DE102021115862A1 - Holding device for aligning wave winding wires, joining device and joining method - Google Patents

Abstract

The invention relates to devices, devices and methods for use in the production of components for electrical machines, in particular stators. According to embodiments of the invention, a rectilinear rake structure or comb structure (24) is provided for holding at least one wave winding wire (12) during transfer to a joining mandrel (18) or the like (also e.g. a component) with outwardly opening grooves. The rake structure or comb structure (24) has a linear rigid base member (28) with teeth (30) extending therefrom. The tooth flanks (32a, 32b) of the teeth (30) are curved and/or inclined in this way and/or b) 1) due to the flexible, elastic configuration of the teeth (30) and/or 2) due to the movable articulation of the teeth (30) movable on the rigid base element in such a way that the receiving slots (34) defined between the tooth flanks (32a, 32b) are adapted to an arcuate movement of the rectilinearly extending wire sections (20) when rolled onto the ring-shaped arrangement such that distances between the rectilinear wire sections (20) also remain essentially the same in this movement.

Description

The invention relates to a holding device for the linear alignment of at least one wave winding wire, which has a series of straight wire sections, which are connected by U-shaped or roof-shaped bent wire areas, to an annular arrangement of radially outward-opening grooves in the course of the manufacture of a component of an electrical machine , comprising a rake or comb structure with a linear base element extending rigidly in a longitudinal direction and a row of teeth extending transversely to the longitudinal direction away from the rigid linear base element with tooth flanks, each having a receiving slot between two adjacent teeth for receiving at least one of the define linearly extending wire sections of the at least one wave winding wire. The invention further relates to a joining device and a joining method for inserting at least one wave winding wire into a laminated core of a stator using such a holding device.

Such a holding device, such a joining device and such a joining method are from DE 10 2019 106 711 A1 , the EP 3 731 373 A1 and the U.S. 2004/0261885 A1 famous. The prior art is also on the U.S. 2010/0000077 A1 pointed out, which, however, does not use a (linear) rake or comb structure with a rigid linear base, but a link chain as a holding device, which can be guided around the ring-shaped arrangement overall and is therefore difficult to handle in terms of process technology. Holding devices with a linear rake or comb structure have proven to be particularly advantageous in the case of small individual wire distances.

The invention lies in the field of manufacturing components for electrical machines, i.e. in particular stators or rotors for generators and electric motors. In particular, coil windings are to be produced for components of electric motors which are to be mass-produced as traction motors for electric vehicles and are preferably to have a rated output in the range from 20 kW to 400 kW.

For an electrical machine, such as in particular an electric motor or generator, it is known from the prior art explained further below to provide a distributed wave winding. Here, as a method, the wave winding is prefabricated outside of the component, such as in particular the stator, usually as a linear coil. The individual wires can be stacked one on top of the other, or they can be interwoven, as is shown in DE 10 2017 104 932 A1 is described and shown. This linear coil can have various head configurations. Such a linear coil is also often called coil mat or just wire mat. In the following, the term "coil mat" is used for such a linear coil.

A coil mat, as is also to be used in exemplary embodiments of the invention, consists, for example, of several individual S-shaped conductors - wave winding wire -, in particular in the form of copper rods, each of which has straight areas - wire section running in a straight line - which are connected to winding heads - U- shaped or roof-shaped bent wire sections - are connected. The straight area is located later in the component slot, such as the stator slot in particular, and the conductor or wire jumps a corresponding number of slots in the so-called end winding.

Such coil mats and their production are in particular from the documents WO 2019/020148 A1 , WO 2019/101272 A1 , WO 2019/166060 A1 and WO 2019/166061 A1 is known, and explicit reference is made to these documents for further details on possible configurations of the coil mats that are processed in the exemplary embodiments of the invention.

In order to insert this linear coil into a ring-shaped component of an electrical machine, such as in particular a cylindrical stator, with internal grooves, a joining method is used in embodiments of the invention in which this linear coil - coil mat - is placed on a cylindrical transfer tool - also called joining tool or depending on the Design also called joining mandrel - is wound up and is thus converted from a linear winding into a rotary winding. The winding can also take on several layers on the transfer tool. Several linear coils - coil mats - can also be placed one on top of the other and wound up. It is also possible for several individual linear partial mats to be wound onto a joining tool at the same time, the start of which can be at the same point or also at different points - for example in the case of partial coils introduced in a spiral shape. A single winding wire can also be picked up and wound up. The joining tool or transfer tool (also known as the joining mandrel) is then immersed in the prepared component, in particular the stator, and the winding is transferred from the joining tool into the component by means of a predominantly radial movement of the individual wire sections. The radial transmission can take place simultaneously for all wire sections or also in sections or one after the other. In this case, the joining tool preferably has the same number of grooves in the same place as the component. In front Preferably, the respective linear section - straight wire section - of the wave winding wire, which is located in the groove of the joining tool and is to be transferred into the component groove, is guided correspondingly narrowly by the joining tool in order to insert the conductor without damage - e.g. an insulating layer - into the tightly toleranced to transfer grooves.

