DE102019201037A1 - Positioning device for positioning copper bars - Google Patents

Abstract

The invention relates to a positioning device for circumferential and radial positioning about a central axis M of a plurality of end sections of copper bars.

Description

The invention relates to a positioning device for circumferential and radial positioning about a central axis M of a plurality of end sections of copper bars, the copper bars being formed essentially U-shaped with a first leg section, a second leg section and a transverse section connecting both leg sections, with a first and a second torsion disk, which can be rotated counter to one another about the central axis M, a plurality of first passages being formed circumferentially in the first torsion disk and a plurality of second passages being circumferentially formed in the second torsion disk, and the first passages can be made to coincide with the respective rotation of the torsion disks are to pass the end portions of the copper bars through aligned first and second passages.

The manufacture of electrical machines, for example electric motors or generators, is about simplifying the assembly process and at the same time improving the quality parameters during the assembly process. A distinction must be made here between stator elements or rotor elements produced in winding technology or produced in hair-pin technology. Hair-pin technology offers the possibility of increasing the power density of electric motors that are to be used in motor vehicles. In the hair-pin technology, specially bent copper rods, which are also referred to as hair pins because of their shape, are introduced into receiving grooves of the stator element or rotor element that are axially extending and arranged around the inside or outside.

In the course of the following description, the term copper rod is used and the English term hair pin is omitted. A copper rod in the sense of this description is preferably bent in a U-shape, so that it has two substantially parallel leg sections which are connected to one another by a transverse section. The length of this cross section determines the so-called span of the copper rod, which accordingly indicates the distance between the two leg sections. The two leg sections are inserted into the receiving grooves of the stator element or rotor element in the assembled state of the copper rods.

The described bend or shape of the copper rod means that, viewed in an axial view, the two leg sections are seated parallel to the central axis M in the receiving grooves, but with two different diameters in relation to the central axis M. These two different diameters, on which copper rods in the receiving grooves of the Stator elements or rotor elements are plugged in, are referred to as a so-called "level".

In the inserted state, the respective transverse sections of the copper rods thus protrude from the stator element or rotor element on one side and the free end sections protrude from the stator element or rotor element on the other side. Following the insertion of the copper bars into the stator element or rotor element and a subsequent bending process at the free end sections, it is necessary to connect the free end sections of different copper bars in pairs in a suitable manner, so that the entirety of the interconnected copper bars or result in several continuous, winding-like wire runs in the stator element or rotor element.

A “level” is created by connecting the free end sections of the copper bars on the outer diameter with the free end sections of the copper bars on the second, inner diameter. In configurations in which a second “level” is located in the receiving grooves of a stator element or rotor element, the copper rods are consequently stuck on a third and a fourth diameter.

The free end sections of the copper sections are generally connected by a joining process, for example soldering or welding. For the joining of the end sections to one another, it is necessary that the end sections to be connected in pairs are arranged as gap-free as possible. Positioning devices are known for this, such as one in the EP 2 684 283 A1 is described. In this device described above, it can be considered disadvantageous that the force acting on the end sections to be joined takes place both in the straight end and in the inclined area in front of it, which has arisen as a result of the bending process carried out previously. In particular, the application of force in the inclined area is undesirable since this can result in damage to the applied insulating varnish in the inclined area. In contrast to this, due to the principle, no insulating varnish was applied to the free end areas of the copper rods, or one was removed, so that the action of force there cannot cause any damage.

Proceeding from this, the object of the present invention is to provide a device by means of which a force can be exerted on the end regions of the copper rods without the risk of damaging the insulation.

The object is achieved by a positioning device for circumferential and radial positioning about a central axis M of a plurality of end sections of copper bars, the copper bars being formed essentially U-shaped with a first leg section, a second leg section and a transverse section connecting both leg sections, with a first and a second torsion disk rotatable counter to one another about the central axis M, wherein a plurality of first passages are circumferentially formed in the first torsion disk and a plurality of second passages are circumferentially formed in the second torsion disk and the first with the second passages are rotated by respective rotation of the torsion disks Can be brought to cover the end sections of the copper rods through first and second passages brought into register, the passages of at least one of the torsion disks tapering in the circumferential direction Has outline contour.

Alignment of the copper rods or their end sections both in the radial and in the circumferential direction, with respect to the central axis M, is achieved by the two rotating disks by the action of force in one plane, namely in the plane in which the end sections are located. The tapering outline contour is realized in that the circumferential side surfaces of the passages are aligned with each other in such a way that the respective passage tapers. For a simplest embodiment, it is conceivable that only one of the side surfaces is set and the other side surface essentially runs along a tangent to the circumference. However, it can also be provided that both side surfaces are set with respect to the respective tangents. It is particularly preferred here if the tapering contour is essentially trapezoidal.

An advantageous embodiment of the invention provides that the two rotating disks are rotatably held by a retaining ring frame. The retaining ring frame can advantageously be used to produce a defined and stable contact with the stator element or rotor element.

An advantageous embodiment of the invention provides that both torsion disks are held axially displaceably on the retaining ring frame along the central axis M. This advantageously ensures that the retaining ring frame is first placed on the stator element or rotor element and then the two rotating disks are placed on the end sections of the copper rods in the axial direction, simultaneously or in succession.

