DE102022128250B3 - Manufacturing device and manufacturing method for an induction device - Google Patents

Abstract

The invention relates to a manufacturing device (200) for an induction device (300), in particular an induction device (300) for an electrodynamic brake (100), comprising a polarizable contact element (202), a polarizable counter-element (204), which is controlled by the contact element (202 ) is arranged spaced apart, and an electrical polarization device (206) which is designed to impose a magnetic polarity on the contact element (202) and the counter element (204). The contact element (202) and/or the counter-element (204) comprise at least one formation element (208) or is/are connectable to the at least one formation element (208), with guide elements (410) between the contact element (202) and the counter-element (204 ) can be arranged and can be aligned with the at least one formation element (208) by means of polarization of the contact element (202) and the counter-element (204). Furthermore, the invention includes an associated manufacturing method.

Description

The present invention relates to a manufacturing device for an induction device and a manufacturing method for such an induction device, in particular an induction device for an electrodynamic brake (eddy current brake).

Eddy current brakes are known in the prior art. For example, disclosed DE 950 939 B an eddy current brake, in which the pole cores of the inductor are arranged on both sides of an armature that is movable relative to the inductor, which consists of one or more bodies that form the eddy current path and are electrically highly conductive and of the magnetic flux that conduct well, through the first-mentioned body or bodies There are parts extending through the body, the parts carrying the magnetic flux protruding on both sides beyond the body or bodies that form the eddy current path, so that the ends of these parts form projections that improve the cooling of the armature.

From the US 4,704,789 A discloses a method for producing electromagnetic elements and in particular a method for producing electromagnetic elements with the properties of magnetic anisotropy and electrical conductivity.

The EP 3 192 084 B1 describes a flexible soft magnetic core comprising a ferromagnetic material arranged to form parallel magnetic paths within a core body consisting of a hardened polymer medium.

The US 3,221,196 A discloses a rotor for an electrical machine, the rotor having a metallic disk comprising an electrically conductive but non-magnetic material.

A well-known problem with eddy current brakes is that a large amount of heat is generated at the same time as the high power density. This heat generated in the material in which the eddy currents are induced must be dissipated via the outer surfaces of the material, so that there is a risk of overheating. Furthermore, as a result of the skin effect, there is the problem that all of the heat occurs in a layer with a very shallow depth in the material, namely within the skin depth. During eddy current induction, there are strong temperature gradients in the material, which put a lot of strain on the material and can possibly destroy it, particularly through the formation of cracks.

From the DE 10 2016 108 646 A1 an electrodynamic brake with a magnetic device for providing a magnetic field is known, which has at least two pole elements and which interacts with an induction device. The induction device is arranged in such a way that in a braking mode it is at least partially exposed to a magnetic field provided via the pole elements of the magnetic device and is designed in such a way that electrical currents are induced in it in a variable magnetic field, the induction device and the pole elements of the magnet device being along a predetermined trajectory can be moved relative to each other.

For the production of such induction devices and in particular the placement of the individual components such as the pins or guide elements, robots, for example pick-and-place robots, articulated arm robots, SCARA robots (“Selective Compliance Assembly Robot Arm”) or delta robots (parallel arm robots), can be used become. These robots are suitable for placing the individual components with precise position and orientation.

Nevertheless, the large number of components to be placed, and in particular the high number of pins or guide elements for such an induction device, requires complex manufacturing processes and long manufacturing times. At the same time, the parallel use of several robots (arms) leads to a reduction in production times, but requires considerable costs.

It is the object of the present invention to propose an improved manufacturing device for an induction device and an electrodynamic brake as well as an improved, in particular time and cost-optimized, manufacturing process.

This object is achieved according to the invention by a manufacturing device according to the features of claim 1 and by a manufacturing method according to the features of claim 9. Advantageous refinements are specified in the respective, associated subclaims.

• - mindestens ein polarisierbares Kontaktelement,
• - mindestens ein polarisierbares Gegenelement, das von dem mindestens einen Kontaktelement beabstandet angeordnet ist,
• - mindestens eine elektrische Polarisationseinrichtung, die ausgebildet ist, um dem Kontaktelement und dem Gegenelement jeweils eine magnetische Polarität aufzuprägen bzw. zu verleihen.

