DE102021125942B3 - Process for pressing a coil winding - Google Patents

Abstract

Method for producing a wave winding mat (1) intended to be drawn into a stator, rotor or into a drawing-in tool, which is formed from a coil winding (10) extending in a longitudinal direction (L), the coil winding (10) having layers (12, 14) comprising a plurality of individual wires (16, 16`) which form wire webs (18, 18') and winding overhangs (22, 22`) running transversely to the longitudinal direction and the wire webs (18, 18') in the course of the individual wires ( 16, 16') are each arranged between two consecutive winding heads (22, 22`) and the winding heads (22, 22`) form lateral areas (24, 26) of the coil winding (10), having the method step:
- Pressing the superimposed layers (12, 14) of the coil winding (10) in at least one lateral area (24, 26) by means of a contact pressure that begins at one end of the coil winding (10) and continues or migrates in the longitudinal direction (L), whereby that
- at least one roller (40, 41, 42, 44, 40`, 41', 42', 44`) is provided for pressing the coil winding (10), which rolls along the coil winding (10) in a lateral area (24, 26 ) rolls longitudinally (L) under pressure,
- wherein first a first lateral area (24) is pressed along the longitudinal direction (L) in a first movement and then the second lateral area (26) of the coil winding (10) is pressed along the longitudinal direction (L) in a second movement, wherein the second movement is in the opposite direction to the first movement.

Description

The invention relates to a method for pressing a wavy coil winding intended for insertion into a stator, rotor or insertion tool.

Coil windings can be made by winding individual wires in wire packets around a former. When the individual wires have a rectangular cross-section, we speak of flat wire windings. A possible method for producing wave-shaped coil windings is from DE 10 2015 120 661 A1 known.

Such a method results in a flat, wavy coil winding, which is also referred to as a wave winding and has roof-shaped end windings that are arranged between two straight wire webs along the course of the individual wires of the wave winding. When it is pulled into a rotor or stator with a cylindrical rotor or stator body, the wave winding with the individual wires lying on top of one another is pulled into slots in the area of the webs and the winding overhangs protrude axially beyond the rotor or stator body and form the offset of the individual wires over different slots. As a rule, the entire coil winding produced is pressed flat so that overlapping wires are as close as possible to one another.

With a coil winding produced according to the method described above, coils of a plurality of electrical circuits can be introduced into a stator or rotor body at once, so that, for example, three-phase operation of an electric motor is possible. The wire packages used therefore preferably have a number of individual wires that is a multiple of three. However, other constellations are also conceivable. It is also conceivable that the wave winding produced is not drawn directly into a rotor or stator, but first into a drawing-in tool, which ultimately converts the wave winding into a rotor or stator body.

Due to the method described above, a strong plastic deformation of the wires when bending the individual wires around the winding template is to be expected, especially when using wires with a rectangular cross section for flat wire windings, namely when the winding template is rotated and the inclined areas around an edge of the winding template shaped and then pressed flat. Depending on the edge formation of the winding template, a more or less strong torsion occurs in the wires with a rectangular cross section, which takes up space on the one hand and can damage an insulation layer on the wires on the other hand. The individual wires are usually made of copper, which is much more ductile than an applied insulating layer of insulating varnish. If the wires are excessively deformed, this insulating layer threatens to flake off and forms a void in the coil winding. Even a defect in a coil winding can lead to the entire component being rejected. When pressing to achieve the smallest possible spatial expansion of the winding overhangs of a coil winding inserted into a rotor, stator or insertion tool, the edges of a wire point can also press into an adjacent wire and destroy the insulation layer.

• - Pressen der übereinanderliegenden Lagen der Spulenwicklung in zumindest einem seitlichen Bereich mittels eines an einem Ende der Spulenwicklung einsetzenden und sich in Längsrichtung fortsetzenden oder wandernden Anpressdrucks.

From the JP 2012- 105 392 A a method is known for producing a wave winding mat intended for insertion into a stator, rotor or an insertion tool, which is formed from a coil winding extending along a longitudinal direction, the coil winding having layers of a plurality of individual wires lying on top of one another, which are transverse to the longitudinal direction form running wire webs and winding heads and the wire webs are arranged between two successive winding heads in the course of the individual wires and the winding heads form lateral areas of the coil winding, having the method step:

• - Pressing the superimposed layers of the coil winding in at least one lateral area by means of a contact pressure that begins at one end of the coil winding and continues or migrates in the longitudinal direction.

