DE102022105057A1 - Method of inserting insulation into the grooves of an insertion tool - Google Patents

Abstract

The method is used to insert insulation (14) into the grooves (22) of an insertion tool (20), with flat wires (28) of a preformed winding mat (30) being pushed into the grooves (22), which are at least partially covered by the insulation (14 ) are enclosed, the insulation (14) being prefabricated before being introduced into the grooves (22). In order to improve process reliability, it is proposed that the insulation (14) be removed from a supply and aligned, with the insulation (14) then being transferred to a defined position in a groove (22) of the insertion tool (20) assigned to them and there held in a predetermined position before the flat wires (28) are inserted into the slots (22), the insulations (14) being carried at least a certain distance into the slots (22).

Description

According to the preamble of claim 1, the invention relates to a method for inserting insulation into the slots of an insertion tool, flat wires of a preformed winding mat being inserted into the slots and being at least partially surrounded by the insulation, the insulation being inserted before it is inserted into the slots be pre-assembled

From the EP 3 391 512 A1 a method is known in which the insulation is placed between the flat wires to be transferred from the drawing-in tool into the stator slots and the stator slots in a final step of the manufacture of a stator and then drawn through the flat wires into the stator. Accessibility can cause difficulties in this assembly step if the insertion tool is accommodated in the cylindrical inner diameter, the gap between the outer diameter of the insertion tool and the inner diameter of the stator should be as small as possible.

It should always be noted that the insulation of the flat wires must meet certain requirements, which increase with increasing operating voltages of the motor in which the stator is to be installed. Care must be taken to ensure sufficiently high breakdown voltages, which are achieved through suitable creepage and clearance distances between the live flat wires and the stator. If the insulation is to be introduced directly into the stator slots, there is a problem in that the flat wires at the inside slot exit have to be closed afterwards. An example of this is in the DE 10 2019 003 258 A1 shown, where the insulation at the inner slot exit is folded over several times to meet the requirements.

She goes a different way DE 10 2008 021 779 B4 , in which the wires are already provided with an insulation before forming into a flat mat.

A problem for arranging the insulation in a production step before the winding mat is transferred into the stator slots can be that the insulation is damaged or, in the case of individual, possibly prefabricated insulations, can slip, which in turn can impair the function of the insulation. Such a slippage can also occur if the insulation is not introduced into the stator slots until the winding mat is installed.

The object of the present invention is to provide a method that allows the insulation to be introduced in a precise, process-reliable manner

According to the invention, the object is achieved by a method of the type mentioned at the outset, in which the insulation is removed from a store and aligned, with the insulation then being transferred to a defined position in a groove of the insertion tool assigned to it and held there in a predetermined position before the flat wires are inserted into the slots, the insulations being carried along at least a certain distance into the slots.

The solution according to the invention offers the advantage that the insulation can be held in a defined position during its transport from the store until it is introduced into the groove, so that slipping or damage can be practically ruled out.

Inserting the insulation when the insertion tool is being fitted has the advantage that the flat wire packages are additionally fixed and positioned by the insulation, so that the subsequent transfer into the stator slots can take place more reliably.

Furthermore, after the insertion of the flat wires into the insertion tool, the insulation can be closed at the radially outer openings of the grooves of the insertion tool, which will be discussed in detail later. After the flat wire windings have been transferred from the slots of the insertion tool into the stator slots, these closing points are in the bottom area of the latter, while the flat wires are covered with closed insulation at the inner ends of the stator slots.

An embodiment of the invention is particularly preferred in which the insulations are pre-folded on lines to be folded during processing before being inserted into the grooves of the insertion tool.

The prefolding, which can be carried out, for example, at the corners lying at the bottom of the grooves and/or at overhanging edges, has several advantages. First of all, this stiffens the insulation and behaves less sensitively in the process, even if it is already separated and/or pre-assembled.

It is particularly preferred to use the prefolded areas to the effect that they are at least partially used to align the insulation be used in the acquisition of the stock and / or on the insertion tool.

The pre-folded edges offer the possibility of aligning to defined stops, whereby the lateral edges of the insulation, in particular its corner areas, can also be used additionally or alternatively for this purpose.

