DE102017219511A1 - Shaping device for producing a conductor element and method for producing a conductor element with the shaping device - Google Patents

Abstract

Bar conductors are used in particular for components of electrical machines, in particular stator and / or rotor. For the production of such bar conductors, for example, shaping devices are used in order to bend the bar conductors into a specific shape. For this purpose, for example, a straight piece of wire is pressed by a punch in a die and preformed for further processing.
For this purpose, a molding apparatus 1 for producing a conductor element 8, with an embossing device 4 for producing an embossment on a preform 7, wherein the embossing device 4 has an embossing section 4a, wherein the embossing section 4a is displaceable in a stamping direction P, so that the preform 7 through the Embossing section 4a is embossed in the stamping direction P, with a bending device 3 for bending the preform 7, wherein the bending device 3 has at least one bending section 3a, b, wherein the bending section 3a, b is displaceable in a direction of displacement V, so that the embossed preform 7 is bent is proposed, wherein the embossing device 4 and the bending device 3 have a common receiving block 5 for receiving the preform 7, so that the preform 7 is guided during the embossing and / or bending guided in the receiving block 5.

Description

The present invention relates to a molding apparatus for manufacturing a conductor member having the features of the preamble of claim 1. Furthermore, the invention relates to a method of manufacturing the conductor member with the molding apparatus.

Bar conductors are used in particular for components of electrical machines, in particular stator and / or rotor. For the production of such bar conductors, for example, shaping devices are used in order to bend the bar conductors into a specific shape. For this purpose, for example, a straight piece of wire is pressed by a punch in a die and preformed for further processing.

The publication EP2559141B1 , which is probably the closest prior art, discloses a preforming device for an electric bar conductor of an electric bar winding, comprising: a punch provided with movable members for applying a pushing force to the conductor during relative preforming, wherein the Punch slides axially along a Vorformrichtung, wherein the punch is provided with a rotor, which is connected to a movable arm, and with a preform head, which is suitable for engaging the conductor, wherein the conductor under preforming conditions is a linear element which along a Transverse direction, which is perpendicular to the preforming direction, is arranged.

The invention has for its object to provide a molding apparatus for producing a conductor element, which has an improved performance and is also cost-optimized. It is another object of the invention to propose a method with the molding apparatus.

This object is achieved by a molding apparatus having the features of claim 1, and a method having the features of claim 8. Preferred embodiments of the invention are disclosed in the subclaims, the following description and the figures.

The invention relates to a molding apparatus which is designed and / or suitable for producing a conductor element. The molding apparatus is used in particular for producing a so-called "hairpin". In particular, the molding apparatus may be formed as an automatic molding machine. Alternatively, the molding apparatus may be formed as a manually operable molding machine. The molding device serves in particular to transform a conductor blank. In particular, the conductor blank is selectively brought into a different shape and / or plastically deformed during forming. Preferably, the finished conductor element or a preform for further processing is produced by the deformation of the conductor blank. In particular, the molding apparatus may be mounted on a base plate.

The molding apparatus has an embossing device, which is designed and / or suitable for producing embossing on a preform. In particular, an already preformed preform is provided with the embossing by the embossing device, so that an embossed preform is produced. The embossing device has an embossing section. In particular, the embossing section is designed as an embossing stamp or has at least this.

The embossing section is displaceable in an embossing direction, so that the preform is embossed by the embossing section in the embossing direction. Preferably, the embossing section designed as an embossing stamp has an offset course, so that the embossing on the preform is formed as an offset. The embossment is particularly preferably designed as an axial offset with respect to the embossing direction. In particular, the stamping direction is directed vertically to the base plate. In particular, the stamping section can be moved mechanically and / or automatically in the stamping direction. The embossing section is preferably straight-lined and / or linearly guided in the embossing direction.

In particular, the preform is V-shaped and preferably has a first and a second side legs. When the embossing section is displaced in the direction of the preform, the first side limb is displaced in the embossing direction relative to the second side limb, so that the two side limbs are offset relative to one another and the offset is formed. Particularly preferably, the preform is embossed in the region of the vertex and / or has the offset in the region of the vertex. In particular, a winding head of the conductor element is formed by the embossing section.

The molding apparatus has a bending device, which is designed and / or suitable for bending the preform. In particular, the embossed preform is bent by the bending device, so that the conductor element is produced. The bending device has at least one bending section. In particular, the bending device serves to generate the bending of the preform by bending or bending.