The invention relates to a manufacturing device for an induction device, in particular an induction device for an electrodynamic brake, or a so-called eddy current brake. The manufacturing device includes the following:

• - at least one polarizable contact element,
• - at least one polarizable counter element, which is arranged at a distance from the at least one contact element,
• - At least one electrical polarization device, which is designed to imprint or impart a magnetic polarity to the contact element and the counter element.

Here, the contact element and/or the counter-element comprises at least one formation element or can be connected to the at least one formation element, wherein a plurality of guide elements can be arranged between the contact element and the counter-element and by means of polarization of the contact element and the counter-element, in particular based on a reluctance force or Maxwell's force , to which at least one formation element can be aligned.

The invention is based on the idea of aligning a large number of guide elements specifically to a formation element, i.e. in particular according to the design of the formation element, by means of a (specific) magnetic field in order to simplify the production of an induction device.

The design of the formation element allows the resulting magnetic field to be shaped, which can be generated by means of the polarization device between the contact element and the counter element.

The guide elements can align or sort themselves within the magnetic field, following the reluctance force or Maxwell's force, relative to the formation element, and also relative to each other, so that a predetermined arrangement of the guide elements can be established.

In particular, it is provided that the guide elements have a magnetically conductive material.

The guide elements could, for example, be designed as at least one pin each, so that an induction device can be formed by means of the guide elements/pins.

The at least one polarization device comprises, for example, one or more current-carrying coils, by means of which a (constant) magnetic field and corresponding magnetic field lines can be formed in the supporting structure of the manufacturing device and in particular in the contact element and the counter-element, so that the contact element and the counter-element are in contact with each other of different polarity, especially along a common longitudinal axis.

Here, the contact and the counter element can be designed to be polarizable by a common polarization device, which can also be a group of interacting polarization devices, such as a group of current-carrying coils.

Alternatively, the contact and counter elements can each be independently connected to their own polarization device, one of which can also be a permanent magnet. In particular, at least the contact element or at least the counter-element can be provided as a permanent magnet.

The contact and counter elements can be arranged on a common support and guide frame, with an advantage being that the polarization device is arranged entirely or partially on the support and guide frame in such a way that the magnetic field lines that form are in at least part of the support - and guide frames are formed.

In an alternative embodiment, it can be provided that at least one polarization device is formed on or in the contact and/or counter element.

Advantageously, the at least one polarization device can be used to form a magnetic field with corresponding magnetic field lines which lead in a common direction from the contact element via the at least one formation element to the counter element.

Preferably, the contact element and the counter-element can each have a formation element or can each be connected to a formation element.

In a further improved embodiment, the formation element and/or the counter element or the contact element has independently polarizable segments or sections. These are in particular connected to independently switchable polarization devices. In this way it can be provided that a magnetic field is formed only in the segment or sections of the formation element and/or the counter element or the contact element. In this way, the feeding and removal of workpieces can be made easier and energy can also be saved.

In order to be able to align workpieces with different axial extents, an advantage can be if the contact and counter elements are mounted so that their distance from one another can be changed. Furthermore, there can be an advantage in that To facilitate the delivery and removal of workpieces if the contact and / or the counter element is/are arranged to be movable or pivotable, in particular are mounted to be pivotable or movable perpendicular to the common longitudinal axis.

Overall, there can be an advantage if the guide fingers are easily interchangeable depending on a device to be manufactured, such as an induction device, and in particular can be changed without tools. Therefore, there may be an advantage if the contact and/or counter element can be connected to the formation element and in particular its base body in a clamping or locking manner.

The structure of the contact or counter element and the (respective) formation element is not to be seen as restrictive; the contact or counter element and the formation element can also be designed in one piece, i.e. monolithically, in that they are made in one piece and cannot be detached from one another in a non-destructive manner .

Particularly in the case of very large formation elements that are required for the production of very large devices, such as large induction devices, it can be advantageous if the formation element is designed to be segmentable, in particular if it is formed from at least two or more ring or circle segments.

In an improved embodiment, it can be provided that the at least one formation element has a base body with a plurality of guide fingers, the guide fingers of the contact element and/or the counter element preferably being aligned parallel to one another. This results in particularly stable magnetic field lines being formed.

If several electrically conductive guide elements, such as pins, bolts or cylinders, are arranged between the two base bodies and their guide fingers, these guide elements will each align concentrically with the guide fingers and the magnetic field lines guided over them.

Ideally, the guide fingers are dimensioned and arranged in a distribution grid such that the diameter of the guide fingers is equal to or smaller than the (average) diameter of a guide element and the distances between two guide fingers are greater than the (average) radius of a guide element. In this way it is ensured that a guide element is always arranged between exactly one pair of guide fingers and that the reluctance force can act through this.