• i) Herstellen der linearen Spulenmatte, z.B. wie in einer der obigen Dokumente beschrieben;
• ii) Ausrichten der Spulenmatte durch ein lineares Übertragungs- oder Haltewerkzeug - im Folgenden Halteeinrichtung genannt;
• iii) Übertragen der Spulenmatte auf ein rotatorisches Fügewerkzeug, welches eine Anordnung radial nach außen offener Nuten aufweist;
• iv) gegebenenfalls Komprimieren der Wicklung oder Spulenmatte auf den Innendurchmesser des Fügewerkzeugs mit einzelnen oder mehreren Pressfingern;
• v) Eintauchen des rotatorischen Fügewerkzeugs mit der Spulenmatte (Wicklung) in das ringförmige Bauteil, wie insbesondere Stator(blechpaket),
• vi) Übertragen der Spulenmatte in das Bauteil, wie insbesondere Stator.

In previous manufacturing processes used in practice, the following process sequence takes place:

• i) producing the linear coil mat, eg as described in one of the above documents;
• ii) aligning the coil mat by a linear transfer or holding tool - hereinafter referred to as holding device;
• iii) transferring the coil mat to a rotary joining tool which has an arrangement of grooves which are open radially to the outside;
• iv) optionally compressing the winding or coil mat to the inside diameter of the joining tool with one or more press fingers;
• v) Dipping the rotary joining tool with the coil mat (winding) into the ring-shaped component, such as in particular the stator (laminated core),
• vi) Transferring the coil mat into the component, such as the stator in particular.

• • WO 2017/102892 A2
• • frühere internationale Patentanmeldung PCT/ DE2020/100194
• • DE 10 2019 106 711 A1
• • frühere europäische Patentanmeldung mit der Anmeldenummer EP20185121.9 .

Exemplary embodiments and details of steps of the aforementioned method can be found in the following references:

• • WO 2017/102892 A2
• • earlier international patent application PCT/ DE2020/100194
• • DE 10 2019 106 711 A1
• • earlier European patent application with the application number EP20185121.9 .

Embodiments of the invention deal with improvements in steps ii) and iii).

The object of the invention is to improve a holding device of the type mentioned in the preamble of the independent claims in such a way that a more reliable transfer of the at least one wave winding wire is made possible with an even further reduced risk of damage.

In order to solve this problem, the invention creates a holding device according to one of claims 1 to 3 and 8. The invention also creates a joining device and a joining method using such a holding device according to the additional dependent claims.

Advantageous configurations are the subject matter of the dependent claims.

According to a first aspect thereof, the invention provides a holding device for linearly aligning at least one wave winding wire, which has a series of straight wire sections which are connected by U-shaped or roof-shaped bent wire areas, and for transferring to an annular arrangement of radially outwardly opening grooves in the During the manufacture of a component of an electrical machine, comprising a rake or comb structure with a linear base element extending rigidly in a longitudinal direction and a row of teeth extending away from the rigid linear base element transversely to the longitudinal direction, with tooth flanks each between two adjacent teeth Defining a receiving slot for receiving at least one of the linearly extending wire sections of the at least one wave winding wire, the receiving slots corresponding to an arcuate movement of the linearly extending wire sections a rolling of the at least one wave winding wire are curved onto the annular arrangement.

According to an alternative embodiment, the invention creates a holding device for linearly aligning at least one wave winding wire, which has a series of straight wire sections that are connected by U-shaped or roof-shaped bent wire areas, and for transferring to an annular arrangement of radially outward-opening grooves in the course the production of a component of an electrical machine, comprising a rake or comb structure with a linear base element extending rigidly in a longitudinal direction and a row of teeth with tooth flanks extending away from the rigid linear base element transversely to the longitudinal direction, each having a receiving slot between two adjacent teeth for receiving at least one of the rectilinearly extending wire sections of the at least one wave winding wire, wherein the teeth or at least their tooth flanks are designed to be elastically yielding, around the receiving slot a rolling of the at least one wave winding wire onto the ring-shaped arrangement to adapt it to an arcuate movement of the wire sections extending in a straight line.

According to a further alternative embodiment, the invention creates a holding device for the linear alignment of at least one shaft winding wire, which has a series of straight wire sections, which are connected by U-shaped or roof-shaped bent wire areas, and for conversion to an annular arrangement of radially outwardly opening grooves in the course of the manufacture of a component of an electrical machine, comprising a rake or comb structure with a linear base element extending rigidly in a longitudinal direction and a row of teeth with tooth flanks extending away from the rigid linear base element transversely to the longitudinal direction, each having a receiving slot between two adjacent teeth for receiving at least one of the wire sections of the at least one wave winding wire extending in a straight line define, wherein the teeth are movably hinged to the base member to adapt the receiving slot to an arcuate movement of the rectilinearly extending Dr adjust seam sections.

In specific embodiments, several of the above-mentioned alternatives are preferably provided in combination.

It is preferred that the teeth extend arcuately from the base member.

It is preferred that the teeth deform under stress from lifting of the straight wire sections.

It is preferred that teeth with different thicknesses are provided.

It is preferable that the accommodating slots narrow as viewed from a foot portion located near the base member toward an open end portion.

