DE102020111962A1 - Method of making a winding - Google Patents

Abstract

A wire mat (1), which has several wire ends (2), is produced from one or more wires that have an electrically insulating sheath. At least one of the wire ends (21, 22, 23, 24) is bent so that it touches another of the wire ends (21, 22, 23, 24). The touching wire ends (21, 22, 23, 24) can in particular be connected to one another in an electrically conductive manner. The wire mat (1) produced in this way is used in the stator or rotor of an electrical machine in order to form the windings of the electrical machine. The wire mat (1) can be single-layer or multi-layer.

Description

The invention relates to a method for producing a winding for an electrical machine.

Electrical machines with stator and rotor have windings on the stator and / or rotor. Various winding methods are known in the prior art for producing these windings. In this case, for example, individual wires are inserted into slots, for example of a stator, with the ends of the wires protruding from a respective slot. To make an electrical connection, respective ends of the wires are bent so that they touch, and an electrical connection is then made between these touching ends. In this way, the necessary interconnection of windings of the electrical machine can be implemented. The bending of the wire ends and the connection between the wire ends in the case of wires already used in the electrical machine is cumbersome, since the other components of the electrical machine restrict the accessibility to the wire ends to be connected.

The object of the invention is to provide a method by which the windings of an electrical machine can be produced more easily.

This object is achieved by a method according to claim 1. Claim 7 relates to an associated wire mat. The subclaims each relate to advantageous configurations.

• Zunächst wird aus einem oder mehreren Drähten eine Drahtmatte hergestellt; die Drahtmatte hat dabei eine Vielzahl von Drahtenden. Die Drähte weisen eine elektrisch isolierende Umhüllung auf. Bei den Drähten kann es sich um Drähte beliebigen Querschnitts, insbesondere beliebiger Querschnittsform, handeln. Dann wird mindestens ein Drahtende der Vielzahl von Drahtenden derart verbogen, dass sich eine Berührung zwischen diesem Drahtende und einem weiteren Drahtende der Vielzahl von Drahtenden ergibt. Schließlich wird die Drahtmatte in einen Stator oder einen Rotor der elektrischen Maschine eingesetzt und bildet die Wicklungen des Stators bzw. des Rotors.

The method according to the invention is used to produce a winding of an electrical machine and comprises the following steps:

• First, a wire mat is made from one or more wires; the wire mat has a large number of wire ends. The wires have an electrically insulating sheath. The wires can be wires of any cross-section, in particular any cross-sectional shape. Then at least one wire end of the multiplicity of wire ends is bent in such a way that there is contact between this wire end and a further wire end of the multiplicity of wire ends. Finally, the wire mat is inserted into a stator or a rotor of the electrical machine and forms the windings of the stator or the rotor.

Before the wire mat is inserted into the stator or rotor, the wire mat and, accordingly, the wire ends are relatively freely accessible. The wire ends can therefore be reached relatively easily in order to bend them as required. The production of the windings of the electrical machine is thus simplified by the method according to the invention.

The wire mat can be produced, for example, in that the wire is not wound on a stator or rotor with known wire feeds and winding nozzles, but rather is deposited on a plane.

Wire mats can thus be produced which correspond to known winding forms, for example, without restricting the invention thereto, wave winding, step winding, step reversal winding.

In one embodiment, several pairs of wire ends are each bent in such a way that there is contact between the wire ends of each pair.

In a general development, at least two wire ends that touch one another are connected to one another in an electrically conductive manner. Thus, the interconnections required for the winding of the electrical machine can be generated by bending one or more wire ends until they touch the wire ends and then electrically conductively connect the touching wire ends. This can be done in particular before the wire mat is inserted into the stator or rotor, so that the creation of the interconnections is simplified compared to the prior art, since the relevant wire ends are more easily accessible. The electrically conductive connection between touching wire ends can be achieved, for example, by soldering or welding the wire ends.

In one embodiment, a portion of the wire mat is inserted into a groove in the stator or the rotor. This replaces the need to insert individual wires into the groove. The necessary electrical connections between individual wire ends are advantageously already created.