Also for the formation of stable, low-interference, magnetic field lines, an advantage can be that in an improved embodiment it can be provided that each guide finger of the contact element (exactly) has a guide finger of the counter element arranged axially aligned opposite or opposite.

In particular, the shadow surfaces of the two opposing base bodies and the respective guide fingers, which are imaged on one another, can be congruent, so that each guide finger has exactly one guide finger opposite it at the same axial distance.

In this way, particularly powerful and clearly defined magnetic field lines are formed, which exert a high reluctance force perpendicular to the field line on a guide element arranged there and align it with the guide fingers.

In an improved embodiment, it can be provided that the diameter of the individual guide fingers is equal to or smaller than the diameter of a guide element to be aligned, in particular is 5% to 20% smaller. Overall, it is advantageous if the diameter of the Leifingers is chosen to be as small as possible.

In an improved embodiment it can be provided that the guide fingers on the base body have two position patterns, a basic shape as the main geometry and a distribution grid.

Here, the basic shape on the base body can be, for example, a circle, a ring or a segment thereof formed in the radial direction or in the circumferential direction. The basic shape results from all the guide fingers as the overarching main geometry or on which the guide fingers are arranged as a base surface. The basic form is the frame and is not to be understood in the strict, mathematical sense.

The distribution grid is to be understood as the arrangement of the guide fingers relative to one another on or within the basic structure. For example, cylindrical guide fingers can be arranged in concentric circles, in a beam-like manner or in other, in particular similar patterns, on, for example, a ring-shaped or circular basic shape of the base body.

• - in einer Gleichverteilung der Leitfinger in oder auf der Grundform und/oder
• - in einer Gruppenverteilung von Leitfingern, die in der Grundform vorliegt.

It can be provided that the distribution grid can consist of the following:

• - in a uniform distribution of the guide fingers in or on the basic shape and/or
• - in a group distribution of guide fingers, which is present in the basic form.

The group distribution of guide fingers is that a plurality of guide fingers form a guide finger group, which have their own group geometry. The shadow or base area of this group geometry can be, for example, a circle or a polygonal structure. The shadow or basic structure is not to be defined in the strict mathematical sense because it results from the shadow areas or the cross-sectional areas of the majority of the guide fingers. It has proven to be particularly advantageous to design the group geometry in the form of a hexagonal group geometry. Overall, however, another group geometry can also be provided, such as a triangular, square or other polygonal structure.

A guide finger group has a group distance from one or more adjacent guide finger groups of the same base body, in particular an average group distance, which is significantly larger than the guide finger distance of two guide fingers of the same guide finger group.

In particular, the ratio of the guide finger distance in the guide finger group to the group distance is 0.4 to 0.04, in particular the average guide finger distances and/or the average group distances being taken as a basis in this case. In this case, only complete guide finger groups, i.e. guide finger groups of the same size, are advantageously provided. Area areas of the basic shape in which a complete guide finger group cannot be arranged are therefore excluded for the aforementioned averaging.

Due to the sometimes very small, delicate structure of the guide fingers, it can be advantageous if, in an improved embodiment, it is provided that at least some of the guide fingers are or can be provided by an additive manufacturing process, in particular on the base body or a segment of the base body is or can be provided by a constructive, additive manufacturing process.

It is possible that the base body is or is or can be provided by an additive process.

In order to be able to introduce a large number of guide elements into the manufacturing device and to align them effectively with one another, in an improved embodiment it can be provided that a carrier plate made of a magnetically non-conductive material is arranged on the contact element. When the manufacturing device is used as intended, the workpieces can be placed on this carrier plate and can subsequently be moved with one end sliding on the carrier plate by the activated polarization device and in accordance with the magnetic field lines that form over the at least one formation element or its guide finger.

The carrier plate can serve to set up the workpieces outside the manufacturing device according to the invention and, if necessary, to group them roughly (pre-formation). Alternatively, the carrier plate rests on the formation element or the guide fingers of the contact element and guide elements are set up there in a suitable manner and grouped or pre-sorted before the final alignment takes place with the help of the polarization device.

In particular, the pre-positioning or pre-grouping and pre-alignment of the guide elements can be simplified by a shaking mechanism or the like

The carrier plate is ideally a plate made of aluminum or a conductive plastic or a conductive carbon material. The carrier plate itself is in particular non-magnetic or non-magnetizable and is not made of a ferritic material.

