DE102021101678B3 - Method for winding a toothed chain extending in a longitudinal direction - Google Patents

Abstract

The invention relates to a method for winding a toothed chain (1) extending in a longitudinal direction (Z), in particular for forming an internally slotted stator of an electrical machine using a needle carrier (2), comprising the following steps: providing a rotatable about its longitudinal axis (3). mounted toothed chain holder (4), fixing the toothed chain (1) with a large number of grooves (5) and teeth (6) in the toothed chain holder (4) arranged alternately in the longitudinal direction (Z) and aligned transversely to the longitudinal direction (Z), providing a plurality of comb-like winding tools (7), each of which has a base body (8) from which at least two clamp webs (9) protrude transversely to the longitudinal extent (X) of the base body (8), fixing the winding tools (7) along the toothed chain (1). the longitudinal extent of the teeth (6), winding the inverted tooth chain (1) with at least one line strand (10), removing the winding tools (7) from the inverted tooth chain (1).

Description

The present invention relates to a method for winding a toothed chain extending in a longitudinal direction, in particular for forming an internally slotted stator of an electrical machine using a needle carrier.

Electrical machines are used to convert electrical energy into mechanical energy and/or vice versa, and generally include a stationary part referred to as a stator, stand or armature and a part referred to as a rotor or runner and arranged movably relative to the stationary part.

The stator of a radial flux machine is usually constructed cylindrically and has grooves which are distributed over the circumference in the electrical lamination and run parallel to the rotor shaft and which accommodate the stator winding or parts of the stator winding. Various winding systems and winding methods are known for inserting a winding into these slots.

the DE 10 2011 011 809 A1 shows, as generic prior art, a method for winding a toothed chain extending in a longitudinal direction Z, in particular for forming an internally slotted stator of an electrical machine using a needle carrier.

From the EP 3 449 553 B1 is a winding machine for winding coils, with a machine stand and with at least one bobbin holder with a receiving space for the bobbin to be wound and at least one winding material feeder. The winding is carried out using different winding techniques.

From the scriptures DE 10 2017 223 859 A1 , U.S. 3,098,616 A and the DE 10 2005 049 536 A1 Winding machines for creating windings of an electric motor and corresponding methods are known.

Out of EP 2 477 315 B1 For example, a needle winding system for winding carriers to be wound with a distributed winding is known. When winding such internally grooved stators, the needle carrier/wire guide must pass through the stator. This creates a high risk of collision and the needle carrier has little freedom of movement. Grooved end caps or fork terminals are also required for a defined wire placement in the winding head. These cannot be avoided due to the control of the wire tension during the winding process. However, an additional axis of rotation in the needle carrier is required for the wire storage in the winding head slots, which significantly increases the complexity of the needle carrier.

It is therefore the task to provide a simplified, faster and more cost-effective method for winding a winding support.

• • Bereitstellen einer um ihre Längsachse drehbar gelagerte Zahnkettenaufnahme,
• • Fixierung der Zahnkette mit einer Vielzahl von in Längsrichtung Z abwechselnd angeordneten im Wesentlichen in Querrichtung zur Längsrichtung Z ausgerichteten Nuten und Zähnen in der Zahnkettenaufnahme,
• • Bereitstellen einer Mehrzahl von kammartigen Wickelwerkzeugen, welche jeweils einen Grundkörper aufweisen, aus welchem quer zur Längserstreckung X des Grundkörpers jeweils wenigstens zwei Klammerstege herausragen,
• • Fixierung der Wickelwerkzeuge an der Zahnkette entlang der Längserstreckung der Zähne,
• • Bewickeln der Zahnkette mit wenigstens einem Leitungsstrang, indem
  • a. der Nadelträger translatorisch aus einer ersten Betriebsstellung entlang der Längserstreckung einer ersten der Nuten in eine zweite Betriebsstellung bewegt und der Leitungsstrang dabei in der ersten Nut abgelegt wird, nachfolgend
  • b. eine Drehung der Zahnkettenaufnahme in einer ersten Drehrichtung um ihre Längsachse erfolgt, anschließend
  • c. eine translatorische Bewegung zwischen dem Nadelträger (2) und der Zahnkettenaufnahme (4) aus der zweiten Betriebsstellung in Längsrichtung Z der Zahnkette in eine dritte Betriebsstellung bewirkt wird, und
  • d. eine Drehung der Zahnkettenaufnahme in einer der ersten Drehrichtung entgegengesetzten zweiten Drehrichtung um ihre Längsachse erfolgt, so dass durch den Nadelträger aus der dritten Betriebsstellung der Leitungsstrang in der zweiten Nut abgelegt wird,
• • Entnahme der Wickelwerkzeuge von der Zahnkette.