The bending section is displaceable in a direction of displacement, so that the embossed preform is bent. In particular, the displacement direction is directed horizontally to the base plate. Preferably, the embossed preform is characterized by the Bending section bent in a bending direction. The bending direction can be rectified to the direction of displacement or the stamping direction. Preferably, however, the bending direction is directed transversely to the direction of displacement. Specifically, the bend portion creates a bend radius on the embossed preform. The bending section can in particular be moved mechanically and / or automatically in the direction of displacement. Preferably, the bending portion is straight and / or linearly guided in the displacement direction.

Upon displacement of the bending section in the direction of the preform, the first and / or the second side limb are bent at least in sections, so that the two side limbs are arranged parallel and / or in the direction of displacement rectified to each other. In particular, a first and a second contact leg of the conductor element are formed by the embossing section.

In the context of the invention, the embossing device and the bending device on a common receiving block for receiving the preform, wherein the preform is received during the embossing and / or bending in the receiving block. In particular, the receiving block serves to guide and / or fix the preform during the bending and / or embossing process. Preferably, the preform is guided in the receiving block and / or reshaped. Preferably, the preform remains permanently in the receiving block during the stamping operation and the bending operation. In particular, the receiving block has a negative contour of the finished conductor element. Preferably, the bending device and the embossing device adapt the preform to the negative contour, so that the preform is arranged complementary or at least partially complementary to the negative contour and the conductor element is produced. The receiving block can be made entirely or at least partially of steel.

The advantage of the invention is, in particular, that two shaping steps can be carried out on the preform by the common receiving block, the preform permanently remaining in the receiving block. As a result, the manufacturing time of the conductor element can be shortened. Furthermore, the preform is fixed in the receiving block during the entire bending and embossing process. By using a common receiving block, the manufacturing cost of the molding apparatus can be reduced. Another advantage is in particular that the loads on the preform are reduced during the forming by the inventive design of the molding apparatus.

In a preferred embodiment of the invention, the molding device has a first forming station for producing the preform and a second forming station for producing the conductor element. The first forming station is preferably arranged in terms of process technology after the second forming station. In particular, the first forming station serves to transform the conductor blank into the preform. For example, the conductor blank of the first forming station and / or the preform of the second forming station can be automatically supplied. In particular, the second forming station serves to transform the preform into the embossed preform and then into the conductor element. For this purpose, the second forming station comprises the embossing device, the bending device and the receiving block.

In a specific embodiment, the receiving block has a first and a second block section. In particular, the receiving block is formed in two parts, wherein preferably the first block portion forms a first component and the second block portion forms a second component. The first and the second block portion are preferably connectable to one another in a form-fitting manner.

The first block portion is slidable relative to the second block portion in the stamping direction. In particular, the first block section is displaceable between a first and a second relative position in the stamping direction, wherein the second block section remains stationary. Preferably, the first block portion is straight in the stamping direction. Optionally in addition, the second block portion may be arranged on the base plate.

In a further concretization, the embossing section is designed as the first block section. In particular, the embossing device has an actuating mechanism for displacing the embossing section. The actuating mechanism can be designed, for example, as a mechanical lever or an electrically and / or hydraulically and / or pneumatically actuated lifting cylinder.

Preferably, the two block sections are arranged spaced from each other in the first relative position in the stamping direction, so that the preform can be arranged between the two block sections. In the second relative position, the two block sections abut each other, so that the embossed preform is formed. Particularly preferably, the preform is subjected to an actuation of the actuating mechanism with an axial force. Particularly preferably, the embossment on the preform can be generated by the first block section.

In a structural embodiment, the receiving block has a die for receiving the preform. In particular, the die forms the negative contour of the conductor element. The die is preferably designed as a groove, in particular a continuous groove. The die can have a rectangular or a semicircular cross section. In particular, the first and / or the second block section has the die. Specifically, the first and second block portions together form the die in the second relative position.

The die has a winding head section and a first and a second leg section. In an axial view with respect to the embossing direction, the two leg sections have a straight course and the winding head section has a curved course. The winding head section preferably has a V-shaped or a U-shaped course in the projection from above. Particularly preferably, the two leg sections are connected to each other directly over the winding head section. The winding head section preferably has the offset in an axial view with respect to the direction of displacement.

The two leg sections preferably extend parallel to one another in the displacement direction. The first leg portion extends on the one hand and the second leg portion on the other hand on a side surface of the receiving block. In particular, the two leg sections are offset from each other in the stamping direction.