According to a further alternative, which can also be provided in combination with one of the aforementioned configurations, the invention creates a holding device for the linear alignment of at least one wave winding wire, which has a series of straight wire sections that are connected by wire areas bent in a U-shape or roof-shape , to an annular arrangement of radially outwardly opening grooves in the course of the manufacture of a component of an electrical machine, comprising a rake or comb structure with a linear base element extending rigidly in a longitudinal direction and a row extending transversely to the longitudinal direction away from the rigid linear base element Teeth with tooth flanks, each defining a receiving slot between two adjacent teeth for receiving at least one of the rectilinearly extending wire sections of the at least one wave winding wire, the teeth sloping away from the base ement extend so that the receiving slots incline obliquely away from the base member.

It is preferred that the teeth are tapered at their ends.

It is preferred that the receiving slots have areas of different curvature and/or areas that run in a straight line and are at different angles to the base element. The receiving slots may also have at least one curved portion and one straight portion, e.g., sloping.

According to a further aspect, the invention creates a joining device for inserting a wave winding wire or a plurality of wave winding wires grouped into a coil mat into a laminated core of a stator of an electrical machine, comprising a holding device according to one or more of the configurations explained above, a joining mandrel with the annular arrangement from radial to rear grooves opening on the outside, which can be moved in the longitudinal direction of the base element while rotating relative to the holding device, and a transfer device for transferring the at least one wave winding wire from the holding device to the joining mandrel.

It is preferred that the transfer device is set up to initially space the straight wire sections from the base element by a predetermined distance and then lift them out of the holding device and transfer them to the joining mandrel.

According to a further aspect, the invention creates a joining method for inserting a wave winding wire or several wave winding wires grouped into a coil mat into a laminated core of a stator, comprising providing the at least one wave winding wire on a holding device according to one or more of the configurations explained above, transferring the at least one wave winding wire a joining mandrel with the annular arrangement of radially outwardly opening grooves, inserting the joining mandrel into the laminated core and transferring the at least one wave winding wire from the joining mandrel into the laminated core.

It is preferred that the holding device is provided in such a way that a constant distance between the wire sections guided in the receiving slots from one another during transfer is maintained from the holding device on the mandrel.

It is preferred that the wave winding wire has an elongate wire cross-section and the holding device is provided in such a way that the area of the tooth flanks located near the straight wire section is essentially perpendicular to each other during transfer from the holding device to the joining mandrel in the course of the curved movement of the straight wire sections of the longitudinal direction of the wire cross-section.

Embodiments of the invention relate to a receiving and rolling-up aid for wire mats.

1. a) derart gekrümmt und/oder schrägstehen verlaufend und/oder
2. b) 1) durch nachgiebig elastische Ausgestaltung der Zähne und/oder 2) durch bewegliche Anlenkung der Zähne an das starre Basiselement derart beweglich sind,

dass die zwischen den Zahnflanken definierten Aufnahmeschlitze an eine bogenförmige Bewegung der sich geradlinig erstreckenden Drahtabschnitte bei einem Aufrollen auf die ringförmige Anordnung derart angepasst sind, dass Abstände zwischen den geradlinigen Drahtabschnitten auch bei dieser Bewegung im Wesentlichen gleichbleiben.According to embodiments of the invention, a straight rake structure or comb structure is provided for holding at least one wave winding wire during transfer to a joining mandrel or the like (also, for example, a component with outwardly opening grooves. The rake structure or comb structure has a straight, rigid base element with teeth striving away from it are the tooth flanks of the teeth

1. a) curved and/or inclined in this way and/or
2. b) 1) are movable in such a way due to the flexible, elastic design of the teeth and/or 2) due to the movable articulation of the teeth on the rigid base element,

that the receiving slots defined between the tooth flanks are adapted to an arcuate movement of the wire sections extending in a straight line when they are rolled onto the ring-shaped arrangement in such a way that distances between the straight wire sections also remain essentially the same during this movement.

Preferred embodiments of the invention have the advantage over corresponding holding devices for coil mats or wave winding wires from the prior art that the wire can be guided precisely during transfer and relative friction between the wire and tool can be significantly reduced and stresses in the wire can be significantly reduced or avoided . Nevertheless, the holding devices have a simple structure and are easy to handle. Due to the simple structure, they are correspondingly inexpensive. If a change in production from one component to a different component is required in a production plant, the joining device can be easily adapted to a changed coil mat and a correspondingly changed movement sequence when transferring to the joining mandrel by exchanging the holding device.

• - keine bzw. reduzierte Verformung der Drahtgeometrie am Draht
• - weniger Beschädigungspotential
• - ein Klemmen des Drahtes / Wickelmatte beim Ausheben durch eine Abrollbewegung wird verhindert.

Some advantages of preferred embodiments of the invention over the prior art are:

• - no or reduced deformation of the wire geometry on the wire
• - Less damage potential
• - the wire/wrapping mat is prevented from getting stuck when it is lifted out by a rolling movement.