This object is achieved by a method for winding a toothed chain extending in a longitudinal direction Z, in particular for forming an internally slotted stator of an electrical machine using a needle carrier, comprising the following steps,

• • Provision of a toothed chain mount rotatably mounted about its longitudinal axis,
• • Fixation of the inverted tooth chain with a large number of grooves and teeth arranged alternately in the longitudinal direction Z and aligned essentially in the transverse direction to the longitudinal direction Z in the inverted tooth chain mount,
• • providing a plurality of comb-like winding tools, each of which has a base body from which at least two clamp webs protrude transversely to the longitudinal extent X of the base body,
• • Fixation of the winding tools on the inverted tooth chain along the length of the teeth,
• • Wrapping the inverted tooth chain with at least one strand of wire by
  • a. the needle carrier is moved translationally from a first operating position along the longitudinal extent of a first of the grooves into a second operating position and the line harness is deposited in the first groove, below
  • b. a rotation of the toothed chain mount takes place in a first direction of rotation about its longitudinal axis, then
  • c. a translational movement is effected between the needle carrier (2) and the toothed chain mount (4) from the second operating position in the longitudinal direction Z of the toothed chain into a third operating position, and
  • i.e. the toothed chain holder is rotated about its longitudinal axis in a second direction of rotation, opposite the first direction of rotation, so that the wire harness is deposited in the second groove by the needle carrier from the third operating position,
• • Removal of the winding tools from the inverted tooth chain.

This has the advantage that a new type of winding process for flat inverted tooth chains can be provided, which is compared to that of methods known from the prior art allow the needle carrier increased freedom of movement, as well as without an axis of rotation in the needle carrier, which leads to a significant reduction in complexity and an increase in production speed.

This makes it possible, in particular, to manufacture a stator as an unrolled inverted tooth chain and to add the distributed winding to the flat inverted tooth chain. With the help of a toothed chain, the freedom of movement of the needle carrier can be increased, since it no longer has to move through the stator to wind the unwound toothed chain, as was previously the case. In addition, by clamping the toothed chain in a rotatably mounted toothed chain holder, the wire deposit in the grooves of the winding tools can be significantly simplified, which will be discussed in more detail in the description of the exemplary embodiment.

According to an advantageous embodiment of the invention, it can be provided that the inverted tooth chain is wound sequentially with strands of wire to be supplied with current individually.

According to a further preferred further development of the invention, it can also be provided that the toothed chain mount can be rotated about its longitudinal axis between 320°-380°, particularly preferably in 90° steps.

Furthermore, according to a likewise advantageous embodiment of the invention, it can be provided that the method steps a-d are repeated in accordance with the desired number of coil turns.

According to a further particularly preferred embodiment of the invention, it can be provided that before carrying out the method steps a-d, insulating paper is inserted into the grooves to be wound.

In this way, the effect can be achieved in particular that insulation can be achieved between different line strands.

Furthermore, the invention can also be further developed in such a way that, after carrying out method steps a-d, insulating paper is used in a plane intersecting the longitudinal extent of the inverted tooth chain on the strands of wire protruding from the grooves.

In a likewise preferred embodiment variant of the invention, it can also be provided that the concentric coils of a coil group of a line section are arranged one above the other in the respective slots.

It can also be advantageous to further develop the invention in such a way that at least six clamp webs protrude from the comb-like winding tools transversely to the longitudinal extent X of the base body. The sequential winding process, together with the winding tools used, results in a 3-level structure in the winding overhang of the different cable strands.

The invention will be explained in more detail below with reference to figures without restricting the general inventive idea.

• 1 ein Wickelwerkzeug in einer perspektivischen Darstellung,
• 2 eine in einem Zahnkettenträger eingesetzte Zahnkette in einer perspektivischen Darstellung,
• 3 eine Zahnkette in einem Zahnkettenträger mit eingesetzten Wickelwerkzeugen in einer perspektivischen Darstellung,
• 4 Zahnkette bei der Bewicklung mit einem Nadelträger in einer ersten Betriebsposition,
• 5 Zahnkette bei der Bewicklung mit einem Nadelträger in einer zweiten Betriebsposition,
• 6 Zahnkette bei der Bewicklung mit einem Nadelträger in einer dritten Betriebsposition,
• 7 Zahnkette bei der Bewicklung mit einem Nadelträger in einer vierten Betriebsposition,
• 8 Zahnkette bei der Bewicklung mit einem Nadelträger in einer fünften Betriebsposition, und
• 9 bewickelte zahnkette mit entfernten Wickelwerkzeugen in einer perspektivischen Darstellung.