The embossing device is designed to emboss the preform in the winding head section. In particular, a winding head of the conductor element is formed by the embossing. The bending device is designed for bending the embossed preform in the first and / or the second leg section. In particular, the first side leg of the preform in the first leg receptacle and the second side leg of the preform in the second leg receptacle are at least partially inflected by the bending section. Specifically, the free ends of the first and / or second side legs are inflected into the respective leg receptacle.

In a development, the bending device has at least one guide rail. In particular, the guide rail is formed as a linear guide rail. Preferably, the guide rail is arranged on the base plate. The guide rail preferably extends in the direction of displacement.

The bending section has at least one bending slide, wherein the bending slide is displaceable relative to the receiving block in the displacement direction and is guided by the guide rail. In particular, the bending slide is arranged in the immediate vicinity or with at least a slight clearance to one of the two leg sections. Preferably, the bending device has exactly two guide rails and exactly two bending sections. In particular, a first bending slide of a first bending section is guided by a first guide rail and a second bending slide of a second bending section is guided by a second guide rail. In particular, the receiving block is arranged between the two guide rails. In particular, the bending device has a further actuating mechanism for displacing the bending section. The further actuating mechanism can be designed, for example, as a mechanical lever or an electrically and / or hydraulically and / or pneumatically actuated lifting cylinder.

In a further specific embodiment, the first forming station has one for producing the preform, wherein the preforming device has a die section for receiving the blank conductor and a stamp section. In particular, the Vorformwegzeug is formed in two parts, wherein the die portion forms a first component and the punch portion forms a second component. The conductor blank may be formed as a linear or pre-bent piece of wire. Preferably, the conductor blank is made of an electrically conductive material, e.g. Copper, made. Optionally in addition, the conductor blank may have an electrically insulating coating.

The stamping portion is slidable relative to the die portion so that the preform is produced. In particular, the conductor blank is arranged between the die section and the stamp section. By the displacement of the stamp portion relative to the die portion, the conductor blank is pressed by the stamp portion in a receiving contour of the die portion. Preferably, the stamp portion forms a contour partner to the die portion. In particular, the receiving contour is V-shaped or U-shaped, so that the conductor blank in the, in particular the receiving contour corresponding formed preform is formed. The preforming direction preferably forms the two side limbs of the preform. Particularly preferably, the preform is produced by a die bending process.

Another object of the invention relates to a method for producing a conductor element with the molding device according to one of the preceding claims or as has been previously described.

In a first method step, the conductor blank is inserted into the preform device, wherein the preform device is used to reshape the conductor blank so that the preform is produced. In particular, the conductor blank is inserted between the die section and the stamp section. The punch portion is displaced toward the die portion, with the conductor blank being deformed in the die portion to produce the preform. Preferably, the conductor blank is thereby preformed at least approximately to the contour of the winding head section.

In a second method step, the preform is inserted into the receiving block. In particular, the preform is inserted between the first and the second receiving block in the region of the winding head section.

In a third method step, the embossing section is displaced in the embossing direction, wherein the preform is embossed in the receiving block. Preferably, the preform is embossed by the embossing device in the region of the winding head section, so that the preform is guided during the embossing guided in the receiving block. In particular, the stamping device generates the offset on the preform.

In a fourth method step, the bending section is displaced in the displacement direction, wherein the embossed preform is bent in the receiving block. Preferably, the embossed preform is bent by the bending device in the region of the first and / or the second leg portion, so that the embossed preform is guided during the bend guided in the receiving block. In particular, the first and / or the second side limb are bent over by the bending device, so that the two side limbs run parallel to one another and the conductor element is produced.

• 1 eine dreidimensionale Darstellung einer Formvorrichtung zur Herstellung eines Leiterelements mit einer ersten und einer zweiten Umformstation als ein Ausführungsbeispiel der Erfindung.

Further features, advantages and effects of the invention will become apparent from the following description of preferred embodiments of the invention. Showing:

• 1 a three-dimensional view of a molding apparatus for producing a conductor element having a first and a second forming station as an embodiment of the invention.

The 1 shows in a three-dimensional representation of a molding apparatus 1 with a first and a second forming station 1a . b , The first forming station 1a has a preforming device 2 on. The second forming station 1b has a bending device 3 , an embossing device 4 as well as a recording block 5 on. The two forming stations 1a . b are on a common base plate 6 arranged. The first forming station 1a is, for example, procedurally before the second forming station 1b arranged.