The object of the invention is to provide a method that eliminates the disadvantages mentioned and, in particular, produces a space-efficient and continuously insulated coil winding.

The above-mentioned object is achieved according to claim 1 with configurations according to one of claims 2 to 7.

For a method for producing a wave winding mat intended to be drawn into a stator, rotor or a drawing-in tool, which is formed from a coil winding extending along a longitudinal direction, the coil winding having layers of a plurality of individual wires lying on top of one another, the wire webs running transversely to the longitudinal direction and form winding heads and the wire webs are arranged in the course of the individual wires between two consecutive winding heads and the winding heads form lateral areas of the coil winding, according to the invention is the pressing of superimposed layers of the coil winding are provided in at least one lateral region by means of a contact pressure which begins at one end of the coil winding and continues or migrates in the longitudinal direction.

The process referred to here as pressing does not usually mean that this results in a deformation in the sense of a change in the thickness of the individual wires. Rather, the term "pressing" refers to pure deformation of the wires in the sense of aligning the winding, which aims to flatten the winding produced and not the individual wires. The pressing can be carried out by pressing the individual wires from a direction perpendicular to the coil winding, or by rolling out the coil winding using a roller. For the term "rolling" mentioned below, it also applies that, unlike e.g.

In this case, the contact pressure can be applied continuously in the longitudinal direction to the coil winding, or can migrate in the longitudinal direction along the coil winding. The pressing of the superimposed layers of the coil winding in the lateral area results on the one hand in a desired compaction of the coil winding, whereby torsion of the winding heads, particularly in the area of the winding head tips, can be avoided by the contact pressure that continues or migrates in the longitudinal direction.

According to the invention, at least one roller is provided for pressing the coil winding, which rolls under pressure along the coil winding in a lateral area in the longitudinal direction. As a result of the unrolling, a moving contact pressure is advantageously achieved, as a result of which the winding heads and in particular the wires in the region of the winding head tips are deformed in a continuous movement. This prevents the build-up of tension in the coil winding and ultimately further reduces the formation of unwanted torsions in the wires.

According to a development of the method, it is provided that the roller presses the coil winding against a base. Rolling on a base, which in a preferred embodiment can be a linear magazine, is also advantageous, since the base forms a support for the contact pressure.

According to a further embodiment of the invention, the coil winding is exposed in the area of the end windings during pressing and two opposite rollers are provided for pressing the coil winding in the lateral area, which are in contact with the coil winding. Provision is therefore made for corresponding rollers to roll synchronously on both sides of the coil winding, with the coil winding being pressed on both sides by the two rollers. By rolling on both sides, a uniform contact pressure is advantageously achieved on both sides of the coil winding.

A further development of the method provides that the coil winding is pressed by means of cascaded rollers. Pressing by means of cascaded rollers, which are preferably arranged next to one another transversely to the longitudinal direction and one behind the other offset in the longitudinal direction, has the advantage that stresses that occur in the individual wires of the coil winding as a result of the pressing process also appear in a direction transverse to the longitudinal direction in the can distribute respective individual wires. This results in the advantage that deformations of the individual wires, such as undesired torsion in the end winding tips, are reduced by the gradual reduction in stress by means of the cascaded rollers.

An embodiment that is not according to the invention results in the fact that both lateral areas of the coil winding are pressed at the same time. In this way, the cycle times in the compression of the coil winding can be reduced.

According to the invention, a first lateral area is first pressed along the longitudinal direction in a first movement and then the second lateral area of the coil winding is pressed along the longitudinal direction in a second movement, the second movement being in the opposite direction to the first movement. According to a further embodiment, it can be provided that a pressing means such as a roller or a cascaded set of rollers is provided for this purpose, which first presses the first lateral area in the longitudinal direction and is then converted in order to press the second lateral area counter to the longitudinal direction.