According to the method according to the invention, the wire mat can be produced in one or more layers. All necessary electrically conductive connections between wire ends of the wire mat are preferably produced before the wire mat is inserted into the electrical machine, that is to say in the stator or rotor of the electrical machine.

The wire mat according to the invention is produced in the course of the method according to the invention described above.

Accordingly, the wire mat comprises one or more wires having an electrically insulating sheath, the wire mat having a plurality of wire ends, and wherein at least two wire ends are in contact. At least two wire ends that are in contact are preferably connected to one another in an electrically conductive manner. The wire mat can be single-layer or multi-layer. The wires of the wire mat can have any cross-section, in particular any cross-sectional shape.

• 1 zeigt ein Stadium der Herstellung einer Drahtmatte entsprechend dem erfindungsgemäßen Verfahren.
• 2 zeigt ein späteres Stadium der Herstellung einer Drahtmatte entsprechend dem erfindungsgemäßen Verfahren.

The invention and its advantages are described in more detail below with reference to the accompanying drawings.

• 1 shows a stage in the production of a wire mat according to the method according to the invention.
• 2 shows a later stage in the manufacture of a wire mat according to the method of the invention.

The drawings merely represent exemplary embodiments of the invention. The drawings are in no way to be construed as limiting the invention to the exemplary embodiments shown.

1 shows a wire mat 1 with a variety of wire ends 2 . The wire ends 2 belong to wires which are in the wire mat 1 are included; these wires have an electrically insulating sheath, not specifically shown here. The wire mat 1 is located outside of an electrical machine, the wire ends are accordingly 2 freely accessible. A sub-area 4th the wire mat 1 is intended to be inserted into a slot of a stator of the electrical machine. The wire mat 1 then forms the windings of the stator.

2 shows the wire mat 1 the end 1 at a later stage of their manufacture. Accordingly, most of the elements shown have already been made in relation to 1 explained. Here are the ends of the wire 21 and 22nd brought into contact with one another and connected to one another in an electrically conductive manner, and so are the wire ends 23 and 24 brought into contact with one another and connected to one another in an electrically conductive manner. Due to the electrically conductive connection between the wire ends, the interconnections required for the operation of the electrical machine are implemented in the windings of the electrical machine. This is done here before the wire mat is inserted into the electrical machine, that is to say with easier access to the wire ends 21 , 22nd , 23 , 24 .

List of reference symbols

1

Wire mat

2

Wire end

4th

Sub-area

21

Wire end

22nd

Wire end

23

Wire end

24

Wire end

Claims (10)

A method for producing a winding of an electrical machine, comprising at least the following steps: Producing a wire mat (1) from one or more wires having an electrically insulating sheath, the wire mat having a plurality of wire ends (2); Bending at least one wire end (21, 22, 23, 24) of the plurality of wire ends in such a way that contact between the at least one wire end (21, 22, 23, 24) of the plurality of wire ends and a further wire end (21, 22, 23, 24) yields the plurality of wire ends; Insertion of the wire mat (1) into a stator or a rotor of the electrical machine. Procedure according to Claim 1 , wherein several pairs of wire ends (21, 22, 23, 24) are each bent so that there is contact between the wire ends (21, 22, 23, 24) of each pair. Method according to one of the preceding claims, wherein at least two wire ends (21, 22, 23, 24) touching one another are connected to one another in an electrically conductive manner. Method according to one of the preceding claims, wherein a portion (4) of the wire mat (1) is inserted into a groove of a stator or a rotor. Method according to one of the preceding claims, wherein the wire mat (1) is single-ply. Method according to one of the preceding claims, wherein the wire mat (1) is multilayered. Wire mat (1) made of one or more wires having an electrically insulating sheath, the wire mat (1) having a plurality of wire ends (2), and wherein at least two wire ends (21, 22, 23, 24) of the plurality of wire ends are in contact . Wire mat (1) Claim 7 , wherein at least two touching wire ends (21, 22, 23, 24) are connected to one another in an electrically conductive manner. Wire mat (1) Claim 7 or 8th , wherein the wire mat (1) is single-ply. Wire mat (1) Claim 7 or 8th , wherein the wire mat (1) is multilayered.

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