• 1 eine perspektivische Ansicht einer herkömmlichen Halteeinrichtung mit Rechen- oder Kammstruktur, an der eine aus mehreren Wellenwicklungsdrähte zusammengesetzte Spulenmatte gehalten ist;
• 2 einen Längsschnitt durch die Halteeinrichtung von 1 mit der Spulenmatte;
• 3 eine vereinfachte Darstellung von 1 mit nur einem Wellenwicklungsdraht wobei ein Aushebevorgang angedeutet ist;
• 4 eine schematische Ansicht einer herkömmlichen Fügevorrichtung mit der Halteeinrichtung von 1 und einem relativ hierzu linear beweglichen und drehbarem Fügewerkzeug in Form eines Fügedorns;
• 5 eine schematische Schnittansicht der Halteeinrichtung wie in 2 mit einer Darstellung der Vorgänge beim Überführen der Spulenmatte von der Halteeinrichtung auf den Fügedorn;
• 6 eine schematische Seitenansicht einer Halteeinrichtung gemäß einer ersten Ausführungsform der Erfindung mit einer Darstellung der Vorgänge beim Überführen der Spulenmatte von der Halteeinrichtung auf den Fügedorn;
• 7 weitere schematische Seitenansicht der Halteeinrichtung gemäß der ersten Ausführungsform mit einer mehrlagigen Spulenmatte während eines Überführens der Spulenmatte von der Halteeinrichtung auf den Fügedorn;
• 8 eine schematische Seitenansicht der Halteeinrichtung gemäß der ersten Ausführungsform ohne Spulenmatte oder Wellenwicklungsdraht;
• 9a eine schematische Schnittansicht einer Halteeinrichtung gemäß einer zweiten Ausführungsform der Erfindung in unbelasteten Zustand;
• 9b eine Ansicht wie in 9a, wobei Zähne der Halteeinrichtung unter Belastung gebogen sind;
• 10 eine schematische Seitenansicht, vergleichbar 8, einer Halteeinrichtung gemäß einer dritten Ausführungsform der Erfindung;
• 11 eine schematische Seitenansicht, vergleichbar 8, einer Halteeinrichtung gemäß einer vierten Ausführungsform der Erfindung;
• 12 eine schematische Seitenansicht, vergleichbar 8, einer Halteeinrichtung gemäß einer fünften Ausführungsform der Erfindung;
• 13 eine schematische Seitenansicht, vergleichbar 8, einer Halteeinrichtung gemäß einer sechsten Ausführungsform der Erfindung;
• 14a eine schematische Schnittansicht einer Halteeinrichtung gemäß einer siebten Ausführungsform der Erfindung in unbelasteten Zustand;
• 14b eine Ansicht wie in 14a, wobei Zähne der Halteeinrichtung um einen Drehpunkt verdreht sind, um die Spulenmatte aufzuwickeln; und
• 15 eine schematische Seitenansicht wie in 6 bei einer abgewandelten Vorgehensweise des Überführens der Spulenmatte von der Halteeinrichtung auf den Fügedorn.

Exemplary embodiments are explained in more detail below with reference to the accompanying drawings. It shows:

• 1 a perspective view of a conventional holding device with a rake or comb structure on which a coil mat composed of a plurality of wave winding wires is held;
• 2 a longitudinal section through the holding device of 1 with the coil mat;
• 3 a simplified representation of 1 with only one wave winding wire, with a lifting process being indicated;
• 4 a schematic view of a conventional joining device with the holding device of 1 and a joining tool in the form of a joining mandrel that is linearly movable and rotatable relative thereto;
• 5 a schematic sectional view of the holding device as in FIG 2 with a representation of the processes involved in transferring the bobbin mat from the holding device to the joining mandrel;
• 6 a schematic side view of a holding device according to a first embodiment of the invention with a representation of the processes involved in transferring the coil mat from the holding device to the joining mandrel;
• 7 further schematic side view of the holding device according to the first embodiment with a multi-layer bobbin mat during a transfer of the bobbin mat from the holding device to the joining mandrel;
• 8th a schematic side view of the holding device according to the first embodiment without coil mat or wave winding wire;
• 9a a schematic sectional view of a holding device according to a second embodiment of the invention in the unloaded state;
• 9b a view as in 9a wherein teeth of the retainer are flexed under load;
• 10 a schematic side view, comparable 8th , a holding device according to a third embodiment of the invention;
• 11 a schematic side view, comparable 8th , a holding device according to a fourth embodiment of the invention;
• 12 a schematic side view, comparable 8th , a holding device according to a fifth embodiment of the invention;
• 13 a schematic side view, comparable 8th , a holding device according to a sixth embodiment of the invention;
• 14a a schematic sectional view of a holding device according to a seventh embodiment of the invention in the unloaded state;
• 14b a view as in 14a wherein teeth of the holder are twisted about a fulcrum to wind up the coil mat; and
• 15 a schematic side view as in 6 with a modified procedure for transferring the coil mat from the holding device to the joining mandrel.

Devices, devices and methods according to exemplary embodiments of the invention are described below with reference to the drawings using the example of a partial step of inserting a coil winding into a stator. In the manufacture of stators using the "wave winding" (continuous hairpin) process, wire mats - hereinafter referred to as coil mats - are produced. These flat mats are advantageously placed in holding devices 10 with “rakes or combs” so that the individual conductors/wires do not cross and are provided in a specific order.

The mats are then wound onto a mandrel as in European patent application number 20185121.9 and its corresponding earlier German patent application 10 2020 107 920.6 executed. With this mandrel, the coil mats are then inserted into the stator, as is the case, for example, in WO 2017/102892 A2 is described and shown.