Show it:

• 1 a winding tool in a perspective view,
• 2 a toothed chain used in a toothed chain carrier in a perspective view,
• 3 a toothed chain in a toothed chain carrier with winding tools used in a perspective view,
• 4 Tooth chain when being wound with a needle carrier in a first operating position,
• 5 Tooth chain being wound with a needle carrier in a second operating position,
• 6 Tooth chain being wound with a needle carrier in a third operating position,
• 7 Tooth chain being wound with a needle carrier in a fourth operating position,
• 8th Tooth chain being wound with a needle carrier in a fifth operating position, and
• 9 wound inverted tooth chain with removed winding tools in a perspective view.

Based on 1-9 a method for winding a toothed chain 1 extending in a longitudinal direction Z by a needle carrier 2 is explained in more detail.

The toothed chain 1 is an unrolled stator with internal slots. A distributed winding is made in this flat silent chain 1 as described below.

In order to allow the internally grooved stator to unroll to form a toothed chain 1 or to allow the toothed chain 1 to be rolled up to form a cylindrical stator, the toothed chain 1 has a V-shaped groove 17 at the base of the groove, so that the adjacent teeth 6 can be rotated by an angle corresponding to the opening angle of the V -shaped groove 17 corresponding angle can be pivoted towards each other. Basically it would be natural also conceivable that the wound stator remains in its linear extension at the end of the winding process, as in the 2 is shown and then used as a stator for a linear motor.

First, the provision of a toothed chain mount 4 rotatably mounted about its longitudinal axis 3 takes place, as is shown in FIG 2 is shown. The toothed chain holder 4 is designed as a vice into which the toothed chain 1 is inserted and can be detachably fixed in the toothed chain holder by a clamping jaw that can be moved translationally in the longitudinal extension of the vice. The toothed chain 1 is thus arranged in the toothed chain mount 4 with a multiplicity of grooves 5 and teeth 6 which are arranged alternately in the longitudinal direction Z and are aligned transversely to the longitudinal direction Z. Insulating paper 15 is inserted into the grooves 5 and projects out of the grooves 5 on both sides in the longitudinal extension of the grooves 5 and protrudes.

A plurality of comb-like winding tools 7 are then provided, each of which has a base body 8 from which at least two clamp webs 9 project transversely to the longitudinal extension X of the base body 8 . A detailed view of the comb-like winding tool 7 is in FIG 1 shown. In the embodiment shown, six clamp webs 9 protrude from the comb-like winding tools 7 transversely to the longitudinal extent X of the base body 8 . These winding tools 7 are fixed to the toothed chain 1 along the length of the teeth 6, as shown in FIG 3 is shown.

After these preparations of the inverted tooth chain 1, the inverted tooth chain 1 is wound with at least one strand of wire 10.

For this purpose, the needle carrier 2 is moved translationally from a first operating position 11 along the longitudinal extent of a first of the grooves 5 into a second operating position 12 and the line harness 10 is thereby deposited in the first groove 5, as in FIG 4 is reproduced.

This is followed by a rotation of the tooth chain holder 4 in a first direction of rotation about its longitudinal axis 3 by 90 °, the needle carrier 2 remains in its second operating position 12, which is in the 5 is shown.

Subsequently, a translational movement of the needle carrier 2 from the second operating position 12 in the longitudinal direction Z of the toothed chain 1 is effected in a third operating position 13, which is indicated by the arrow in FIG 6 is indicated. What the 6 it can also be seen that the concentric coils of a coil group of a line section 10 are arranged one above the other in the respective slots 5 .

After reaching the third operating position 13 of the needle carrier 2, whose operating position in the 7 is reproduced, the toothed chain receptacle 4 is rotated in a second direction of rotation, opposite the first direction of rotation, about its longitudinal axis 3 by 90°, so that the needle carrier 2 from the third operating position 13 places the cable strand 10 in the second groove 5, just as it is in the 8th is shown.

These process steps of winding the toothed chain 1 with the needle carrier 2 are repeated according to the desired number of coil turns.

In order to form different phases of the winding, the toothed chain 1 is wound sequentially with individual strands of wire 10 to be energized 1 reveals. The individual phases of the winding are then assigned to the associated wire storage areas 16 and are thus spaced apart from one another in the longitudinal extent of the comb-like winding tool 7 . In the example shown, the toothed chain 1 is wound in 3 phases.