The pre-folded insulation can be held in an aligned position on the insertion tool, e.g. by means of compressed air suction devices, before the flat wires are then transferred, e.g. from a linear magazine, into the grooves of the insertion tool, taking the insulation with it. The insulation can also be partially inserted into the grooves beforehand.

The pre-folding can take place in an intermediate process step after the insulation has been removed from a magazine or after the insulation has been separated by cutting it off from an endless strip.

The paper is folded in a way that is adapted to the insulating paper used for the insulation, the type of wire dimensions and the slot geometry.

In a preferred further development of the method, it is provided that lateral overhangs of the insulation are successively folded inwards after the wires have been drawn in, with adhesive being introduced between the overlapping layers of insulation and these being permanently connected to it.

This measure represents a way of enclosing the wire package on all sides with the insulation before it is transferred into the stator slots, which means that the step of transferring can be carried out more reliably and particularly good insulation is achieved in the stator slot because there is no insulation seam in the area of the radially inner groove opening is present.

As already mentioned, it can be advantageous for the insulation to be stored in a magazine prefabricated in strips, with it being in a defined position and being able to be removed from the magazine in a correspondingly exact alignment.

Alternatively, however, it can also be provided that the insulation is pulled from a supply of tape and cut to the desired width or length for pre-assembly before being transferred to the insertion tool. The cut edge can be used as a defined position in order to be able to take over the insulation in a defined position.

The subject matter of the present invention is also a device for inserting insulation into the grooves of a rotatably driven insertion tool, with an insertion device being provided for inserting flat wires into the grooves, taking the insulation with it. According to the invention, a transfer device is provided, which picks up the insulation from a supply and transfers it to a holding station on the insertion tool, which holds the insulation in a defined position in relation to a groove.

By providing an additional transfer device, it is possible to hold the insulation in a defined position in all process steps. In addition, the cycle speed of the system can be increased if the transfer device is preferably designed in such a way that it can pick up several insulations at the same time and then transfer them successively to the holding stations of the insertion tool.

Provision is preferably made for holding stations to be formed on all grooves of the insertion tool in order to hold the insulating paper in a defined position before the insulation is pushed into the grooves by the flat wires.

The holding stations can have mechanical clamping means or suction devices that hold the insulation in the defined positions. The suction devices can be formed by suction air ducts on the side of the grooves.

In a further preferred embodiment of the invention it is provided that the transfer device has at least one, preferably two or more holding devices, which hold the insulation removed from the store in a defined position during transfer. The holding devices can be designed in a similar way to the holding stations and can hold the insulation in the defined position by means of suction air or mechanical clamping means.

A multi-part folding device and/or gluing device is preferably provided on the transfer device in order to close the flat wire bundles embedded in the grooves of the tool with the respective insulation, the folding device and/or the gluing device being stationary, i.e. not rotating with the insertion tool. This device with all the details described here can also be used advantageously independently of the invention described here for other types of application of the insulation in the grooves of the insertion tool in order to to enclose the flat wires securely on all sides with the insulation.

Parts of the folding device can be designed as fixed bending edges against which the insulation runs when the insertion tool is rotated, while other parts can be designed to be actively movable in order to fold the protruding sections of the insulation, with the gluing device introducing a suitable adhesive between the layers.

• 1 eine schematische Ansicht einer Transfervorrichtung und eines Magazins für Isolierungen;
• 2 eine schematische Ansicht einer alternativen, das Magazin in 1 ersetzende Zufuhr für Isolierungen;
• 3 eine schematische Ansicht der Transfervorrichtung mit zwei Haltestationen;
• 4 a bis c schematisch in drei Schritten das Überführen der Flachdrähte in die Nut des Einziehwerkzeuges;
• 5 bis 10 schrittweise den Vorgang des Verschließens der Isolierung;
• 11 eine schematische Ansicht einer Isolierung mit einer Vorfaltung;
• 12 eine schematische Seitenansicht einer Transfervorrichtung mit einer Vorfaltstation;
• 13 einen schematischen Schnitt einer Haltestation zum Zusammenwirken mit der Vorfaltstation;
• 14 a bis d eine Ablauffolge des Vorfaltens der Isolierung in der Vorfaltstation.

