DE102019207865A1 - Winding needle, winding system for wire windings and method for producing a wire winding - Google Patents

Abstract

According to embodiments, the invention relates to a winding needle (100) for feeding a wire (110) to be wound during a winding process for producing a wire winding. The winding needle (100) is designed as a hollow needle, and the wire (110) to be wound is guided through the winding needle (100). The winding needle comprises a strain sensor (107) for detecting a bending of the winding needle (100).

Description

The present invention relates to a winding needle for feeding in a wire to be wound during a winding process for producing a wire winding, a winding system and a method for producing a wire winding.

In electrical engineering, coils are an essential element in a variety of applications such as electric motors, transformers, relays, and others. Coils can be designed, for example, as a winding of a current conductor, for example made of insulated copper wire.

For example, a three-phase electric machine has a rotor and a stator. The stator is usually constructed from a stator core and a three-phase winding. 1A FIG. 11 shows a schematic view for explaining an exemplary method for manufacturing a stator. A plurality of stator teeth 310 are each arranged at a distance from one another by a groove 320 on the inside of a housing. The stator teeth 310 each form the core of the coils.

Stators with different types of windings, for example concentrated or distributed windings, can be produced, for example, with needle winding technology. In this process, the wire is wound directly into the slots of the stator with a winding needle, which is designed as a hollow needle, under wire tension, as in 1A is indicated. The winding needle 100 can be attached to a needle holder 120. The wire 110 to be wound is passed through the winding needle 100.

The general aim of a winding is to achieve a winding structure that is as uniform as possible. In the best case, an orthocyclic winding structure is achieved in which the center points of the wire windings of adjacent windings are each arranged at positions of an equilateral triangle. In this case, a high electrical fill factor (copper fill factor) can be achieved. This brings about a reduction in line losses and thus an increase in efficiency and an increase in power density.

General needle winding processes are described in, for example EP 1 759 446 B1 or DE 10 2011 008 662 A1 described. A method and a device for regulating the wire tension of a coil winding wire are disclosed in DE 10 2005 028 053 B3 described.

Although the description essentially relates to the production of wire windings on a stator, it goes without saying that the described method and the described elements can also be used for the production of other windings, in particular windings for rotors but also for windings for other electrical components .

The electrical fill factor is an essential parameter that determines the power density and efficiency of electrical machines and transformers. The electrical fill factor describes the ratio of the cross-section of all conductors to the area of the space provided for wire storage (e.g. the groove of an electrical machine). Maximizing the electrical fill factor is of crucial importance for the use of the electric motor as a traction drive in an electric car.

In order to maximize the electrical fill factor, an attempt is made in automated winding processes to achieve the best possible wire storage. This can be achieved, for example, using the needle winding technique, in which the wire is deposited directly into the groove with a guided hollow needle. This enables exact wire storage. By cleverly storing the wires in the slot, it is possible to optimize the electrical fill factor in the slot.

1B FIG. 13 shows a cross-sectional view through the stator between I and I 'as in FIG 1A indicated. 1B illustrates schematically a movement process of the winding needle and stator during the manufacture of a wire winding with the aid of needle winding technology. The winding needle is advanced radially into a stator slot 320. To generate the winding, the needle holder 120 or the winding needle 100 then performs a vertical movement (movement 1), so that the horizontally aligned winding needle moves in the vertical direction in the groove. If the winding needle 100 reaches the end of the laminated core, the stator can, for example, be rotated by one slot pitch (movement 2). The winding needle 100 then moves vertically in the direction opposite to the first groove (movement 3). As soon as the winding needle has reached the other face of the laminated core, the stator rotates backwards again (step 4). In this case, the winding needle 100 is moved in a parallel movement radially by the amount of the wire diameter, so that the individual turns are arranged next to one another on the tooth 310 of the laminated core to be wound. These process steps are repeated until the specified number of turns has been generated.

The wire tensile force at the needle outlet during the production process is decisive for the winding result. On the one hand, this has an influence on the wire diameter (plastic deformation) and thus on the winding resistance. Furthermore, that is important for the exact wire placement Wire alignment depends crucially on the wire tension.

The present invention is based on the object of providing an improved winding needle, an improved winding system and an improved method for producing a wire winding.

According to an embodiment, the object is achieved by the subject matter of the independent patent claims. Advantageous refinements with expedient developments are specified in the dependent claims.

According to embodiments, a winding needle for supplying a wire to be wound during a winding process for producing a wire winding is provided, the winding needle being designed as a hollow needle and the wire to be wound being guided through the winding needle. the winding needle comprises a strain sensor for detecting a bending of the needle.