Different configurations of a holding device 10 for a wave winding wire 12 or for a coil mat 14 formed from a plurality of such wave winding wires 12 are explained in more detail below with reference to the attached drawings. The holding device 10 is used in particular in a joining device 16 when carrying out a joining method for inserting the at least one wave winding wire 12 into a component of an electrical machine (not shown). For this purpose, the wave winding wire 12 or the plurality of wave winding wires grouped to form a coil mat 14 is applied, e.g. B. by the joining mandrel 18 in the in 4 shown manner is moved over the holding device 10 with rotation relative to the holding device 10 and the at least one wave winding wire 12 is transferred by means of a transfer device not shown in detail from the holding device 10 to the joining mandrel 18. The wave winding wires 12 are then transferred, for example, into a laminated core of a stator (not shown) by means of the joining mandrel 18 . Such joining devices 16 are, for example, from US2014/0196282 A1 or the EP1639688 B1 known and are therefore not described in detail here. A preferred embodiment of the joining device 16, which is to be provided with the holding device 10 according to embodiments according to the invention, is described in detail in the European patent application with the application number 20 185 121.9 and its corresponding earlier German patent application 10 2020 107 920.6 described and shown, which are hereby incorporated by reference. For further details on possible configurations of the joining device 16, reference is expressly made to these patent applications.

The holding device 10 thus serves to linearly align at least one wave winding wire 12, which has a series of straight wire sections 20 which are connected by U-shaped or roof-shaped bent wire areas—winding head 22—and to transfer the at least one wave winding wire 12 to an annular arrangement 19 grooves opening radially outwards in the course of the manufacture of a component of an electrical machine. Instead of being transferred to a joining tool, the holding device 10 can also be used when transferring the at least one wave winding wire 12 directly to a component (such as a rotor or a stator of an external rotor motor) with outwardly opening grooves.

the 1 until 3 show different representations of a holding device 10 according to conventional design, while the 5 until 16 show different representations of the holding device 10 according to embodiments of the invention. 4 shows schematically the joining device 16 with the holding device 10 and the one that is rotatable and linearly movable relative to the holding device 10 Joining mandrel 18. The common features of the holding devices 10 will now first be described before the differences between the holding devices 10 according to the embodiments according to the invention are discussed in more detail.

The holding device 10 has a rake or comb structure 24, simply called rake 26 below. The rake or comb structure 24 comprises a self-supporting base element 28 rigidly extending in a longitudinal direction, for example formed as a long base plate, slat or rod. A series of longitudinally consecutive teeth 30 are provided on the base element 28 . The teeth 30 extend away from the base member 28 in a direction transverse to the longitudinal direction. The teeth 30 each have tooth flanks 32a, 32b, with mutually directed tooth flanks 32a, 32b of adjacent successive teeth 30 each defining a receiving slot 34 which serves to receive at least one straight wire section 20 each. In the case of a multi-layer coil mat, two or more straight wire sections 20 lying one on top of the other can also be accommodated per accommodation slot 34 .

1 and 2 show a holding device 10 of conventional design, in which a single-layer coil mat 14 is inserted. 3 shows a simplified representation with only one wave winding wire 12 of the coil mat 14 in order to clarify the straight wire sections and the winding overhangs 22.

In the conventional design, the teeth 30 are straight. The receiving slots 34 run at right angles to the longitudinal direction of the base element 28, i.e. in other words the central plane defined by the same distance from the corresponding tooth flanks runs perpendicular to the longitudinal direction of the base element 28.

4 shows the winding of the coil mat 14 onto the assembly mandrel 18. When the coil mat 14 is wound onto the assembly mandrel 18, the straight wire sections 20 are gradually pushed out/pulled out of the rake 26.

The coil mat 14 or, in the simplified representation, the wave winding wire 12 is gradually (not evenly) pushed out of the rake 26 . How one 3 and 5 can be seen due to the change in length due to the diagonal 36, the wave winding wires 12 and in particular their roof shape in the winding overhang 22 are bent. As a result, the wire geometry is changed, which is very disadvantageous and there is also a great potential for damage to the wire.

For this reason, in some earlier approaches to a solution, essentially conical teeth were provided overall, but this means that the mouth is very wide and the transition between the receiving slot 34 and the groove is not defined. This can also lead to bending and damage to the wire.

In embodiments of the invention, as described below with reference to 6 until 15 are explained, the course of the receiving slots 34 is adapted to the curved path of the straight wire section received therein during its transfer from the holding device 10 to the annular arrangement of radially outward-opening grooves, e.g. of the joining mandrel 18, as is shown in 6 is shown based on a first embodiment of the holding device 10 according to the invention. The course of the receiving slot 34 here means the course of the geometric center surface of the receiving slot 34 . The geometric center surface is defined by the sum of all points at the same distance from the two tooth flanks 32a, 32b that delimit the receiving slot 34. Correspondingly, a receiving slot 34 is bent or curved when the geometric center surface between its tooth flanks 32a, 32b is bent or curved.

By adapting the course of the receiving slots 34 to the path of movement, the tooth flanks 32a, 32b can be spaced so closely that the straight wire section 20 is guided with minimal play over essentially the entire course of the receiving slot 34. In preferred embodiments, there is no change in the length of the distance between straight wire sections 20 connected by a winding overhang 22 either at the foot region 38 of the receiving slot 34 near the base element 28 or in the open mouth region 40 near the open end of the receiving slot 34 due to the guidance through the receiving slot 34. At least such a change in length compared to the conventional holding devices 10 of the 1 until 3 significantly reduced.