As already mentioned above, in an improved embodiment it can be provided that the contact element and the counter-element are movable relative to one another, in particular in the direction of a (common) longitudinal axis of the contact element and the counter-element. In order to enable a quiet and stable change in position, the contact and/or the counter element are mounted so that they can be moved in a linear or translational manner.

Although the contact element is described herein as a carrier for the carrier plate and the counter-element remains spaced from the free ends of the workpieces when the workpieces are set up, this is not to be understood as restrictive and serves primarily for explanation. Analogously, the counter element could carry or hold the carrier plate and the contact element could be spaced in an analogous manner.

Even if a support plate is described here, on which guide elements are placed and freely moved in two directions under the influence of field lines, this is not to be understood as restrictive. The carrier plate could also have guide geometries such as grooves and grooves, in particular circumferential grooves or grooves in which a plurality of guide elements are moved under the influence of magnetic field lines and are aligned to one another in an analogous manner via the position of the guide fingers.

Particularly with such guidance in grooves or grooves, the contact and counter elements can also be aligned horizontally.

To further increase the performance of the manufacturing device, an improvement can be that it includes a feed device for guide elements or can be connected to it.

The feeding device can be a sorting and/or introduction device, in particular comprising a robot with a gripping or suction hand in order to place the plurality of guide elements in particular on the contact element and/or the carrier plate. In particular, the sorting and introduction device can comprise an alignment station which is constructed analogously to the aforementioned manufacturing device, but which in particular has no guide fingers. In this alignment station, a number of guide elements are aligned parallel to one another in a magnetic field without a defined distance from one another.

Another advantage can be if a position sensor is provided. By means of the position sensor, which can in particular be an optical or acoustic position sensor, the completeness can be checked before and/or after aligning the workpieces.

The position sensor can in particular be an ultrasonic sensor, a laser sensor or a camera. It can also be advantageous if an actuator is provided, such as a robot or a robot arm, which has a gripping element, in particular a suction gripping element, by means of which misplaced workpieces can be removed individually and/or individually onto the contact element and/or the carrier plate can be set up.

Furthermore, it is advantageous if a transfer device is provided, by means of which at least one support element can be lowered over the aligned guide elements, in particular can be lowered over all guide elements at the same time.

With this manufacturing device and the method described below, a large number of magnetically conductive guide elements, in particular pins or similar simple shapes, can be positioned simultaneously and precisely.

This shortens the manufacturing process and consequently reduces manufacturing costs. Furthermore, the IT effort, such as programming and automation effort, is significantly reduced.

• - Bereitstellen mindestens eines Stützelementes mit einer Vielzahl von Öffnungen in einem vorgebbaren Verteilungsraster,
• - Einführen von Leitelementen in die Öffnungen des Stützelementes,

wobei in einem Justierschritt, insbesondere vor der Einführung der Leitelemente in die Öffnungen des mindestens einen Stützelementes, mindestens eine Teilanzahl von Leitelementen mittels einer Magnetkraft, insbesondere einer Reluktanzkraft (Maxwellscher Kraft), auf das Verteilungsraster der Öffnungen des Stützelementes, und vorzugsweise parallel zueinander, ausgerichtet werden. The invention further includes a manufacturing method for manufacturing an induction device for an electrodynamic brake, in particular using a manufacturing device (200) according to one of the preceding claims. This has the following steps:

• - Providing at least one support element with a large number of openings in a predeterminable distribution grid,
• - Insertion of guide elements into the openings of the support element,

wherein in an adjustment step, in particular before the introduction of the guide elements into the openings of the at least one support element, at least a partial number of guide elements are aligned by means of a magnetic force, in particular a reluctance force (Maxwell force), to the distribution grid of the openings of the support element, and preferably parallel to one another become.

All aspects and advantages mentioned above for the manufacturing device apply in an analogous manner to the manufacturing process and vice versa.

Here, the hole pattern of the at least one support element essentially corresponds to the distribution grid of the design of the at least one formation element or the guide fingers and is arranged in a substantially identical basic shape.

In an improved method, it can be provided that before the adjustment step, the workpieces are aligned parallel to one another and placed on a support plate (upright) in the longitudinal direction, in particular in a pre-formation (upright).