According to a development of the invention, it is provided that the coil winding is moved between the rollers or on a base under at least one roller in the longitudinal direction, while the roller exerts a contact pressure on the coil winding. In this way, the reel can be made stationary while the coil winding is moved relative to the reel. This configuration is particularly advantageous when a coil winding is fed continuously to the method.

According to a further embodiment of the invention, it is provided that the at least one roller is driven in rotation or axially. An active drive of the roller has the advantage that both the roller can be moved by the driving force on the coil winding and can exert the continuing or migrating contact pressure on the coil winding. Equally, the rotary or axial drive can also be used to move the coil winding or possibly the coil winding present on a base relative to the roll if the coil winding itself or the base are movably mounted.

According to a development of the invention, it is provided that the at least one roller is moved translationally in at least two or in all three degrees of freedom. In particular, it is provided that the rollers are moved relative to the coil winding. In this case, the rollers can exert a contact pressure on the coil winding or be lifted off the coil winding during the movement. The movement of the rollers in the degrees of freedom that lie parallel to the plane of the coil winding results in the advantage that stresses in the individual wires of the coil winding can be distributed in a targeted manner.

According to a further embodiment of the invention, the at least one roller is driven to rotate about an axis normal to the coil winding during the movement. It is optionally provided that the rollers are driven to rotate about this axis during the process. This additional rotational degree of freedom allows the rollers to also be aligned at an angle to the longitudinal direction and the individual wires of the coil winding to be pressed in such a direction. In particular in the area of the winding overhangs with the inclined wire sections, this contributes to the fact that stresses in the area of the winding overhang tips can be effectively avoided or can be transferred to other wire areas, so that the torsion potential is reduced.

According to a development of the invention, it is provided that the winding mat is placed in a linear magazine before pressing. Optionally, it can be provided that the wire webs of the coil winding are inserted in grooves of the linear magazine between webs of the linear magazine before pressing. According to a further optional embodiment, it is provided that the linear magazine has at least one groove provided in the webs and extending along the longitudinal direction, in which the at least one roller is moved in the longitudinal direction.

The linear magazine makes it possible to adjust differences in cycle times between winding the coil winding in a winding device upstream of the pressing and drawing the coil winding into a drawing-in tool or a rotor or stator body downstream of the pressing. In addition, the wave winding produced can be transported in a linear magazine without significant structural impairment from a winding device to a feed device. In particular, the slots can stabilize the coil winding in the longitudinal direction during pressing. The groove can advantageously serve as a guide for the pressing means used, such as rollers.

Further features, details and advantages of the invention result from the wording of the claims and from the following description of exemplary embodiments based on the drawings.

• 1: eine schematische Darstellung des Pressvorgangs einer in ein Linearmagazin eingelegten Spulenwicklung in einer Draufsicht
• 2: eine Schnittansicht einer Spulenwicklung, die nach einer Ausführungsform des Verfahrens gepresst wird.

In the figures show:

• 1 1: a schematic representation of the pressing process of a coil winding placed in a linear magazine in a plan view
• 2 1: a sectional view of a coil winding being pressed according to an embodiment of the method.

In the following, the same reference numbers are used for all figures to identify the same elements, unless otherwise stated.

1 shows a wave winding mat 1 with a coil winding 10 which is inserted into a linear magazine 30. FIG. The wire webs 18 , 18 ′ of several individual wires 16 , 16 ′ of the coil winding 10 lie in grooves 62 between webs 64 of the linear magazine 60 . The coil winding 10 extends in the longitudinal direction L and, like the linear magazine 60, is shown in detail in this illustration. The wire webs 18 , 18 ′ of the coil winding 10 are each formed between lateral end windings 22 of the coil winding 10 . In each end winding 22, the respective individual wire 16, 16' of the coil winding 10 first runs in a wire section 19 inclined relative to the wire web 18, 18', forms a winding head tip 25 and continues in a further inclined wire section 19'. In this way, the roof-shaped winding heads 22 are formed, through which an offset of the wire webs 18, 18' of the individual wires 16, 16' in the longitudinal direction L is achieved.