After the inverted tooth chain 1 has been wound, the winding tools 7 are removed from the inverted tooth chain 1 . The toothed chain 1 wound in this way can finally be rolled up and joined to form a cylindrical stator with internal slots.

At the 9 It is easy to see that after the process steps ad have been carried out, insulation paper 15 is used in a plane intersecting the longitudinal extent of the inverted tooth chain 1 on the line strands 10 protruding from the grooves 5 .

The wound toothed chain 1 can then be rolled up and formed into a cylindrical stator.

In the 9 also shows the position and designation of the axes of the coordinate system used in this application. The Z-axis corresponds to the longitudinal direction Z of the inverted tooth chain 1, while the grooves 5 run at right angles thereto along the X-axis.

The invention is not limited to the embodiments shown in the figures. The foregoing description is therefore not to be considered as limiting but as illustrative. The following patent claims are to be understood in such a way that a mentioned feature is present in at least one embodiment of the invention. This does not exclude the presence of other features. If the patent claims and the above description define 'first' and 'second' feature, this designation serves to distinguish between two features of the same type, without establishing a ranking.

Reference List

1

tooth chain

2

needle carrier

3

longitudinal axis

4

Tooth chain mount

5

grooves

6

teeth

7

winding tools

8th

body

9

clip bars

10

wiring harness

11

first operating position

12

second operating position

13

third operating position

15

insulation paper

16

wire storage area

17

groove

Claims (8)

Method for winding a toothed chain (1) extending in a longitudinal direction (Z), in particular for forming an internally slotted stator of an electrical machine using a needle carrier (2), comprising the following steps, characterized in that • providing a force around its longitudinal axis (3rd ) rotatably mounted toothed chain mount (4), • fixing of the toothed chain (1) with a large number of grooves (5) and teeth (6) arranged alternately in the longitudinal direction (Z) and aligned essentially in the transverse direction to the longitudinal direction (Z) in the toothed chain mount (4 ), • providing a plurality of comb-like winding tools (7), each of which has a base body (8) from which at least two clamp webs (9) protrude transversely to the longitudinal extension (X) of the base body (8), • fixing the winding tools (7 ) on the inverted tooth chain (1) along the longitudinal extent of the teeth (6), • winding the inverted tooth chain (1) with at least one line strand (10) by a. the needle carrier (2) is moved translationally from a first operating position (11) along the longitudinal extent of a first of the grooves (5) into a second operating position (12) and the cable harness (10) is thereby deposited in the first groove (5), hereinafter b . the toothed chain mount (4) is rotated in a first direction of rotation about its longitudinal axis (3), then c. a translational movement between the needle carrier (2) and the toothed chain mount (4) from the second operating position (12) in the longitudinal direction (Z) of the toothed chain (1) into a third operating position (13) is effected, and d. the toothed chain holder (4) is rotated about its longitudinal axis (3) in a second direction of rotation, opposite to the first direction of rotation, so that the needle carrier (2) moves the line harness (10) from the third operating position (13) into the second groove (5) is put down, • removal of the winding tools (7) from the inverted tooth chain (1). Method for winding a toothed chain (1) extending in a longitudinal direction (Z). claim 1 , characterized in that the toothed chain (1) is wound sequentially with strands of wire (10) to which current is to be applied individually. Method for winding a toothed chain (1) extending in a longitudinal direction (Z) according to one of the preceding claims, characterized in that the toothed chain holder (4) can be rotated about its longitudinal axis (3) between 320°-380°, particularly preferably in can be rotated in 90° steps. Method for winding a toothed chain (1) extending in a longitudinal direction (Z) according to one of the preceding claims, characterized in that the method steps ad are repeated in accordance with the desired number of coil windings. Method for winding a toothed chain (1) extending in a longitudinal direction (Z) according to one of the preceding claims, characterized in that before carrying out the method steps ad, insulating paper (15) is inserted into the grooves (5) to be wound. Method for winding an inverted tooth chain (1) extending in a longitudinal direction (Z) according to one of the preceding claims, characterized in that after carrying out the method steps ad insulation paper (15) cut the longitudinal extent of the inverted tooth chain (1). is used in the plane on the line strands (10) protruding from the grooves (5). Method for winding a toothed chain (1) extending in a longitudinal direction (Z) according to one of the preceding claims, characterized in that the concentric coils of a coil group of a cable strand (10) are arranged one above the other in the respective grooves (5). Method for winding a toothed chain (1) extending in a longitudinal direction (Z) according to one of the preceding claims, characterized in that at least six clamp webs ( 9) protrude.

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