Here, the step of pre-formation, for example by a feed device, can consist of setting up workpieces without approaching the distribution grid, or have an arrangement that corresponds to the desired distribution grid or the respective final end position with a tolerance of +/- 15%, in particular + /- 10% corresponds.

The pre-formation can continue to be carried out step by step by placing smaller groups of workpieces one after the other on the contact element and/or a carrier plate. In particular, the number of individual workpieces in a work group of pieces can be placed sequentially by the feed device in the area of the associated guide finger group.

An improvement can consist in placing the workpieces from the feed device onto the contact element or the carrier plate while the polarization device induces a magnetic field at least in a partial area of the contact element and/or the counter element.

It can be particularly advantageous if the guide elements are aligned with a manufacturing device according to one of the above embodiments or variants.

One advantage can be if the guide elements are aligned on a carrier plate arranged on the contact element of the manufacturing device, in particular under the parallel action of a magnetic or reluctance force.

In a further improved method variant, it can be provided that at least one support element having a distribution grid (hole pattern) is brought in and lowered vertically over at least a subset of the guide elements in order to insert the guide elements, while the subset of the guide elements is arranged aligned on the contact element of the manufacturing device, in particular two or more support elements are brought up and lowered vertically over at least a portion of the guide elements, while the portion of the guide elements are arranged aligned on the contact element.

Here, the support elements are brought up one after the other and in particular the support elements are lowered or pushed along over all guide elements at the same time, up to the respective, defined end position and the TARGET distance,

This method variant can be further improved by aligning the workpieces at least temporarily by means of a magnetic force, in particular by means of a magnetic flux or under an (active) magnetic flux, while the at least one support element is brought up and/or vertically over at least the partial number of guide elements is lowered.

• - dieses mindestens eine Stützelement auf der Trägerplatte und/oder der jeweiligen Leitfingergruppe des Kontaktelements auf- oder angelegt wird,
• - nachfolgend die jeweiligen Leitelemente mittels einer Zuführeinrichtung und/oder eines Greifers in die Öffnung des Stützelementes gestellt wird/werden und
• - nachfolgend oder parallel diese jeweiligen Leitelemente mittels des Magnetfeldes ausgerichtet wird und dann
• - das mindestens eine Stützelement auf eine definierte Position in Richtung der Längsachsen der Leitelemente verschoben oder angehoben wird.

It can also be advantageous if, in the case of attaching guide elements or groups of guide elements in at least one support element,

• - this at least one support element is placed or placed on the carrier plate and/or the respective guide finger group of the contact element,
• - subsequently the respective guide elements are/are placed into the opening of the support element by means of a feed device and/or a gripper and
• - Subsequently or in parallel, these respective guide elements are aligned using the magnetic field and then
• - The at least one support element is moved or raised to a defined position in the direction of the longitudinal axes of the guide elements.

Here, the active magnetic flux means that the polarization device is activated in parallel and impresses a magnetic field and corresponding magnetic field lines over the base body or their guide fingers.

For parallel or final inspection, it can be advantageous if at least one optical inspection of the preformed and/or the guide elements aligned in the adjustment step is carried out, in particular before the first support element is brought up, lowered and/or brought into the respective final position.

Advantageously, an actuator is provided, such as a robot or a robot arm, which has a gripping element, in particular a suction gripping element, by means of which a redundant, misplaced or misaligned guide element can be removed individually and / or a guide element individually onto the contact element, into the opening at least one support element and / or can be placed on or in the support plate.

This gripper can advantageously be a suction gripper, which in particular has a deformable suction tip. The advantage of such a suction gripper is that it does not require any additional lateral movement space for gripping elements and it can be placed on any surface section of the guide element.

“In one piece” preferably means that the element described thereby forms a single element, in particular one that can be handled separately, and that individual components of it cannot be separated without the element being destroyed in the process. Preferably, individual components of the element described as “one-piece” are cohesively connected to one another.

Although the term “guide element” is used here, what is meant in particular are pins, rods or pin-like workpieces that have an elongated extension, i.e. whose ratio of diameter to length is less than 1/5, for example less than 1/10, in particular less than 1/15. This Individual workpieces can in particular have a cylindrical shape or a polygonal structure, with a hexagonal shape being particularly advantageous.

In an advantageous method it is provided that guide elements with a diameter of less than 5 mm, advantageously less than 2.5 mm and in particular for workpieces with diameters of less than 1.5 mm are aligned and fixed in at least one support element.