The wire can also be slowly conveyed upwards along any curved path, in the best case the wire cross-section is at right angles to the wall of the slot. A single wire - wave winding wire 12 - or a multi-layer wire mat - coil mat 14 - can be excavated in this way.

7 shows this a holding device 10 in the inventive design, in which a more la gige coil mat 14 of wave winding wires 12 is added with a rectangular wire cross section.

The multi-layer coil mat 14 is lifted over a cam track. The course of both tooth flanks 32a, 32b of each receiving slot 34 is adapted according to the curved path in such a way that the wire section 20 is guided on both sides and yet little or no change in length of the distance between the wire sections 20 occurs until the wire section 20 is pushed out at the open end.

6 until 8th show a first embodiment of the holding device 10, which is formed with curved teeth 30.

Because of the bending, the ends of the teeth 30 are offset backwards relative to their base regions, counter to the direction of movement 42 with which the holding device moves relative to the joining mandrel 18 .

The front tooth flanks 32a pointing in the direction of movement 42 are convexly curved and the rear tooth flanks 32b pointing counter to the direction of movement 42 are curved concavely. The distance between the tooth flanks 32a, 32b and thus the width of the receiving slot 34 is constant over a large part of the receiving slot 34 and corresponds to the longitudinal extent of the wire cross section plus a small amount of play.

In order to keep the change in length of the distance between the straight wire sections 20 and the resulting deformation of the wave winding wire 12 when pushing out/pulling out as small as possible, the teeth 30 of the rake 26 are made curved.

The radius of the bend or the contour of the rake 26 can be adapted to any wire geometry and the shape can be freely designed.

The wire can also be slowly conveyed upwards along any curved path, ideally the wire cross-section is at right angles to the tooth flank. A single wire - wave winding wire 12 - or a multi-layer wire mat - coil mat 14 - can be excavated in this way.

9 with the 9a , 9b shows a second embodiment with elastic teeth 30 which deform under load. 9a shows a possible design of the unloaded teeth 30 while 9b shows an elastic bending under load in the course of lifting the coil mat 14 or the individual winding wire 12. The teeth, or at least their tooth flanks 32a, 32b, are therefore designed to be elastically flexible in order to adapt the receiving slot 34 to an arcuate movement of the wire sections 20 extending in a straight line when the wave winding wire 12 or the coil mat 14 is rolled onto the annular arrangement of grooves.

The teeth 30 of the rake 26 can also have different thicknesses, which results in further advantages during the winding process.

10 shows a third embodiment of the holding device 10 with a configuration in which the thickness of the teeth 30 increases as seen from the base area 38 to the mouth area 40 .

The receiving slot 34, in which the straight wire section 20 is guided, narrows towards the top in order to ensure a more precise transfer to the joining mandrel 18. In 10 the width B2 of the receiving slot 34 in the mouth area 40, which is reduced compared to the width B1 in the foot area 38, can be clearly seen.

11 shows a fourth embodiment of the holding device 10 according to the invention. Here, too, the teeth 30 have different thicknesses, viewed from the foot region to the muzzle end. Here, too, the width B2, which is reduced compared to the width B1 in the foot area, is provided in the opening area 40, with the teeth 30 tapering towards their end, so that the open end of the opening area 40 of the receiving slot 34 is widened in a funnel shape to allow the straight wire sections to be inserted 20 when depositing the at least one wave winding wire 12 on the holding device 10 and yet to enable precise transfer of the wave winding wire 12 to the joining mandrel 18 or the like. The extent of the funnel-shaped widening in terms of height preferably corresponds at most to a wire thickness.

12 shows a fifth embodiment of the holding device 10 according to the invention. The teeth 30 are set at an angle relative to the base element 28, that is to say they run obliquely. The orientation of the oblique course is, corresponding to the curved course, such that the tips of the teeth 30 are offset more counter to the direction of movement 42 of the holding device 10 relative to the joining mandrel 18 than their base areas. As a result, the receiving slots 34 are formed obliquely, with their width preferably remaining the same or decreasing over a large part of the base region towards the mouth. In this embodiment it is thus provided that the teeth 30 slope away from the base element 28 extend, so that the receiving slots 34 rearward - incline obliquely away from the base member 28 - counter to the direction of movement 42.

13 shows a sixth embodiment of the holding device 10 according to the invention. The teeth 30 or at least their tooth flanks 32a, 32b have areas of different curvature, for example areas with a different radius of curvature or an area with a curvature and an area running in a straight line. In the illustrated embodiment, the foot portion 38 is straight obliquely as in the embodiment of FIG 12 , while the mouth portion 40 is curved as in the embodiment of FIG 8th .

