoulding direction on the runner center point. The runners preferably extend from the central runner point substantially perpendicular to the Entformungsrichtung.

The casting tool comprises a slider for each mold cavity. The slider is movable along an axis defined as the "slider direction". Both the mold cavity formed in the two mold sides and the slide are shaping the respective coil. The mold cavity and the slide thus form the negative form of the coil. In addition to the slides described herein, the casting tool may also include additional slides.

The movable arrangement of the slide in or between the two sides of the mold requires a certain amount of space. This space must be both sufficient for the size of the slider as well as for its displacement along the slide direction. Furthermore, it must be taken into account that a separate slider must be available for each mold cavity. Furthermore, the mold cavities must be arranged with the smallest possible and as equal as possible distance to Gießlaufzentralpunkt, so that the liquid material distributed as evenly as possible on all mold cavities and with the lowest possible thermal losses. This makes it possible to integrate relatively many mold cavities in a casting mold and to use a permanent mold for casting. Particularly preferably, it is also possible to cast in the cold chamber process.

These advantages are achieved by a special arrangement of the mold cavities or the slide:

For describing this arrangement, an auxiliary straight line is defined, which, when viewed on a plane perpendicular to the Entungsungsrichtung, through a coil center of each Formnests and the Gießlaufzointpunkt. The coil center preferably lies in the geometric center of the coil to be cast, when viewed in the direction perpendicular to the Entformungsrichtung plane. When determining the coil center point, only the turns are considered and any projecting extensions of the coil, which form electrical connections, are disregarded.

The slide direction of the respective slide considered here intersects the respective auxiliary straight line in the center of the coil at an angle α. In the context of this invention, the smaller angles between two straight lines are always measured. According to the invention, this angle α is less than 90 °.

In a simple arrangement of the mold cavities on a circle around the Gießlaufzentralpunkt, the Gießlaufarme would run straight and star-shaped from Gießlaufzentralpunkt outward. The defined auxiliary straight lines would cut the slider directions at 90 °. However, this would mean that the space of the slide with the space for the adjacent mold cavity competes and consequently the mold cavities must be arranged with a relatively large distance from each other.

Since, according to the invention, the angle α is less than 90 °, the slide directions do not extend tangentially to the circle around the center of the runner, but are inclined outwards, resulting in radially outwardly of the circle sufficient space for the arrangement of the slide at the individual mold cavities.

In a preferred embodiment, it is provided that the angle α is at most 80 °, preferably at most 65 °, particularly preferably at most 50 °. The smaller this angle is chosen, the more space is available for the slide radially outside the mold cavity.

Furthermore, it is provided in a preferred embodiment that the angle α is at least 10 °, preferably at least 25 °, particularly preferably at least 40 °. By this minimum size of the angle is taken into account that the mold cavity is preferably flown perpendicular to the slide direction with the liquid material. However, the smaller the angle α is chosen, the stronger the runner arms have to be bent.

It is preferably provided that the slider is in each case shaping the hollow core region of the coil. Accordingly, the two mold sides are preferably shaping the voids between the individual turns. In the case of a conventional geometry of the coil, it can be seen that preferably the slide directions are perpendicular to the removal direction. The mold cavities are preferably arranged so that the flow with the liquid material from the Gießlaufarmen is perpendicular to the slide direction.

It is preferably provided that at least in the casting tool 8th , preferably at least 12 , more preferably at least 16 , particularly preferably at least 24 Mold cavities are formed. Each mold nest is connected via its own caster arm to the common caster central point.

When viewed on a plane perpendicular to the Entformungsrichtung all mold cavities are preferably arranged around the Gießlaufzentralpunkt. In particular, the coil centers of all mold cavities are located on a circle around the casting center.