In a further improved method it is provided that the guide elements are/are fixed by at least one support element in at least one fixing step in at least one opening, in particular all openings.

• - einen Gießschritt aufweisen, in welchem die Leitelemente mit einem Gießmaterial umgossen, übergossen und/oder getaucht werden, und
• - einen Aushärtungsschritt, bei welchem das Gießmaterial mindestens im Bereich der Öffnungen aushärtet.

The fixing step can in particular

• - have a casting step in which the guide elements are cast, poured over and/or dipped with a casting material, and
• - a curing step in which the casting material hardens at least in the area of the openings.

Advantageously, it can be provided that the guide elements are changed in position together with the support elements after a first fixing step and primarily after the first curing step, in particular rotated through 180 °.

It can be advantageous if a pre-fixing step takes place before the at least one fixing step, in particular a pre-fixing step with a detachable or removable fixing agent.

In the pre-fixing step, the workpieces can be held in their position in the openings of the support element using a directly adhesive pre-fixing agent, such as an adhesive film or a deformable image mass. They can subsequently be removed together, guide elements and support elements, from the contact element and further processed outside the polarization device, in particular subjected to the fixing step.

Alternatively, the prefixing agent is a very fast-curing, flowable adhesive, such as a hot glue or a UV-curable adhesive. This can be completely or partially removed mechanically, chemically or physically before or after the fixation step.

A further improved method variant can consist in the fact that the polarizing connection or deactivation of segments or sections of the contact element and/or the counter-element as well as the associated formation elements or base body and/or guide fingers or guide finger groups ensures the uniform distribution of workpieces during feeding is controlled.

In particular, it can be advantageous if guide fingers and/or guide finger groups are switched on in rows, rings and/or segments, so that newly supplied guide elements are always arranged in the next TARGET position and these are not magnetically fixed too early on the feed path become. This early fixation with a view from the direction of a feed route or feed source would lead to unoccupied TARGET positions that would have to be filled individually.

It can also be advantageous if the pre-fixing agent remains on the support element and/or the guide elements during the fixing step and serves as a sealing material or sealing layer for the casting material.

Further details and advantages of the invention will now be explained in more detail using exemplary embodiments shown in the drawings.

• 1 die Herstellungsvorrichtung in einer schematischen Darstellung als ein erstes Ausführungsbeispiel;
• 2 ein zur 1 alternatives Ausführungsbeispiel;
• 3 eine Detailansicht der beiden Ausführungsbeispiele nach 1 und 2;
• 4 eine mittels der Herstellungsvorrichtung (teil-)gefertigte Induktionseinrichtung in einem ersten Ausführungsbeispiel und
• 5 eine zur 4 alternative Ausführungsform einer Induktionseinrichtung.

Show it:

• 1 the manufacturing device in a schematic representation as a first exemplary embodiment;
• 2 one to 1 alternative embodiment;
• 3 a detailed view of the two exemplary embodiments 1 and 2 ;
• 4 an induction device (partially) manufactured by means of the manufacturing device in a first exemplary embodiment and
• 5 one for 4 alternative embodiment of an induction device.

Due to the selected exemplary embodiments, we will no longer speak (exclusively) of guide elements, but rather of pins and pin groups in particular for better understanding. This choice of terminology should not be understood as a limitation for the exemplary embodiments shown and described.

In the 1 the manufacturing device 200 is shown for an induction device 300, not shown, wherein the manufacturing device 200 has one Support and guide frame 220 has a polarization device 206 and a contact element 202 as a lower pole plate (north pole) and an oppositely arranged counter element 204 as an upper pole plate (south pole).

The contact element 202 and the counter element 204 can be formed in one piece from a base body 210 with guide fingers 212 each projecting perpendicularly on the base body 210 in the direction of the longitudinal axis 224.

On the guide fingers 212 of the contact element 202 is according to 1 a support plate 218 is provided on which three pins 410 are placed.

The longitudinal axes of the pins 410 are aligned parallel to one another and to the longitudinal axis 224.

The polarization device 206 is in the present case designed as a current-carrying coil and wraps around a section of the support and guide frame 220.

Here, field lines 230 are formed in the support and guide frame 230 in the manner shown, which run from top to bottom in the polarization device 206 and lead from the contact element 202 (north pole) through the pins 410 into the counter element 204 (south pole).

The field lines 230 are guided and centered by aligned, opposite guide fingers 212 of the contact element 202 and the counter element 204.