Further features, details and advantages of the invention result from the wording of the claims and from the exemplary embodiment described below with reference to the drawing. Show it:

• 1 a schematic view of a transfer device and a magazine for insulation;
• 2 a schematic view of an alternative, the magazine in 1 replacing feed for insulations;
• 3 a schematic view of the transfer device with two holding stations;
• 4 a until c schematically shows the transfer of the flat wires into the groove of the insertion tool in three steps;
• 5 until 10 step by step the process of sealing the insulation;
• 11 a schematic view of insulation with a pre-fold;
• 12 a schematic side view of a transfer device with a pre-folding station;
• 13 a schematic section of a holding station for cooperation with the pre-folding station;
• 14 a until i.e a sequence of prefolding the insulation at the prefolding station.

In 1 a transfer device 10 is outlined, which has at least two holding devices 12 (see 3 ) for receiving prefabricated insulation 14 in the exact position, here in the form of strips of insulating paper, from a magazine 16, in which the prefabricated insulation 14 is preferably held in a defined position.

The transfer device 10 is intended to transfer the insulation 14 to holding stations 18 on an insertion tool 20 in the exact position by means of the holding devices 12 . The insertion tool 20 has a multiplicity of grooves 22 which extend radially inwards from a cylindrical outer surface 24 and serve for the temporary accommodation of webs 26 of a winding mat 30 wound from flat wire 28 . The webs 26, which are connected to one another by roof-shaped winding overhangs (not shown here), are transferred in a subsequent work step, which is known per se and is not the subject of this application, into the slots of a stator for an electric motor, with the flat wires radially outwards from the Grooves 22 of the insertion tool 20 are transferred into the inwardly open grooves of the stator.

As an alternative to a magazine 16, the insulation 14 can also be supplied from an endless supply 32 of an insulating paper reel 34 (see 2 ) and separated from the tape by a cutting device 36 during or shortly before being received in one of the holding devices 12 of the transfer device 10 .

In 3 an exemplary embodiment of a transfer device 10 is shown, which is designed as a rotating suction roller 38 . Suction roller means that the holding devices 12 have suction channels 40, which are subjected to a negative pressure compared to the environment, so that the insulation 14 removed from the magazine 16 is held securely when it is transferred to the holding stations 18 of the insertion tool by rotation of the suction roller. In the example shown, one suction channel 40 opens into a plurality of suction funnels 42 per holding device 12, so that an even hold is achieved. The position of the insulation 14 is defined by a stop edge 44 on the edge of the holding device 12 which, in cooperation with the suction effect, ensures that the insulation is still in a defined position when it is transferred to the holding station 18 .

At the in 3 The transfer device shown shows two holding devices 12, so that when a holding device 12 is loaded with insulation 14 from the magazine 16, insulation can be transferred to a holding station 18 of the insertion tool on the opposite side of the transfer device 10 at the same time. It is also possible to have more holding devices distributed over the circumference of the transfer device 10, in particular if the insulation is to be processed in intermediate steps, for example one later in connection with FIG 12 until 15 described prefolding.

The transfer device 10 does not have to be designed as a rotating body, it can also have freely movable gripping arms, for example, on which the holding devices can be designed.

The negative pressure in the suction channels 40 can be controlled to enable safe pick-up and transfer of the insulation.

Instead of the suction devices, mechanical grippers with suitable positioning devices can also be used.

In 4 a until c the insertion of the flat wires 28 into the grooves 22 is briefly illustrated in order to clarify the further process and the position of the insulation before the final sealing of the insulation, which is shown in 5 until 11 is explained in more detail before the flat wires 28 are transferred from the slots 22 of the insertion tool 20 with the insulation 14 surrounding them into the slots of the stator.

4a shows the position of the insulation 14 in a holding station 18 of the insertion tool, with each groove 22 being assigned a holding station 18. The holding stations of the drawing-in tool have holding means, here in the form of further suction air ducts 46, which are arranged next to the grooves 22. In turn, stop edges can be provided in order to secure the position of the insulation, but this is not absolutely necessary since the insulation 14 is transferred from a defined position in the holding devices 12 of the transfer device. Again, mechanical holding means are also possible.

In 4b a subsequent step is shown, in which a first layer of flat wire is transferred into the groove 22 with entrainment of a middle section 48 in the groove. The lateral edges 50 of the insulation 14 stand up here, forming fold lines 51 between the middle section 48 and the edges 50 . The edges 50 are also longer than the depth of the groove so that after all layers of wire have been inserted, lateral projections 52 are formed which protrude from the groove 22 and are subsequently used to seal the insulation in connection with 5 until 11 will be dealt with in more detail.