According to embodiments, the strain sensor comprises one or more, for example 2, 3 or 4, strain gauges.

According to embodiments, a winding system for wire windings comprises a winding needle for feeding a wire to be wound during a winding process for producing a wire winding on a workpiece, the winding needle being designed as a hollow needle and the wire to be wound being guided through the winding needle. The winding system further comprises a device for measuring a wire tension of the wire to be wound on the workpiece and a device for setting a wire tension during the winding process. According to embodiments, the device for setting the wire tension can be regulated using a measurement result that is determined by the device for measuring the wire tension. For example, the device for setting the wire tension can be regulated in such a way that a maximum wire tension of the wire to be wound on the workpiece is not exceeded.

For example, the winding needle is designed as a hollow needle in which the wire to be wound is passed through the winding needle. The device for measuring the wire tension has a strain sensor for detecting a bending of the needle. The device for setting the wire tension can be regulated in such a way that a maximum predetermined bending force is not exceeded.

The strain sensor can comprise one or more strain gauges, for example.

According to embodiments, the device for setting can be regulated in such a way that a predefined bending force interval is maintained. The bending force interval can be fixed or it can also vary.

For example, the device for setting the wire tension can be regulated by a control device. The control device can perform the control based on a bending force acting on the winding needle, which can be determined using measurement results from the device for wire tension.

According to embodiments, the winding system comprises the regulating device.

According to embodiments, the strain sensor can be suitable for determining the bending force acting on the winding needle due to the wire tension during the winding process.

For example, the device for setting the wire tension can be a wire brake.

According to embodiments, a method for producing a wire winding on a workpiece is carried out using a needle winding method. In the method, a wire tension of a wire to be wound on the workpiece is detected. The wire tension during the winding process is controlled using the measured wire tension. For example, the wire tension is regulated in such a way that a maximum wire tension of the wire to be wound on the workpiece is not exceeded.

According to embodiments, a winding needle is designed as a hollow needle, and the wire to be wound is guided through the winding needle. The winding needle includes a strain sensor for detecting a bending of the needle. The device for setting the wire tension can be regulated in such a way that a maximum predetermined bending force is not exceeded.

For example, a stator winding or a rotor winding is produced by the method. For example, a stator winding is produced for a separately excited synchronous machine.

• 1A eine schematische Ansicht eines Stators bei Herstellung einer Wicklung;
• 1B zeigt eine Querschnittsansicht des Stators bei Durchführung eines Verfahrens zur Herstellung einer Wicklung;
• 2A veranschaulicht eine Wickelnadel gemäß Ausführungsformen;
• 2B zeigt eine perspektivische Ansicht der Wickelnadel;
• 3 zeigt ein Wickelsystem gemäß Ausführungsformen.

Further advantages, features and details of the invention emerge from the patent claims, the following description of preferred embodiments and on the basis of the drawings. It shows:

• 1A a schematic view of a stator in the manufacture of a winding;
• 1B shows a cross-sectional view of the stator when performing a method of manufacturing a winding;
• 2A illustrates a winding needle in accordance with embodiments;
• 2 B Figure 3 shows a perspective view of the winding needle;
• 3 shows a winding system according to embodiments.

2A shows a side plan view of a winding needle 100 . The winding needle 100 is for feeding a wire to be wound 110 suitable for producing a wire winding during a winding process. The winding needle 100 is designed as a hollow needle, and the wire to be wound 110 is through the winding needle 100 to be led. The winding needle includes a strain sensor 107 to detect a bend in the needle.

The strain sensor 107 can for example one or more strain gauges 105 ₁ , 105 ₂ , 105 ₃ , 105 ₄ include. Strain gauges measure the elastic deformation of a component, in this case the winding needle 100 , due to the wire tension according to Hooke's law about changes in the sensor resistances. For example, the strain sensor 107 Strain gauges 105 ₁ , 105 ₂ , 105 ₃ , 105 ₄ , a resistance measuring device 215 and supply lines 106 ₁ , 106 ₂ have that with the resistance measuring device 215 are connected. For example, the winding needle 100 a single strain gauge 105 ₁ exhibit. This can be oriented, for example, in such a way that its loading direction or measuring direction runs parallel to the wire tension direction or to the main wire tension direction.

The strain sensor can, however, also be designed in any other form. For example, the strain sensor can be any force sensor. The strain sensor can for example be based on piezoelectric, optical, inductive or capacitive measuring methods.