The first forming station 1a serves to transform a conductor blank, eg a straight piece of wire, so that a preformed preform 7 is formed. For this purpose, the preforming device 2 a die section 2a and a stamp section 2 B on. The die section 2a has a V-shaped receiving contour, wherein the stamp portion 2 B as a contour partner to the die section 2a is trained. The stamp section 2 B is relative to the die section 2a slidably, wherein the die section 2a remains stationary. For example, the die section 2a For this purpose via a screw connection to the base plate 6 firmly connected.

For the production of the preform 7 becomes the conductor blank between the die section 2a and the stamp section 2 B arranged. The stamp section 2 B then goes in the direction of the die section 2a shifted so that the conductor blank in the receiving contour of the die section 2a is transformed. This will be the lead blank V Shaped so that the preform 7 , with in particular two side legs, is formed. The stamp section 2 B is moved back to its starting position and the preform 7 from the preforming tool 2 away.

The second forming station 1b serves the preform 7 continue to transform, so that a conductor element 8th is formed. The preform 7 is in the recording block 5 arranged. The recording block 5 is formed in two parts and has a first and a second block portion 5a . b on. The preform 7 is at least in sections between the two block sections 5a , b arranged.

The embossing device 4 has a stamping section 4a on, wherein the embossing section 4a in a stamping direction P is displaceable. The stamping direction P is vertical or perpendicular to the base plate 6 directed. The embossing device 4 has an actuating mechanism 4b on, with the actuating mechanism 4b for displacement of the embossing section 4a is trained. The actuating mechanism 4b is designed, for example, as a mechanical lever mechanism. The first block section 5a is through the embossing section 4a formed and thus with the embossing device 4 operatively connected. Thus, the first block section 5a relative to the second block section 5b in the stamping direction P displaceable, wherein the second block section 5b remains stationary. For example, the second block section 5b For this purpose, firmly with the base plate 6 connected.

The bending device 3 has a first and a second bending section 3a , b on, wherein the first and the second bending section 3a , b in a direction of displacement V are displaceable. The direction of displacement V is horizontal to the base plate 6 directed. The bending device 3 has a further actuating mechanism 3c on, with the further actuating mechanism 3c for displacement of the first and / or the second bending section 3a . b is trained. The further actuating mechanism 3c is designed, for example, as a mechanical lever mechanism.

The two bending sections 3a . b are each formed as a bending slide and with the further actuating mechanism 3c operatively connected. Furthermore, the bending device 3 a first and a second guide rail 9a , b on. The first bending section 3a is through the first guide rail 9a and the second bending section 3b is through the second guide rail 9b in the direction of displacement V guided straight. The recording block 5 is between the two guide rails 9a , b arranged. The two bending sections 3a . b are relative to the recording block 5 in the direction of displacement V displaceable, wherein the receiving block 5 , in particular the second block section 5b , remains stationary. Thus, the first block section 5a be moved between an open and a closed position, wherein in the open position of the preform 7 in the recording block 5 can be inserted or the finished reshaped conductor element 8th from the recording block 5 can be taken out.

The recording block 5 has a die 10 for receiving the preform 7 on, so the preform 7 in the mold 10 is guided deformable. The matrix 10 has a first and a second leg portion 10a . b and a winding head section 10c on. In particular, the die is 10 in a separation region of the two block sections 5a , B arranged, wherein the first and the second block section 5a . b together the matrix 10 form. The two leg sections 10a . b run in the direction of displacement V parallel to each other, with the two leg sections 10a . b in the stamping direction P offset from one another.

The winding head section 10c has a V-shaped course, which, for example, approximately the V-shaped portion of the preform 7 equivalent. Optionally in addition to the winding head section 10c in the stamping direction P have a stepped offset. The winding head section 10c connects the two leg sections 10a . b directly with each other, so the die 10 is formed as a continuous groove.

For the production of the conductor element 8th , in the detail view THERE shown, the recording block 5 via the operating mechanism 4b open. The preform 7 is between the two block sections 5a . b in the region of the winding overhang section 10c inserted. Subsequently, the recording block 5 via the operating mechanism 4b closed, the first block section 5a in the direction of the second block section 5b is moved. Due to the offset in the winding overhang section 10c , becomes the preform 7 in the stamping direction P shaped so that the offset in the preform 7 is embossed and a winding head of the conductor element 8th is formed.

In a further method step, the first and the second bending section 3a , b about the further operating mechanism 3c moved in the direction of displacement. The first bending section 3a slides in the direction of displacement V along the recording block 5 , in particular in the region of the first leg section 10a , and the second bending section 3b slides at the same time in the direction of displacement V along the recording block 5 , in particular in the region of the second leg section 10b , This is the embossed preform 7 , in particular the two free ends of the side legs, in the first and the second leg portion 10a , b bent in sections, so that two contact legs of the conductor element 8th be formed and the preform 7 in the U-shaped conductor element 8th is transformed. Subsequently, the recording block 5 be reopened and the conductor element 8th removed or removed.