Furthermore, it is preferably provided that all mold cavities are arranged in the same plane. This is in particular a plane perpendicular to the Entformungsrichtung level. Alternatively, it is provided that the mold cavities are arranged in different, perpendicular to the Entformungsrichtung planes. In particular, the mold cavities are arranged in two, three or four planes. Despite the arrangement in different levels, all mold cavities are connected to the same caster center via individual runners. Due to the arrangement in different levels, many mold cavities can be integrated into the casting tool.

When viewed in a plane perpendicular to the demolding direction, the runner arms preferably extend from the center of gravity of the runner or in an arcuate shape. For this curved course of Gießlaufarme an angle β is defined. Specifically, the angle β is defined between a first straight line passing through the run center and the center of the start of the respective runner arm and a second straight line passing through the center of the end of the respective runner arm and the center of the reel. The angle β is preferably β = (270 ° -3α) +/- 20 °, particularly preferably β = (270 ° -3α) +/- 10 °; in particular with the angle α defined above between 10 ° and 80 °. More preferably, all the runners are bent in the same direction.

The mold cavities preferably each have their own overflow. During pouring, the liquid material passes from the run center of gravity through the runner arm into the mold cavity. In the flow direction after the mold cavity, the liquid material runs into the overflow of the respective mold cavity. The overflow is preferably designed such that the liquid material from all turns of the produced coil converges in the overflow. As a result, the overflow forms a sufficiently large volume in which any impurities can collect.

The respective slider is preferably guided linearly movable in the direction of the slide on one of the two sides of the casting. Furthermore, on Slider and preferably formed on the other mold side inclined surfaces. These surfaces are skewed with respect to the direction of demolding. When opening and closing, ie during the relative movement of the two mold pages to each other, the inclined surfaces slide together. As a result, the slides move when opening and closing along the slide direction. It therefore requires no own drive the slide. It is particularly preferred that oblique columns are arranged on a casting mold side, which slide in a correspondingly inclined column receptacle in the individual slides.

With the described casting tool basically coils of any geometry can be cast.

It is preferably provided that the mold cavities and slides are designed to form the following coil:

The turns of this coil, when viewed on a plane perpendicular to the coil axis, have two opposite first sides and two opposite second sides. Along the hollow core region, the coil axis is defined. The windings thus wind around the coil axis. Preferably, the first sides are perpendicular to the second sides, resulting in a rectangular shape. However, for example, a trapezoidal shape, diamond shape, round shape or oval shape are possible.

The first two sides are flat and extend only in a plane perpendicular to the coil axis. The two first pages thus do not contribute to the slope of the coil. The slope of the coil is formed by the two second sides. For this purpose, the two second sides are formed as floors and extend in a plane inclined to the coil axis.

Preferably, when viewed on a plane perpendicular to the coil axis, the two first sides are shorter than the two second sides.

The first two pages determine a width of the coil. The two second sides determine a length of the coil. Perpendicular to the width and the length runs a height of the coil, parallel to the coil axis. Preferably, the Entformungsrichtung is arranged parallel to the width of the coil. Furthermore, it is preferably provided that the Entformungsrichtung perpendicular to the length of the coil. Furthermore, the slide direction preferably runs parallel to the height of the coil.

The mold cavities are preferably arranged so that the liquid material from the respective runner arm runs along the length of the spool, and thus preferably perpendicular to the height and width, to the overflow.

Due to the described embodiment, the shaping elements of the mold pages need not be tapered to form the turns, which simplifies the production of the tool.

The present invention further includes a method for manufacturing the electrotechnical coils. The coils are preferably cast from aluminum or an aluminum alloy. The method uses the described casting tool.

In particular, a die-casting method, preferably in the cold chamber method, is used. Furthermore, it is preferably provided that during casting the Entformungsrichtung is aligned horizontally with +/- 20 °.

The invention further comprises a cast electro-technical coil. This is preferably produced with the described casting tool or according to the described method. The coil includes a plurality of spaced turns around a hollow core region. Along the core area a coil axis is defined. The windings thus wind around the coil axis.