2 B Figure 10 shows a perspective view of the winding needle 100 . The winding needle 100 can have more than one strain gauge 105 include. For example, the winding needle 100 comprise two strain gauges, the directions of which intersect each other. For example, their centers of gravity are arranged at a distance of 90 °. According to further embodiments, the winding needle 100 also four strain gauges 105 ₁ , 105 ₂ , 105 ₃ and 105 ₄ include, the centers of which can each be arranged at a distance of 90 ° from one another.

In the 2A and 2 B The winding needle shown can thus pull wire forces perpendicular to the central axis 107 the needle 100 act through which the strain gauges are recorded. Accordingly, it is possible to determine the wire tensile forces directly at the needle tip. The wire tensile force is thus determined at the point at which the influence of the wire tensile force on the winding process is particularly strong. Accordingly, it is possible to monitor the winding process particularly effectively and, as will be explained later, to regulate it.

The direction of pull (α _w , β _w ) contains on the one hand a horizontal component, the horizontal or azimuthal angle α _w , which is related to an axis 108 is measured perpendicular to the central axis 107 runs and for example through the position of one or more strain gauges 105 is determined. The component β _w denotes the vertical component or the elevation angle in relation to the central axis 107 is measured.

The wire tensile force F _w acts on the needle 100 and, depending on the direction of pull (α _w , β _w ) - for example if four strain gauges are present - generates four measurement signals δ _sg : $${\mathrm{\delta }}_{\text{so called}}={\left[{\mathrm{\delta }}_{\text{sg1}},{\mathrm{\delta }}_{\text{sg2}},{\mathrm{\delta }}_{\text{sg3}},{\mathrm{\delta }}_{\text{sg4}}\right]}^{\text{T}}.$$

$$\kappa =E\cdot {\left[\begin{array}{cccc}\frac{1}{A_1}& \frac{1}{A_2}& \frac{1}{A_3}& \frac{1}{A_4}\end{array}\right]}^T$$

According to embodiments it is possible to identify the wire tensile force F _w and the direction of tensile α _w from the measurement signals δ _sg . Simulations of the winding needle using the finite element method show a linear and symmetrical bending behavior of the component. The wire tensile force F _w and the component elongation δ _sg are directly proportional according to Hooke's law. For example, the tensile strength can be determined from the strain signals as follows: $${\delta }_{\mathrm{S.}G}\approx \kappa \circ \underset{G\left({\alpha }_{\mathrm{W.}},\zeta \right)}{\underbrace{\left[\begin{array}{c}\text{sin}\left({\alpha }_{\mathrm{W.}}+{\zeta }_1\right)\\ -\text{cos}\left({\alpha }_{\mathrm{W.}}+{\zeta }_2\right)\\ -\text{sin}\left({\alpha }_{\mathrm{W.}}+{\zeta }_3\right)\\ \text{cos}\left({\alpha }_{\mathrm{W.}}+{\zeta }_{\mathrm{4th}}\right)\end{array}\right]}}\cdot \text{sin}\left({\beta }_{\mathrm{W.}}\right)\cdot {\mathrm{F.}}_{\mathrm{W.}}$$

$$\kappa =\mathrm{E.}\cdot {\left[\begin{array}{cccc}\frac{1}{{\mathrm{A.}}_1}& \frac{1}{{\mathrm{A.}}_2}& \frac{1}{{\mathrm{A.}}_3}& \frac{1}{{\mathrm{A.}}_{\mathrm{4th}}}\end{array}\right]}^T$$

The scaling factor κ is determined by the cross-sectional area A for each strain gauge of the component and the modulus of elasticity. Deviations in the sticker position are corrected by the factor ξ. The factors κ and ξ are learned through a calibration, since they cannot be exactly determined in advance. Deviations, for example in the resistance of the strain gauges, can be compensated for.

According to embodiments, reference data can be recorded beforehand for calibration. For example, an external force sensor measures the tensile force F _w for discrete combinations of α _w and β _w . For example, the parameters κ and ξ can be optimally adapted by applying a nonlinear optimization based on the method of the smallest square deviation and calculating the global minimum of a cost function as follows: $$\begin{array}{l}J\left[k\right]\left(\kappa ,\zeta \right)={\delta }_{\mathrm{S.}G}\left[k\right]-\kappa \circ G\left({\alpha }_{\mathrm{W.}}\left[k\right],\zeta \right)\cdot \text{sin}\left({\beta }_{\mathrm{W.}}\left[k\right]\right)\cdot {\mathrm{F.}}_{\mathrm{W.}}\left[k\right]\\ \kappa ,\zeta =\underset{\kappa ,\zeta }{{\displaystyle \text{bad min}}}{{\displaystyle {\sum }_{k=1}^N\left(J\left[k\right]\left(\kappa ,\zeta \right)\right)}}^2\end{array}$$

If the angle β _w cannot be determined from the measurement signals δ _sg , it can be calculated using a geometric simulation model, for example using the component geometry and the trajectory of the winding needle in space.