14 12 shows a seventh embodiment of the holding device 10 according to the invention, in which the teeth 30 are movably hinged at a pivot point 46 on the base element 28. FIG. The pivot point 46 can be formed, for example, by a pivot bearing—for example with a pin and eye—and/or by a solid bearing with an elastic connection. the 14a Fig. 12 shows the condition when picking up the coil mat 14, in which the teeth 30 extend perpendicularly away from the base element 28, for example, and Figs 14b shows the condition of the affected teeth 30 during winding, these teeth 30 tilting to obtain the position as in FIG 12 to take

15 shows a side view of the holding device 10 according to the first embodiment with a modified procedure for transferring the coil mat 14 from the holding device 10 to the joining mandrel 18, in which the respective straight wire sections 20 are lifted out in several levels. In the 15 1, a first wire section 20a is shown still resting at the bottom of the receiving slot 34. FIG. Opposite the position of the first wire section 20a, a second wire section 20b has already been raised to a first level E1, with the curvature of the foot area of the receiving slot 34 being adjusted in such a way that when the wire section 20b is raised from the base of the receiving slot 34 to the first level E1, no or only a reduced change in length of the distance between the first wire section 20a and the second wire section 20b occurs. A third wire section 20c is also shown which, after being raised to the first level E1, has been raised to a second level E2 near the end of the receiving slot 34, from where it is pushed out and transferred to the joining mandrel 18. The curvature of the mouth area 40 is such that when the third wire section 20c is raised from the first level E1 to the second level E2, there is no or only a reduced change in length of the distance between the second wire section 20b and the third wire section 20c. A transfer device not shown here is designed accordingly for multi-stage lifting. For example, an inclined plane with two differently inclined areas is provided for this purpose, on which the end windings 22 are guided. Gentle transfer by means of an inclined plane is described in more detail in the European patent application with the application number 20 185 121.9 and its corresponding earlier German patent application 10 2020 107 920.6 executed.

Of course, the features described above of the different embodiments of the holding device 10 according to the invention can be combined with one another as desired. For example, inclined teeth can also be designed to be elastic, with different thickness ranges and/or articulated so as to be rotatable. Other combinations are possible.

1. a) derart gekrümmt und/oder schrägstehen verlaufend und/oder
2. b) 1) durch nachgiebig elastische Ausgestaltung der Zähne und/oder 2) durch bewegliche Anlenkung der Zähne an das starre Basiselement derart beweglich,

dass die zwischen den Zahnflanken 32a, 32b definierten Aufnahmeschlitze 34 an eine bogenförmige Bewegung der sich geradlinig erstreckenden Drahtabschnitte 20 bei einem Aufrollen auf die ringförmige Anordnung derart angepasst sind, dass Abstände zwischen den geradlinigen Drahtabschnitten 20 auch bei dieser Bewegung im Wesentlichen gleichbleiben.According to embodiments of the invention, a rectilinear rake structure or comb structure 24 is provided for holding at least one wave winding wire 12 during transfer to a joining mandrel 18 or the like (also eg a component) with outwardly opening grooves. The rake structure or comb structure 24 includes a linear rigid base member 28 with teeth 30 depending therefrom. The tooth flanks 32a, 32b of the teeth 30

1. a) curved and/or inclined in this way and/or
2. b) 1) due to the flexible, elastic design of the teeth and/or 2) due to the flexible articulation of the teeth on the rigid base element such that they can be moved in such a way that

that the receiving slots 34 defined between the tooth flanks 32a, 32b are adapted to an arcuate movement of the wire sections 20 extending in a straight line when they are rolled onto the ring-shaped arrangement in such a way that distances between the straight wire sections 20 also remain essentially the same during this movement.

Reference List

10

holding device

12

wave winding wire

14

coil mat

16

joining device

18

joining mandrel

19

arrangement

20

straight section of wire

20a

first wire section

20b

second section of wire

20c

third section of wire

22

winding head

24

Rake or comb structure

26

rake

28

base element

30

Tooth

32a

front tooth flank

32b

rear tooth flank

34

receiving slot

36

diagonal

38

footer

40

mouth area

42

Relative direction of movement of the holding device (relative to the arrangement of radially outwardly open grooves)

46

pivot point

B1

width in the foot area

B2

Width in the mouth area

E1

first floor

E2

second level

QUOTES INCLUDED IN DESCRIPTION

This list of the documents cited 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

• DE 102019106711 A1 [0002, 0009]
• EP 3731373 A1 [0002]
• US20040261885A1 [0002]
• US20100000077A1[0002]
• DE 102017104932 A1 [0004]
• WO 2019020148 A1 [0006]
• WO 2019101272 A1 [0006]
• WO 2019166060 A1 [0006]
• WO 2019166061 A1 [0006]
• WO 2017102892 A2 [0009, 0036]
• DE 2020100194 [0009]
• EP201851219 [0009]
• DE 102020107920 [0036, 0037, 0065]
• US20140196282A1 [0037]
• EP 1639688 B1 [0037]

Claims (15)