The turns of this coil, when viewed on a plane perpendicular to the coil axis, have two opposite first sides and two opposite second sides. Preferably, the first sides are perpendicular to the second sides, resulting in a rectangular shape. However, for example, a trapezoidal shape, diamond shape, round shape or oval shape are possible.

The first two sides are flat and extend only in a plane perpendicular to the coil axis. The two first pages thus do not contribute to the slope of the coil. The slope of the coil is formed by the two second sides. For this purpose, the two second sides are formed as floors and extend in a plane inclined to the coil axis.

• 1 eine schematische Ansicht des erfindungsgemäßen Gusswerkzeugs auf eine zur Entformungsrichtung senkrechte Ebene,
• 2 eine schematische Ansicht eines durch das erfindungsgemäße Gusswerkzeug gegossenen Positivs,
• 3 eine Detailansicht aus 2,
• 4 verschiedene Ansichten einer mit dem erfindungsgemäßen Gusswerkzeug herstellbaren Spule gemäß einer ersten Variante,
• 5 verschiedene Ansichten einer mit dem erfindungsgemäßen Gusswerkzeug herstellbaren Spule gemäß einer zweiten Variante,
• 6 eine schematische Seitenansicht des erfindungsgemäßen Gusswerkzeug,
• 7 eine erste schematische Ansicht eines Schiebers des erfindungsgemäßen Gusswerkzeugs, und
• 8 eine zweite schematische Ansicht des Schiebers des erfindungsgemäßen Gusswerkzeugs.

In the following the invention will be explained in more detail with reference to an embodiment. Show:

• 1 a schematic view of the casting tool according to the invention on a plane perpendicular to the Entformungsrichtung,
• 2 a schematic view of a cast by the casting tool according to the invention positive,
• 3 a detailed view 2 .
• 4 different views of a producible with the casting tool according to the invention coil according to a first variant,
• 5 different views of a producible with the casting tool according to the invention coil according to a second variant,
• 6 a schematic side view of the casting tool according to the invention,
• 7 a first schematic view of a slider of the casting tool according to the invention, and
• 8th a second schematic view of the slider of the casting tool according to the invention.

The following is an embodiment of a casting tool 1 explained in detail. It is on the 1 to 8th Referenced.

The casting tool 1 includes a solid mold side 2 and a movable mold page 3 , The two mold pages 2 . 3 are relative to each other along a Entformungsrichtung 4 movable. 1 shows a view perpendicular to this Entformungsrichtung 4 , In 6 is a view parallel to the Entformungsrichtung 4 shown. In the casting tool 1 it is a permanent mold for die casting. The one with the casting tool 1 cast and solidified material is in 2 shown. 2 thus shows a positive representation by the casting tool 1 formed negative mold. 3 shows a detail 2 ,

In particular 1 and 2 show are in the two mold pages 2 . 3 twelve mold nests 5 educated. In every mold nest 5 becomes an electrotechnical coil 30 cast. The mold nests 15 are thus shaping for the respective coil 30 ,

The casting tool 1 includes for every mold nest 5 a slider 6 , the inside of the casting tool 1 along a slide direction 11 is linearly movable.

The 1 and 2 show a watering center 8th , To this waterfall central point 8th leads parallel to Entformungsrichtung 4 a sprue section 7 , From the watering place central point 8th the runner splits into twelve runners 9 , In each case a Gießlaufarm 9 leads to a mold cavity 5 , At the end of the mold nest 5 there is an overflow 10 ,

In every mold nest 5 is a coil center 13 as shown in 1 Are defined. The coil center 13 is in terms of in 1 shown representation centrally in the coil to be cast 30 and on the slider direction 11 , which are centered by the slider 6 runs. The mold nests 5 are all around the Gießlaufzentralpunkt 8 arranged so that all coil centers 13 on a circle 14 are located.