The coil winding 10 placed in the linear magazine 60 thus has two lateral areas 22 , 24 which lie next to the linear magazine 60 . The End windings 22 are formed in the lateral areas 24, 26. In the course of an individual wire 16, 16', a change in direction takes place after each end winding 22, as a result of which the individual wires 16, 16' lie in the linear magazine 60 in a wavy pattern. The individual wires 16, 16' are present in wire groups, with two individual wires 16, 16' being able to overlap in the grooves 62. The coil winding 10 has a certain height due to the overlapping of the individual wires 16, 16′ and the change in direction generated in the winding overhangs 22 over the course of the individual wires and can be compressed to achieve an optimized use of space.

For this purpose, the method provides for the superimposed layers 12, 14 of the coil winding 10 to be pressed in at least one lateral region 24, 26 by means of a contact pressure starting at one end of the coil winding 10 and continuing or moving in the longitudinal direction L. For this is in the in 1 Schematically illustrated embodiment of the method, a first set of cascaded rollers 40, 42, 44 is provided in the first lateral area 24, and a second set of cascaded rollers 40', 42', 44' is provided in the second lateral area 26 of the coil winding.

The cascaded rollers 40, 42, 44, 40', 42', 44' press the coil winding 10 in the lateral areas 24, 26, as a result of which the winding overhangs 20 are compressed. The cascaded rollers 40, 42, 44, 40', 42', 44' are movable in the longitudinal direction L according to one embodiment of the method. Alternatively, the linear magazine 0 with the coil winding 10 inserted in it can also be moved under the cascaded rollers 40, 42, 44, 40`, 42`, 44`, while between the rollers 40, 42, 44, 40`, 42`, 44 ` and the coil winding a contact pressure is established.

It is also conceivable that instead of the cascaded rollers 40, 42, 44, 40', 42', 44', individual rollers 40, 40' or other pressing means are used.

In this embodiment, two sets of cascaded rollers 40, 42, 44 and 40', 42', 44' are selected, which press the lateral regions 24, 26 of the coil winding 10 in opposite directions while applying a migrating contact pressure to the respective end windings 22 in the lateral Areas 24, 26 exercise. It can also be conceivable that only one set of cascaded rollers 40, 42, 44 or a single roller 40 is used for this purpose, which initially presses the first lateral region 24 in a first movement in the longitudinal direction L, this roller 40 or the set cascaded rollers 40, 42, 44 is implemented in the second lateral area and the winding heads 22 lying therein are pressed in a second movement opposite to the first movement or presses.

In general, it can be provided that the contact pressure does not migrate with the rollers 40, 42, 44, 40', 42', 44' in relation to the coil winding, but is maintained. This can be realized, for example, by a pressing means (not shown) that, following the pressing by the roller 40, 42, 44, 40', 42', 44', is pressed onto the respective end windings in the lateral area.

In this embodiment, cascaded rollers 40, 42, 44, 40', 42', 44' are shown, which are arranged one behind the other in the longitudinal direction L and laterally offset transversely to the longitudinal direction L in the lateral regions 24, 26. It can also be conceivable that the end windings 22 are only pressed on by a single roller 40, 40'.

The coil winding 10 is supported in the lateral areas 24, 26 either by a suitable base 50, which optionally moves with the movement of the rollers 40, 42, 44, 40', 42', 44', or by corresponding and counter-rotating spinning reels (in 1 not shown) on the opposite side, i.e. the back of the coil winding 10.

The webs 64 of the linear magazine 60 have grooves 66, 66' running in the longitudinal direction L, in which further rollers (not shown) can also exert a contact pressure on the wire webs 18, 18'.

2 shows a sectional view through a coil winding 10 placed in a linear magazine, which is pressed according to a further embodiment of the method. The coil winding 10 lies in a groove of the linear magazine 60 between webs 64 of the linear magazine. The linear magazine 60 shown here has no grooves 66, 66' running in the longitudinal direction L. Nevertheless, grooves 66, 66' can also be provided in this embodiment, in which the rollers or other rollers can also press the wire webs 18, 18'. The longitudinal direction L runs in 2 into the viewing plane.

The rollers in the lateral areas are designed here as corresponding pairs of rollers 40, 41 and 40', 41' and press the coil winding 10 on both sides between the pairs of rollers 40, 41 and 40', 41'.