An advantageous embodiment of the invention provides that a common rotary drive is provided for the two rotating disks, which can be converted at least alternately into an operative connection with one of the rotating disks.

An advantageous embodiment of the invention provides that the passages tapering in their contour are arranged on the rotating disc on at least two concentric circles around the central axis M.

• 1a) eine Darstellung eines einzelnen Kupferstabes;
• 1b) Statorelement bzw. Rotorelement mit Kupferstäben;
• 2 eine erfindungsgemäße Positioniervorrichtung;
• 3 eine erfindungsgemäße Positioniervorrichtung;
• 4 eine erste Darstellung der Positionierung und
• 5 eine zweite Darstellung der Positionierung.

The invention is explained below with further features, details and advantages with reference to the accompanying figures. The figures only illustrate exemplary embodiments of the invention. Show here

• 1a) an illustration of a single copper rod;
• 1b) Stator element or rotor element with copper rods;
• 2 a positioning device according to the invention;
• 3 a positioning device according to the invention;
• 4 a first representation of the positioning and
• 5 a second representation of the positioning.

The 1a) first shows a single copper rod 2 which is substantially U-shaped with a first leg section 4 ₁ , a second leg section 4 ₂ and one both leg sections 4 ₁ . 4 ₂ connecting cross section 8th is formed. The end of each leg section shown below 4 ₁ . 4 ₂ can as end section 6 ₁ . 6 ₂ are referred to, in contrast to the rest of the leg section and continuing upward 4 ₁ . 4 ₂ has no insulation, for example by an insulating varnish, of the copper material.

The 1b) shows a stator element or rotor element 1 , the circumference with a plurality of copper rods 2 is equipped, which in not shown grooves of the stator or rotor element 2 incarcerated. The copper elements 2 thus sit in the stator element or rotor element 1 one that they have an axial side with the cross sections 8th and to the other axial side with the end sections 61 . 62 protrude beyond the respective end face. M denotes a central axis, which is used in later operation of the stator element or rotor element 1 is to be equated with the axis of rotation.

The 2 shows a positioning device according to the invention 10 , in the one with copper rods 2 equipped stator element or rotor element 1 is included. For this purpose, the positioning device can be a base plate 16 have over which the stator element or rotor element 1 with the cross sections 8th the copper rods 2 to the base plate 16 is kept pointing. For this purpose, for example, several on the base plate 16 circumferentially positioned clamping devices can be provided. The positioning device further comprises 10 a retaining ring frame 18 , which is functionally regarded as a counterpart to the base plate 16 acts and the stator element or rotor element 1 holds on the side where the end sections 6 ₁ . 6 ₂ escape. Furthermore, a plurality of tension elements 24 provided over which the retaining ring frame 18 with the interposition of the stator element or rotor element 1 opposite the base plate 16 can be braced. On or on the retaining ring frame 18 are concentric with each other and directly on top of each other a first rotating disc 12 and a second rotating disc 14 held rotatable about the central axis M. The retaining ring frame can be used for this 18 have a bearing in a suitable manner in the region of the central axis M. A stator element or rotor element is present 1 shown with two "levels". According to the definition of “level” already given above, this means that through the stator element or rotor element 1 always two pairs of copper rods on a radius 2 are inserted and thus four end cuts 6 ₁ to 6 ₄ exit upwards, cf. here in particular 4 , Both torsion disks 12 . 14 have passages arranged circumferentially 20 . 22 on through which the end section 6 ₁ to 6 ₄ step up. Based on 2 it can be seen that the upper torsion disc 14 two passes each on a radius 22 ₁ and 22 ₂ has so that through each of the passages 22 ₁ and 22 ₂ two of the end cuts 6 ₁ to 6 ₄ pass.

The 5 shows the positioning device 10 , where the upper turntable 14 has been omitted from the illustration. The lower torsion disc can therefore be seen 12 and the passages 20 ₁ . 20 ₂ , which in the present case are designed as longitudinal slots running in the radial direction. Each of the passages 20 ₁ . 20 ₂ thus takes two pairs of the end sections 6 ₁ . 6 ₂ on.

The 4 and 5 shows a sequence of the respective rotation of the torsion disks 12 . 14 for gap-free and pair-wise positioning of the end sections 6 ₁ . 6 ₂ to each other in order to be able to join them in the positioned state. The 4a) first shows a passage in a schematic representation 20 the lower rotating disc 12 and two pairs of end sections 6 ₁ to 6 ₄ the copper rods 2 going through the passage 20 pass. The end sections 6 ₁ to 6 ₄ step through the passage in an initial state 20 therethrough. This initial state essentially results from the previously performed bending process and a different spring back of the individual end sections afterwards 6 ₁ to 6 ₄ towards their original shape. This is with the reference line R the line on which the end sections are drawn purely as an example 6 ₁ to 6 ₄ have to be positioned for pairwise joining. That the respective upper end section 6 ₁ and 6 ₃ and the lower end portions 6 ₂ and 6 ₄ on opposite sides of the reference line R in the depicted initial state is due to the fact that the copper rods 2 when exiting the grooves of the stator element or rotor element 1 were bent in opposite circumferential directions, hence their end portions 6 ₁ to 6 ₄ alternating with copper rods 2 belong in the axial direction in the opposite circumferential direction in the stator or rotor element 1 into running. This results in the end sections 6 ₁ to 6 ₄ an opposite springback behavior after the bending process. Based on 4b) is the rotation of the lower rotating disc 12 shown, in the present case a rotation D ₁ counterclockwise. In the 4c ) is finally after rotation D ₁ the rotating disc 12 the position of the end sections 6 ₁ to 6 ₄ related to the reference line R shown. It can be seen that the respective upper end sections 6 ₁ and 6 ₃ through the rotating disc 12 or the side surface 26 have not been changed in position because of rotation D ₁ the rotating disc 12 and the side surface 26 behind the reference line R lies.