1 shows an example of a mold cavity 5 an auxiliary straight 12 passing through the coil center 13 and the Gießlaufzentralpunkt 8 runs. This auxiliary straight 12 forms with the associated slide direction 11 which also through the center of the coil 13 runs, the angle α. The smaller angle between these two straight lines is always measured. The angle α is here chosen to be significantly smaller than 90 ° with 45 °. The slide direction 11 thus deviates significantly from a tangent to the circle 14 from. This results radially outward of the circle 14 sufficient space for the arrangement of the slide 6 ,

4 shows in different views the coil 30 in accordance with the casting tool shown 1 , The sink 30 includes a plurality of turns 31 , which are around a hollow core area 32 squirm. The described slides 6 are shaping the core areas 32 the coils 30 , The distances between the turns 31 be by appropriate shaping extensions of the two Gussformseiten 2 . 3 educated.

4 shows a coil axis 33 passing through the core area 32 and the coil center 13 runs.

At the two ends of the coil 30 are each connections 34 formed in the form of extensions. In particular 2 and 3 show, these connections extend 34 in the direction of the overflow 10 , When determining the coil center point 13 as well as the definition of width B , Length L and height H the coil 30 stay these connections 34 unconsidered.

The sink 30 points parallel to the slide direction 11 and thus parallel to the coil axis 33 the height H on. Perpendicular to the demoulding direction 4 is the length L the coil 30 Are defined. Parallel to the demoulding direction 4 is the width B the coil 30 Are defined. A smallest thickness D the coil 30 or the turns 31 is preferably in the range of 5 mm to 0.5 mm.

As 4 shows lie two opposite first pages 36 the coil 30 flat in one to the coil axis 33 vertical plane. These two first pages 36 are located at the width B the coil 30 , Two opposite second sides 37 form floors 35 and thus define the slope the coil 30 , The width B The coil is much smaller than the length L ,

5 shows an alternative embodiment of the coil 30 , where the floors 35 only on one of the first two pages 36 and thus formed on the narrow broadside. Also this coil 30 can with the described casting tool 1 getting produced. However, it should be noted that the shaping extensions of the two mold pages 2 . 3 for the design of the floors 35 have to taper pointed or wedge-shaped.

7 and 8th show schematic views of an embodiment for moving the slider 6 without a separate drive for the slides 6 is necessary. 7 shows the casting tool 1 in an open position. 8th shows the casting tool 1 in a closed position.

The sliders 6 are linearly movable on the movable mold side 3 guided. At the solid casting side 2 is for each slide 6 a skew column 16 with inclined surfaces 15 , In every slider 6 is a column photograph 17 , also with inclined surfaces 15 educated. By moving the two sides of the mold 2 . 3 along the Entformungsrichtung 4 , the inclined surfaces 15 slide against each other, causing the slider 6 in slide direction 11 to be moved.

LIST OF REFERENCE NUMBERS

1

casting tool

2

solid casting side

3

movable mold page

4

unmolding

5

cavities

6

pusher

7

Angus section

8th

Gießlaufzentralpunkt

9

Gießlaufarme

10

overflow

11

slide direction

12

auxiliary straight

13

Coil center

14

circle

15

inclined surfaces

16

angle pin

17

tower holder

30

Kitchen sink

31

turns

32

core area

33

coil axis

34

connections

35

Floors

36

first pages

37

second pages

B

width

L

length

H

height

D

thickness

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

• DE 102013000899 A1 [0002]

Claims (15)