Provision can also be made in this embodiment for the rollers 40, 41, 40', 41' to be driven passively, for example indirectly by the movement Movement of the linear magazine 60 with the coil winding 10 between the pairs of rollers 40, 41 and 40', 41', while these exert a contact pressure on the coil winding 10.

Likewise, analogous to the statements 1 be provided that the rollers 40, 41, 40 ', 41' are actively driven axially or rotationally and move in the lateral areas 24, 26 relative to the coil winding 10 in the longitudinal direction L.

The rollers 40, 41, 40', 41' can be moved along all three translational degrees of freedom. this is in 2 shown as an example for the role 40. Furthermore, the rollers 40, 41, 40', 41' are mounted such that they can rotate about the axis of rotation. Provision can also be made for the rollers 40, 41, 40', 41' to be rotatable about an axis aligned normal to the coil winding.

For the method and all embodiments, ie in particular also the embodiment according to 1 it can accordingly be provided that the rollers 40, 41, 42, 44, 40', 41', 42', 44' are moved translationally and preferably force- and/or path-controlled along at least one degree of freedom. As an alternative or in addition to this, it can be provided for the method that the rollers 40, 41, 42, 44, 40′, 41′, 42′, 44′ are actively rotated about an axis oriented normal to the coil winding or follow up passively.

reference list

1

wave winding mat

10

coil winding

12, 14

superimposed layers

16, 16`

single wire

18, 18`

wire bar

19, 19'

inclined wire section

22, 22'

winding head

24, 26

lateral area

25, 25'

winding head tip

40, 41, 42, 44, 40`, 41`, 42`, 44`

role

60

linear magazine

62

groove

64

web

66, 66'

groove

L

longitudinal direction

Claims (7)

Method for producing a wave winding mat (1) intended to be drawn into a stator, rotor or into a drawing-in tool, which is formed from a coil winding (10) extending in a longitudinal direction (L), the coil winding (10) having layers (12, 14) comprising a plurality of individual wires (16, 16`) which form wire webs (18, 18') and winding overhangs (22, 22`) running transversely to the longitudinal direction and the wire webs (18, 18') in the course of the individual wires ( 16, 16') are each arranged between two successive winding heads (22, 22`) and the winding heads (22, 22`) form lateral areas (24, 26) of the coil winding (10), having the method step: - pressing the superimposed layers (12, 14) of the coil winding (10) in at least one lateral region (24, 26) by means of a contact pressure which begins at one end of the coil winding (10) and continues or migrates in the longitudinal direction (L). ncharacterizes that - for pressing the coil winding (10), at least one roller (40, 41, 42, 44, 40`, 41', 42', 44`) is provided, which runs along the coil winding (10) in a lateral area ( 24, 26) in the longitudinal direction (L) under pressure, - with a first lateral area (24) being pressed along the longitudinal direction (L) in a first movement and then the second lateral area (26) along the coil winding (10). the longitudinal direction (L) is pressed in a second movement, the second movement being in the opposite direction to the first movement. procedure after claim 1 , wherein the coil winding (10) is moved between the rollers (40, 41, 40`, 41') or a base (50) under at least one roller (40, 40`) in the longitudinal direction (L) while the roller ( 40, 40`) exerts a contact pressure on the coil winding (10). procedure after claim 2 , wherein the coil winding (10) is exposed in the area of the end windings (22) during pressing and for pressing the coil winding (10) in the lateral area (24, 26) two opposite rollers (40, 41, 40`, 41') are provided which are in contact with the coil winding (10). Procedure according to one of claims 2 until 3 , wherein the coil winding (10) is pressed by means of cascaded rollers (40, 42, 44, 40`, 42', 44`). Procedure according to one of Claims 1 until 4 , wherein the at least one roller (40, 41, 42, 44, 40`, 41', 42`, 44`) is driven in rotation or axially. Procedure according to one of Claims 1 until 5 , wherein the at least one roller (40, 41, 42, 44, 40`, 41', 42', 44`) is moved translationally in at least two or in all three degrees of freedom. Method according to one of the preceding claims, in which the winding mat (1) is placed in a linear magazine (60) before pressing, the wire webs (18, 18') of the coil winding (10) being placed in grooves (62) of the linear magazine ( 60) between webs (64) of the linear magazine (60).

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