Holding device (10) for linearly aligning at least one wave winding wire (12), which has a series of straight wire sections (20) which are connected by wire areas bent in a U-shape or roof shape, and for transferring the at least one wave winding wire (12) to an annular one Arrangement (19) of radially outwardly opening grooves during the manufacture of a component of an electrical machine, comprising a rake or comb structure (24) with a rigid linear base element (28) extending in a longitudinal direction and a row extending from the rigid linear base element (28) teeth (30) extending transversely to the longitudinal direction, with tooth flanks (32a, 32b), each of which has a receiving slot (34) between two adjacent teeth (30) for receiving at least one of the straight wire sections (20) of the at least one Defining the wave winding wire (12), characterized in that the receiving slots (34) correspond to are curved in an arc shape in accordance with an arc-shaped movement of the wire sections (20) extending in a straight line when the at least one wave winding wire (12) is rolled up onto the ring-shaped arrangement. Holding device (10) for linearly aligning at least one wave winding wire (12), which has a series of straight wire sections (20) which are connected by wire areas bent in a U-shape or roof shape, and for transferring the at least one wave winding wire (12) to an annular one Arrangement (19) of radially outwardly opening grooves during the manufacture of a component of an electrical machine, comprising a rake or comb structure (24) with a rigid linear base element (28) extending in a longitudinal direction and a row extending from the rigid linear base element (28) teeth (30) extending transversely to the longitudinal direction, with tooth flanks (32a, 32b), each of which has a receiving slot (34) between two adjacent teeth (30) for receiving at least one of the straight wire sections (20) of the at least one Defining wave winding wire (12), characterized in that teeth (30) or at least their Tooth flanks (32a, 32b) are designed to be elastically flexible in order to adapt the receiving slot (34) to an arcuate movement of the wire sections extending in a straight line when the at least one wave winding wire (12) is rolled onto the ring-shaped arrangement (19). Holding device (10) for linearly aligning at least one wave winding wire (12), which has a series of straight wire sections (20) which are connected by wire areas bent in a U-shape or roof shape, and for transferring the at least one wave winding wire (12) to an annular one Arrangement (19) of radially outwardly opening grooves during the manufacture of a component of an electrical machine, comprising a rake or comb structure (24) with a rigid linear base element (28) extending in a longitudinal direction and a row extending from the rigid linear base element (28) teeth (30) extending transversely to the longitudinal direction, with tooth flanks (32a, 32b), each of which has a receiving slot (34) between two adjacent teeth (30) for receiving at least one of the straight wire sections (20) of the at least one Defining the wave winding wire (12), characterized in that the teeth (30) are movably attached to the Base element (28) are articulated in order to adapt the receiving slot (34) to an arcuate movement of the rectilinearly extending wire sections (20) when the at least one wave winding wire (12) is rolled onto the annular arrangement (19). A retainer (10) according to any one of the preceding claims, characterized in that the teeth (30) extend arcuately from the base member (28). Holding device (10) according to one of the preceding claims, characterized in that the teeth (30) deform or move when subjected to a load by lifting the straight wire sections (20). Holding device (10) according to one of the preceding claims, characterized in that teeth (30) are provided with different thicknesses. Holding device (10) according to one of the preceding claims, characterized in that the receiving slots (34) narrow viewed from a foot region (38) arranged near the base element (28) towards an open mouth region (40). Holding device (10), in particular according to one of the preceding claims, for linearly aligning at least one wave winding wire (12) which has a series of straight wire sections (20) which are connected by U-shaped or roof-shaped bent wire areas, and for transferring the at least a wave winding wire (12) on an annular arrangement (19) radially outwardly opening grooves in the course of manufacturing a component of an electrical machine, comprising a rake or comb structure (24) with a rigid in a Longitudinally extending linear base member (28) and a row of teeth (30) extending transversely to the longitudinal direction away from the rigid linear base member (28) with tooth flanks (32a, 32b) each having a receiving slot (34) between two adjacent teeth (30) for receiving at least one of the straightly extending wire sections (20) of the at least one wave winding wire (12), characterized in that the teeth (30) extend obliquely away from the base element (28), so that the receiving slots (34) incline obliquely away from the base member (34). Holding device (10) according to one of the preceding claims, characterized in that the teeth (30) run out to a point at their ends. Retaining device (10) according to one of the preceding claims, characterized in that the receiving slots (28) have areas (38, 40) of different curvature and/or different inclinations to the base element (28). Joining device (16) for inserting a wave winding wire (12) or a plurality of wave winding wires (12) grouped into a coil mat (14) into a laminated core of a stator of an electrical machine, comprising a holding device (10) according to one of the preceding claims, a joining mandrel (18) with the ring-shaped arrangement (19) of radially outwardly opening grooves, which is movable with rotation relative to the holding device (10) in the longitudinal direction of the base element (28) and a transfer device for transferring the at least one wave winding wire (12) from the holding device (10) on the assembly mandrel (18). Joining device (16) after claim 11 , characterized in that the transfer device is set up to first space the straight wire sections (20) from the base element (28) by a predetermined distance and then lift them out of the holding device (10) and transfer them to the joining mandrel (18). Joining method for inserting a wave winding wire (12) or several wave winding wires (12) grouped into a coil mat (14) into a laminated core of a stator, comprising providing the at least one wave winding wire (12) on a holding device (10) according to one of the Claims 1 until 10 , Transferring the at least one wave winding wire (12) to a joining mandrel (18) with the annular arrangement (19) of radially outwardly opening grooves, inserting the joining mandrel (18) into the laminated core and transferring the at least one wave winding wire (12) from the Joining mandrel (18) in the laminated core. joining process Claim 13 , characterized in that the holding device (10) is provided in such a way that a constant distance between the wire sections guided in the receiving slots (34) to one another is maintained during transfer from the holding device (10) to the joining mandrel (18). Joining method according to one of Claims 13 or 14 , characterized in that the wave winding wire (12) has an elongate wire cross-section and the holding device (10) is provided in such a way that the area of the tooth flanks (32a, 32b) located near the straight wire section opens up when being transferred from the holding device (10). extends the joining mandrel in the course of the arcuate movement of the straight wire sections (20) substantially perpendicularly to the longitudinal direction of the wire cross section.

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