A casting tool (1) for producing molded electrotechnical coils (30), the cast coil (30) having a plurality of spaced turns (31) about a hollow core region (32), the casting tool (1) comprising: At least two mold sides (2, 3) movable relative to each other in a demoulding direction (4) ◯ for forming a plurality of mold cavities (5), wherein in each case a mold cavity (5) for a coil (30) is shaping, and ◯ for forming a casting run with a Gießlaufzentralpunkt (8) from which Gießlaufarme (9) lead to the individual mold cavities (5), and For each mold cavity (5) a slide (6) which can be moved in the direction of the slide (11), shaping the respective coil (30), Wherein in a direction perpendicular to the Entformungsrichtung (4) plane an auxiliary line (12) through a coil center (13) of the respective mold cavity (5) and the Gießlaufzpunktpunkt (8) is defined, wherein an angle α between the slide direction (11) of the respective mold cavity (5) and the auxiliary line (12) is not 90 °. Casting tool after Claim 1 , wherein the angle α • maximum 80 °, preferably at most 65 °, more preferably at most 50 °, and / or • at least 10 °, preferably at least 25 °, particularly preferably at least 40 °. Casting tools according to one of the preceding claims, wherein the slides (6) are shaping for the respective core region (32). Casting tools according to one of the preceding claims, wherein at least 8, preferably at least 12, more preferably at least 16, more preferably at least 24, mold cavities (5) are formed, each of which is connected via its own Gießlaufarm (9) to the common Gießlaufzentralpunkt (8) Casting tool according to one of the preceding claims, wherein all the coil center points (13) lie on a circle (14) when viewed in a plane perpendicular to the demoulding direction (4). Casting tool according to one of the preceding claims, • Wherein all mold cavities (5) in the same, preferably one to the Entformungsrichtung (4) vertical plane are arranged, or • wherein the mold cavities (5) are arranged offset in different, preferably two or three, perpendicular to the Entformungsrichtung (4) planes. Casting tool according to one of the preceding claims, wherein the casting runners (9), viewed in a direction perpendicular to the Entformungsrichtung (4) plane from the Gießlaufzentralpunkt (8) to the respective mold cavity (5) are bent, preferably at an angle β with β = (270 ° - 3α) +/- 20 °. Casting tool according to one of the preceding claims, wherein the mold cavities (5) each form an overflow (10), in which the casting of all windings (31) of the coil (30) converges. Casting tool according to one of the preceding claims, • wherein the respective slide (6) on one of the Gussformseiten (3) in the slide direction (11) is linearly guided, and Wherein the slider (6) by corresponding inclined surfaces (15) on the slider (6) and on the other mold side (2) during the relative movement of the Gussformseiten (2, 3) is movable. Casting tool according to one of the preceding claims, wherein the mold cavities (5) and slides (6) are shaped for the following coil (30): Spool (30) having a plurality of spaced turns (31) about a hollow core portion (32) extending along a spool axis (33) through the spool center (13), Wherein the windings (31), when viewed on a plane perpendicular to the coil axis, have two opposite first sides (36) and two opposite second sides (37), • wherein the two first sides (36) extend flat, in a plane perpendicular to the coil axis (33), and • wherein the two second sides (37) extend as floors (35) in a plane inclined to the coil axis (33). Casting tool after Claim 10 wherein, when viewed on a plane perpendicular to the spool axis (33), the first two sides (36) are shorter than the two second sides (37). Casting tool after Claim 11 in which the demolding direction (4) runs parallel to the width (B) of the coil (30) determined by the first sides (36) and / or the demolding direction (4) perpendicular to the length determined by the second sides (37) ( L) of the coil (30). Method for producing electrotechnical coils (30), preferably made of aluminum or an aluminum alloy, with a casting tool (1) according to one of the preceding claims. Cast electrical coil (30), preferably manufactured with a casting tool (1) after one of the Claims 1 to 12 or according to the method Claim 13 , comprising a plurality of spaced apart turns (31) about a hollow core region (32) extending along a coil axis (33), said turns (31) facing two opposite to said coil axis (33) first sides (36) and two opposite second sides (37), • wherein the two first sides (36) extend flat, in a plane perpendicular to the coil axis (33), and • wherein the two second sides (37) as Extending floors (35) in a direction to the coil axis (3) inclined plane. Coil after Claim 14 wherein, when viewed on a plane perpendicular to the spool axis (33), the first two sides (36) are shorter than the two second sides (37).

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