3 shows a winding system 200 according to embodiments. The winding system 200 includes a winding needle 100 for feeding a wire to be wound during a winding process for producing a wire winding on a workpiece. The winding needle 100 is designed as a hollow needle, and the wire to be wound is fed through the winding needle. The winding system further comprises a device 230 for measuring a wire tension of the wire to be wound on the workpiece and a device 210 for setting a wire tension during the winding process.

According to embodiments, the device is 210 for adjustment using a measurement result obtained from the facility 230 for measuring the wire tension is determined, adjustable. For example, the device 210 be adjustable in such a way that a maximum predetermined wire tension of the wire to be wound on the workpiece is not exceeded. According to further embodiments, it is also possible that the device 230 the wire tension is determined to measure the wire tension. This measurement result is used to control the device 210 to adjust the wire tension during the winding process. In the subsequent winding process, the device 230 Used to measure wire tension, to measure or monitor the wire tension that occurs during the winding process. In this case, the wire tension does not necessarily have to be regulated on the basis of the measurement result.

The workpiece can, for example, in the 1A and 1B shown stator 300 his. According to further embodiments, the workpiece can also be a rotor, a general core or part that is to be wound. The establishment 230 To measure the wire tension, it is suitable to record the wire tension of the wire to be wound directly on the workpiece. For example, the facility is 230 for measuring the wire tension in the vicinity or adjacent to the workpiece. For example, a shortest distance between the device 230 to measure the wire tension and the workpiece must be smaller than a shortest distance between the device 230 for measuring the wire tension and the device 210 for setting the wire tension. The establishment 230 to measure the wire tension or components of the device can be attached directly to the winding needle 100 to be appropriate.

In 3 becomes the wire 110 starting from a wire supply 240 via the device for setting a wire tension 210 the winding needle 100 fed. For example, the needle 100 to a needle holder 120 be attached. The winding system 200 can use different deflection coils 250 included as well as steering or guiding devices 260 to the wire 110 the winding needle 100 feed. The needle holder 120 is provided to move the needle according to a predetermined movement pattern 100 to move so for example the winding as referring to 1A and 1B can be made. For example, the winding needle 100 be carried out as described above. For example, the facility 230 to measure the wire tension comprise a strain sensor for detecting a bending of the needle, as described with reference to the 2A and 2 B has been described. The establishment 230 to measure the wire tension or a part of it can thus be part of the winding needle 100 his. The device for setting the wire tension can be regulated in such a way that a maximum predetermined bending force is not exceeded.

The contraption 210 for setting the wire tension, it can be regulated, for example, in such a way that a predetermined bending force interval is maintained, ie a range between a minimum bending force and a maximum bending force. The bending force interval does not have to be constant but can also change in the course of the winding process, for example as a function of a control concept. For example, the device 210 a wire brake, for example a delay device designed as a brake wheel, to set the wire tension.

For example, the device for adjusting the wire tension can be through a regulating device 220 be controllable. The control device 220 the regulation can for example be based on an on the winding needle 100 acting bending force. The bending force can be determined using measurement results from the strain sensors. For example, the control device can be part of the winding system 200 his. According to further embodiments, the control device 220 but also outside of the winding system 200 be arranged. For example, the control device 220 by a computer (not shown in 3 ) be realized that the measurement results of the strain sensor 105 receives and the device 210 controls accordingly to set the wire tension.

According to embodiments, the strain sensor can for example be able to convert a measured resistance into a bending force or wire tension. According to further embodiments, the control device can also 220 or another device, for example a computer, may be able to do this conversion.

Further embodiments relate to a method for producing a wire winding on a workpiece using a needle winding method in which a wire tension of a wire to be wound on the workpiece is detected. Furthermore, the wire tension during the winding process is regulated using the measured wire tension. For example, the wire tension can be regulated in such a way that a maximum wire tension of the wire to be wound on the workpiece is not exceeded. For example, the winding needle in the needle winding process as in 1A and 1B shown. For example, the wire tension through the device 230 to measure the wire tension.

According to embodiments, a winding needle is used in the method 100 , which is designed as a hollow needle and in which the wire to be wound 110 is passed through the winding needle. For example, the winding needle 100 a strain sensor 105 to detect a bend in the needle. The device for setting the wire tension can be regulated in such a way that a maximum predetermined bending force is not exceeded.