In 5 is the in 4c shown holding station 18 on a slot 22 of the insertion tool 20 equipped with flat wire 28 and a folded insulation 14, which has been moved into the area of a folding and gluing device 54 by rotating the insertion tool 20. Only the overhangs 52 of the insulation are shown. A first leg 56 of the projections 52, the length of which is not greater than the width of the groove, runs through the rotating insertion tool against a passive folding edge 58 and becomes corresponding to the width of the groove 22 as the rotation continues 6 into the in 7 end position shown folded over.

A metered amount of suitable adhesive 60 is now applied to the folded leg 56 through a channel 59 . The passive folding edge 58 then pivots outwards about a pivot axis 61 .

In 8th and 9 1 shows the function of an active folding edge 62 which is subsequently used and which, after the passive folding edge 58 has been removed, is pushed in laterally and in the process folds the not yet folded second leg 64 onto the first leg 56 . In order to ensure that the two legs 56, 64 are securely and permanently glued together, the folder 66, on which the active folding edge 62 is formed, is actively pivoted in the direction of the legs about a pivot axis 67 in order to generate a contact pressure which is necessary for the gluing is beneficial.

As in 10 As can be seen, after the folding and gluing has been completed, the flat wire package is insulated on all sides on the circumference, which can be transferred as a package into the slots of the stator.

For the operation of inserting the packet into the slots of the stator, the known steps outlined above can be carried out.

As an additional measure to improve the course of the process, provision can be made for the insulation 14 to be provided with a pre-fold 68 at later kinks 70 of the legs 56, 64. The pre-fold 68 is in 11 shown schematically, in reality this is not formed as a notch as in 11 shown. The primary aim is to reduce the stiffness at the kinks by pre-folding, so that when the wires are inserted into the groove of the insertion tool, the insulation can follow the wires with less resistance and with.

As a possible exemplary embodiment of a device suitable for such a pre-folding, the transfer device 10 is designed with holding devices 12 (see FIG 13 ), which have a counter-punch 72 which is movable in a groove 74 against the load of a prestressed compression spring 76 inwards. The dimensions of the groove 74 essentially correspond to those of the grooves 22 of the insertion tool 20, but they can be made deeper. The insulation 14 removed from the magazine 16 is held in position in the holding device 12 by means of suction air in the manner already described.

At a Vorfaltstation 78 between the removal station from the magazine / the cutting before direction and the point of transfer to the holding station 18 of the insertion tool 20, a pre-folding die 80 is provided, the dimensions of which are adapted to the flat wires 28 to be transferred later into the grooves 18 of the insertion tool.

The process of pre-folding is in 14a until i.e 11, showing in longitudinal section a fixture 12 with insulation 14 in the prefolding station 78 position.

In this pre-folding station 78, the pre-folding stamp 80 first presses the insulation 14 into the groove 74, the counter-stamp 72 also being pressed into the groove against the increasing tension of the compression spring 76. Similar to the previously described process of inserting the flat wires 28 into the groove 22 of the insertion tool 20, the insulation 14 is now in the pre-folding step on the fold lines 51 between central sections 48 and lateral edges 50. Due to the deeper design of the groove 74 and a corresponding long stroke of the pre-folding stamp 80, there is no protrusion at the lateral edges 50 from the groove 74. (please refer 15b) .

When the pre-folding stamp 80 is pulled back out of the groove 74, the counter-stamp 72 then lifts the insulation 14 out of the groove 74 under the action of the relaxing compression spring 76, the kinks on the fold lines 51 initially remaining intact (see Fig 15c ).

In order to simplify further handling, the kinked edges can be flattened using hold-down devices 82, whereby this can be supported by the suction air or also be accomplished solely by the suction air (see Fig 15d ). Even when the edges 50 are laid flat again, the flexural rigidity in the folding lines remains reduced, so that the folding is repeated when the flat wires 28 are inserted into the groove 22 of the insertion tool 20 at the point defined by the pre-folding.