The 5a) and 5b) show after pre-positioning through the lower rotating disc 12 the end sections 6 ₁ to 6 ₄ in their spatial or positional relationship to the upper rotating disc 14 , The passages arranged in pairs can be seen 22 ₁ and 22 ₂ the rotating disc 14 through which the end sections 6 ₁ to 6 ₄ pass. The end sections 6 ₁ to 6 ₄ can, as shown here, from the edges of the passageways 22 ₁ . 22 ₂ be exempt. Starting from this position, a rotation takes place D ₂ the upper rotating disc 14 , the rotation D ₂ clockwise and thus the rotation D ₁ is opposite. The rotation D ₂ is based on the 5c ) and 5d). The passages 22 ₁ . 22 ₂ have a contour tapering in the circumferential direction 28 on. In particular, it is provided that the passages 22 ₁ . 22 ₂ against the direction of rotation D ₂ rejuvenate. As a result, the side surfaces function 30 ₁ . 30 ₂ as sliding slopes to which the end areas 6 ₁ . 6 ₂ first come to rest and with continued rotation D ₂ be clamped against each other. It is particularly useful if the passages 22 ₁ . 22 ₂ are trapezoidal. Thus the passages take over 22 ₁ . 22 ₂ The second Verdrehscheibe 14 first the function of the radial positioning of the end areas 6 ₁ . 6 ₂ the copper rods 2 , The passages continue to take over 22 ₁ . 22 ₂ the second rotating disc 14 in interaction with the passage 20 the first rotating disc 12 also the function of the final extensive positioning of the end regions 6 ₁ . 6 ₂ the copper rods 2 with respect to the reference line R ,

LIST OF REFERENCE NUMBERS

1

Stator element or rotor element

2

copper rod

4

leg portion

6

end

8th

cross section

10

positioning

12

Verdrehscheibe

14

Verdrehscheibe

16

baseplate

18

Retaining ring frame

20

passage

22

passage

24

tension element

26

side surface

28

outline contour

30

faces

R

reference line

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included 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.

Patent literature cited

• EP 2684283 A1 [0007]

Claims (6)

Positioning device (10) for circumferential and radial positioning about a central axis M of a plurality of end sections (6 ₁ , 6 ₂ ) of copper bars (2), the copper bars (2) being essentially U-shaped with a first leg section (4 ₁ ), a second leg section (4 ₂ ) and a cross section (8) connecting both leg sections (4 ₁ , 4 ₂ ) are formed, with a first and a second torsion disk (12, 14) which can be rotated counter to one another about the central axis M, wherein in the first Twist plate (12) circumferentially a plurality of first passages (20 ₁ , 20 ₂ , ...) and in the second twist plate (14) circumferentially a plurality of second passages (22 ₁ , 22 ₂ , ...) are formed and the first with the second passages (20 ₁ , 20 ₂ , ..., 22 ₁ , 22 ₂ , ...) can be made to coincide with the respective rotation of the rotating disks (12, 14) in order to cover the end sections (6 ₁ , 6 ₂ ) of the copper rods (2) by covering them first n and second passages (20 ₁ , 20 ₂ , ..., 22 ₁ , 22 ₂ , ...), characterized in that the passages (20 ₁ , 20 ₂ , ..., 22 ₁ , 22 ₂ , ...) at least one of the rotating disks (12, 14) has an outline contour (28) that tapers in the circumferential direction. Positioning device (10) after Claim 1 , characterized in that the two rotating disks (12, 14) are rotatably held by a retaining ring frame (18). Positioning device after Claim 2 , characterized in that the two rotating disks (12, 14) are held axially displaceably on the retaining ring frame (18) or via the retaining frame ring (18) along the central axis M. Positioning device (10) according to one of the Claims 1 to 3 , characterized in that a common rotary drive is provided for the two rotating disks (12, 14), which can be converted at least alternately into an operative connection with one of the rotating disks (12, 14). Positioning device (10) according to one of the Claims 1 to 4 , characterized in that the tapering contour (28) is substantially trapezoidal. Positioning device (10) according to one of the Claims 1 to 5 , characterized in that the passages (22 ₁ , 22 ₂ , ...) tapering in their contour (28) are arranged on the rotating disc (14) on at least two concentric circles around the central axis M.

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