According to embodiments, a stator winding or a rotor winding can be produced by the method. According to further embodiments, however, any desired windings can also be produced for any desired electrical engineering applications. The method can be carried out in such a way that the wire tension is regulated in accordance with the wire tension that is determined by the strain sensors.

As has been described, the wire tensile force can be measured directly in front of the workpiece with the winding needle or the winding system or the method described. As a result, the wire tension signal can then be used to regulate the wire tension. For example, targeted control interventions on the wire tensioning brake can improve the wire tension in the vicinity of the component. As a result, the product quality, in particular the electrical fill factor, is increased. A regulated wire tension can also control plastic deformation of the wires and avoid an increase in resistance. Furthermore, the electrical filling factor can be increased by placing the winding wire in a precisely positioned position.

This is particularly advantageous in a separately excited synchronous machine in which the rotor contains needle-wound concentrated windings. Precise wire storage is very advantageous here both for reasons of power density and for reasons of the mechanical strength of the windings. As a result, electric magnets with coils in the rotor can be provided, making it possible to replace permanent magnets based on rare earth materials with coils.

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was 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.

Patent literature cited

• EP 1759446 B1 [0006]
• DE 102011008662 A1 [0006]
• DE 102005028053 B3 [0006]

Claims (18)

Winding needle (100) for feeding a wire (110) to be wound during a winding process for producing a wire winding, the winding needle (100) being designed as a hollow needle and the wire (110) to be wound being guided through the winding needle (100), comprising a Strain sensor (107) for detecting a bending of the winding needle (100). Winding needle (100) Claim 1 , wherein the strain sensor (107) comprises a strain gauge (105). Winding needle (100) Claim 2 , in which the strain sensor (107) comprises two strain gauges (105). A winding system (200) for wire winding, comprising a winding needle (100) for feeding a wire (110) to be wound during a winding process for producing a wire winding on a workpiece, the winding needle (100) being designed as a hollow needle and the wire (110) to be wound being guided through the winding needle (100) becomes; a device (230) for measuring a wire tension of the wire to be wound (110) on the workpiece, and a device (210) for setting a wire tension during the winding process. Winding system (200) Claim 4 , in which the device (210) for setting the wire tension can be regulated using a measurement result which is determined by the device (230) for measuring the wire tension. Winding system according to Claim 5 , in which the device (210) for adjusting the wire tension can be regulated in such a way that a maximum wire tension of the wire (110) to be wound on the workpiece is not exceeded. Winding system (200) according to one of the Claims 4 to 6th , in which the winding needle (100) is designed as a hollow needle and the wire (110) to be wound is guided through the winding needle (100), the device (230) for measuring the wire tension having a strain sensor (107) for detecting a bending of the winding needle (100) and the device (210) for setting the wire tension can be regulated such that a maximum predetermined bending force is not exceeded. Winding system (200) Claim 7 , in which the strain sensor (107) comprises a strain gauge (105) which is attached to the winding needle (100). Winding system (200) Claim 7 or 8th , the device (210) for adjustment being controllable in such a way that a predetermined bending force interval is maintained. Winding system (200) according to one of the Claims 7 to 9 , in which the device (210) for setting the wire tension can be regulated by a regulating device (220) and the regulating device carries out the regulation based on a bending force acting on the winding needle (100), which can be determined using measurement results from the strain sensor (107). Winding system (200) Claim 10 , which comprises the control device (220). Winding system (200) according to one of the Claims 7 to 11 , in which the strain sensor (107) is suitable for determining the bending force acting on the winding needle (100) due to the wire tension during the winding process. Winding system (200) according to one of the Claims 4 to 12 , in which the device (210) for adjusting the wire tension is a wire brake. A method for producing a wire winding on a workpiece using a needle winding method, in which a wire tension of a wire to be wound on the workpiece is detected and the wire tension is controlled during the winding process using the measured wire tension. Procedure according to Claim 14 , in which the wire tension is regulated in such a way that a maximum wire tension of the wire to be wound on the workpiece is not exceeded. Procedure according to Claim 15 , in which a winding needle, which is designed as a hollow needle and in which the wire to be wound is guided through the winding needle, comprises a strain sensor for detecting a bending of the needle and the device for adjusting the wire tension can be regulated such that a maximum predetermined bending force is not is exceeded. Procedure according to Claim 15 or 16 , in which a stator winding or a rotor winding is made. Procedure according to Claim 17 , in which a rotor winding is produced for a separately excited synchronous machine.

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