LIST OF REFERENCE NUMBERS

1

molding machine

2

preforming device

2a

swaging

2 B

stamp section

3

bender

3a

first bending section

3b

second bending section

3c

actuating mechanism

4

embosser

4a

stamping section

4b

another operating mechanism

5

receiving block

5a

first block section

5b

second block section

6

baseplate

7

preform

8th

conductor element

9a

first guide rail

9b

second guide rail

10

die

10a

first leg intake

10b

second leg intake

10c

Winding section

THERE

detailed view

P

embossing direction

V

displacement direction

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

• EP 2559141 B1 [0003]

Claims (12)

Forming device (1) for producing a conductor element (8), with an embossing device (4) for producing an embossment on a preform (7), wherein the embossing device (4) has an embossing section (4a), wherein the embossing section (4a) in a Stamping direction (P) is displaceable, so that the preform (7) by the embossing portion (4a) is embossed in the embossing direction (P), with a bending device (3) for bending the preform (7), wherein the bending device (3) at least one Bending section (3a, b), wherein the bending section (3a, b) is displaceable in a displacement direction (V), so that the embossed preform (7) is bent, characterized in that the embossing device (4) and the bending device (3) a common receiving block (5) for receiving the preform (7), wherein the preform (7) during embossing and / or bending in the receiving block (5) is accommodated. Shaping device (1) according to Claim 1 , characterized in that the forming device (1) has a first forming station (1a) for producing the preform (7) and a second forming station (1b) for producing the conductor element (8), wherein the second forming station (1b) comprises the embossing device (4 ) comprising the bending device (3) and the receiving block (5). Shaping device (1) according to Claim 1 or 2 , characterized in that the receiving block (5) has a first and a second block portion (5a, b), wherein the first block portion (5a) relative to the second block portion (5b) in the stamping direction (P) is displaceable. Forming device after Claim 3 , characterized in that at least one of the two block sections is formed as the embossing section. Shaping device (1) according to one of the preceding claims, characterized in that the receiving block (5) has a die (10) for receiving the preform (7), wherein the die (10) has a first and a second leg portion (10a, b). and a winding head section (10c), wherein the embossing device (4) for embossing the preform (7) in the winding head section (10c) and the bending device (3) for bending the embossed preform (7) in the first and / or the second leg section (10). 10a, b) is formed. Shaping device (1) according to one of the preceding claims, characterized in that the bending device (3) has at least one guide rail (9a, b), wherein the bending section (3a, b) is designed as a bending slide, and wherein the bending section (3a, b) relative to the receiving block (5) in the displacement direction (V) is displaceable and guided by the guide rail (9 a, b). Shaping device (1) according to one of Claims 2 to 6 , characterized in that the first forming station (1a) comprises a preforming device (2) for producing the preform (7), wherein the preforming device (2) has a die section (2a) for receiving a blank conductor and a punch section (2b), wherein the Stamping portion (2b) relative to the die portion (2a) is displaceable, so that the preform (7) is generated. Method for producing a conductor element (8) with the molding device (1) according to one of the preceding claims, in which: - The preform (7) is inserted into the receiving block (5), - the embossing section (4a) is displaced in the embossing direction (P), the preform (7) being embossed in the receiving block (5), - The bending section (3a, b) is displaced in the direction of displacement (V), wherein the embossed preform (7) is bent in the receiving block (5). Method according to Claim 8 , characterized in that the preform (7) by the embossing device (4) in the region of the winding head portion (10c) is embossed, so that the preform (7) during the embossing in the receiving block (5) is guided transformed. Method according to Claim 8 or 9 , characterized in that the embossed preform (7) is bent by the bending device (3) in the region of the first and / or the second leg portion (10a, b), so that the embossed preform (7) during the bending in the receiving block (5 ) is transformed. Method according to one of Claims 8 to 10 , characterized in that in a first method step, the conductor blank is inserted into the preforming device (2), wherein by the preforming device (2) the conductor blank is reshaped, so that the preform (7) is produced. Method according to Claim 11 , characterized in that: - the conductor blank is inserted between the die portion (2a) and the die portion (2b); - And the punch portion (2b) relative to the die portion (2a) is moved, wherein the Conductor blank is formed in the preforming device (2), so that the preform (7) is produced.

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