As already mentioned, when a pre-folding station 78 is formed on the transfer device 120, it makes sense to provide at least one additional holding device 12, so that the pre-folding of one piece of insulation takes place at the same time as another piece of insulation is picked up from the magazine and a third piece of insulation is transferred to the insertion tool can. As a result, the cycle time for the transfer remains the same despite the additional station. More stations are also possible over the circumference of the transfer device 10, e.g. B. four holding devices 12, with one device also being able to pass through a lee station (see 12 ).

The pre-folding does not necessarily have to take place during the recording in a holding device 18 of the transfer device, it can also be carried out before the magazine is fitted with the insulation 14 or during the cutting process when separating from an endless supply.

The invention is not limited to one of the embodiments described above, but can be modified in many ways.

All of the features and advantages resulting from the claims and the description, including structural details, spatial arrangements and method steps, can be essential to the invention both on their own and in the most varied of combinations.

Reference List

10

transfer device

12

holding device

14

insulation

16

magazine

18

holding station

20

retraction tool

22

Grooves in the pull-in tool

24

cylindrical outer surface

26

webs

28

flat wire

30

winding mat

32

Endless supply of insulating paper

34

insulating paper reel

36

cutting device

38

suction roll

40

suction channels

42

suction funnel

44

stop edge

46

Suction air ducts in the insertion tool

48

middle section (of insulation)

50

edges (of insulation)

51

fold lines (of insulation)

52

supernatants

54

Folding and gluing device

56

first leg (of insulation)

58

passive folding edge

59

channel

60

adhesive

61

Pivoting axis of the passive folding edge

62

active folding edge

64

second leg (of insulation)

66

butterfly

67

pivot axis of the folder

68

prefold

70

kinks in the thighs

72

countermark

74

groove

76

compression spring

78

prefolding station

80

prefold stamp

82

hold-down

QUOTES INCLUDED IN DESCRIPTION

This list of 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

• EP 3391512 A1 [0002]
• DE 102019003258 A1 [0003]
• DE 102008021779 B4 [0004]

Claims (10)

Method for introducing insulation (14) into the grooves (22) of an insertion tool (20), flat wires (28) of a preformed winding mat (30) being inserted into the grooves (22) and at least partially surrounded by the insulation (14). be, wherein the insulation (14) before being introduced into the grooves (22) are prefabricated, characterized in that the insulation (14) are removed from a supply and aligned, the insulation (14) then in a defined position at a transferred to the groove (22) of the insertion tool (20) assigned to them and held there in a predetermined position before the flat wires (28) are inserted into the grooves (22), the insulation (14) being inserted at least over a specific distance into the Grooves (22) are taken. procedure after claim 1 , characterized in that the insulations (14) are pre-folded at lines (15) to be folded during processing before insertion into the grooves (22) of the insertion tool (20). procedure after claim 2 , characterized in that the pre-folded areas (51) are used at least partially to align the insulation (14) when it is taken over from the supply and/or on the insertion tool (20). Method according to one of the preceding claims, characterized in that lateral projections (52) of the insulation (14) are successively folded inwards after the wires (28) have been drawn in, adhesive being introduced between the overlapping legs (56, 64) of the insulation and these are permanently connected to it. Method according to one of the preceding claims, characterized in that the insulation (14) is stored in a magazine (16) prefabricated in strip form. Procedure according to one of Claims 1 until 4 , characterized in that the insulation is pulled from a supply of tape (32) and cut to the desired width for pre-assembly before being transferred to the insertion tool (20). Device for inserting insulation (14) into the grooves (22) of a rotatably driven insertion tool (20), with an insertion device being provided for inserting flat wires (28) into the grooves (22) while taking the insulation (14) with it, characterized that a transfer device (10) is provided, which picks up the insulation (14) from a supply and transfers it to a holding station (18) on the insertion tool (20), which holds the insulation (14) in relation to a groove (22) in holds a defined position. device after claim 7 , characterized in that holding stations (18) are formed on all grooves (22) of the insertion tool (20). device after claim 7 or 8th , characterized in that the transfer device (10) has at least one holding device (18) which holds the insulation (14) taken from the supply in a defined position during transfer. Device according to one of Claims 7 until 9 , characterized in that a multi-part folding device and/or gluing device (54) is provided on the insertion tool (20), the folding and/or gluing device (54) being arranged in a stationary manner.

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