The guide elements or pins 410, which can be moved transversely thereto, align themselves with the guide fingers 212 under the magnetic force or magnetic reluctance force.

Thus, the distribution grid of the guide fingers 212 can be used to generate an identical distribution grid in a group of guide elements or pins 410 of virtually any size.

This alignment step of the pins 410 after the generation of the magnetic field via the contact element 202 and the counter element 204 requires (usually) significantly less than a second, depending on the longest movement distance of the pin 410 on the carrier plate 218, which is furthest away from the associated guide finger 212.

The embodiment of the manufacturing device 200 according to 2 is comparable to the following 1 .

It differs from the execution according to the 1 among other things, in that the contact element 202 and the counter element 204 are connected to the respective base body 210 via (tool-free) fastening means 226, which according to 2 are designed as clamp elements.

Furthermore, the counter element 204 can be moved linearly in the vertical direction 238, so that the distance between the counter element 202 and the contact element 202 can be varied. The contact element 202 can be pivoted horizontally about a vertical axis 236 with the lower branch of the support and guide frame 220.

On the support element 228 of the manufacturing device 200, a feed device 216 designed as a one-arm robot is arranged, which has a gripper unit 234 on the robot arm, which is designed as a flat suction gripper and is connected to a central control unit 232.

Furthermore, according to 2 a position sensor 222 is provided, which is also connected to the control unit 232.

By means of the gripper unit 234, groups of individual pins 410 can be moved relative to the contact element 202 and the carrier plate 218 placed there.

Since the gripper unit 224 can be designed as a flat suction element, transverse forces on the conductor elements or pins 410 are largely avoided. With the same gripper unit 224, a support element 400 can be brought up and placed on the aligned pins 410 or groups of pins or guided over them.

3 shows a detailed view of the contact element 202 and the counter-element 204 analogous to 2 .

The contact element 202 and the counter element 204 are releasably screwed to a base body 210.

The guide fingers 410 may have a diameter of 3 mm and are distributed within a main geometry 424 in uniform rows 440 and columns 442, as shown in FIG 4 is shown in detail.

The guide fingers 410 are opposite each other on the same axis and the pins 410 arranged on the carrier plate 218 are shown in the position already aligned with the field lines, so that the opening axis 404, the longitudinal axis of the Pins 410 and the longitudinal axes of the guide fingers 212 are aligned congruently.

The induction device 300 to be manufactured is shown in early, incomplete production stages; the necessary support elements 400 are shown in the illustration 3 not yet set up or created.

In the 4 is the one for 3 analog induction device 300 for an electrodynamic brake 100 shown.

It has seven horizontal support elements 400, with a large number of openings 402.

A cylindrical pin 410 is set in each opening 402.

The guide elements or pins 410 penetrate all seven support elements 400 and their longitudinal axes are congruent with the respective opening axis 404 of an opening.

A wall element 418, shown in simplified form, is arranged inside and outside of the induction device 300, which delimits the induction device 300 on both sides of the narrow sides.

According to the exemplary embodiment shown, the diameter 442 of the pins 410 can be in 4 be 3 mm.

The guide elements or pins 410 are arranged in rows 440 and columns 442 running at an angle thereto, the pins 410 of two parallel rows 440 being able to stand at a gap from one another.

In the 5 is one for 4 different arrangement of the pins 410 shown.

The guide elements or pins 410 are arranged as pin groups 416 within the annular main geometry 424 in a hexagonal distribution grid, with the openings 402 being designed as uniform, hexagonal geometries.

The hexagonal basic structure of the openings 402 is shown in detail as an example of an opening 402. The large number of hexagonal openings 402 results in a honeycomb-like grid of the webs 406. A pin group 416 is arranged in each opening 402 and is aligned with the opening axis 404.

According to the example shown, the narrow width of the opening may be 6.3 mm and thus may have an opening area of 31.17 mm ² .

In the example shown, a pin group 416 includes the 4 a total of 37 individual guide elements or pins 410, which can each have a pin width 422 or an exemplary diameter of 1 mm and can therefore, in total, cover an area in the opening of 29.06 mm ² .

Furthermore, the web width 408 outside the node surfaces can be 1.38 mm.

A theoretical occupancy area of 38.37 mm ² can result, which is calculated from the aforementioned opening area plus half the web area around the respective opening 402.

Starting from the in 5 In the example shown, an exemplary occupancy level of 0.964 pins per mm ² surface of the support element 400 can result.

Overall, an occupancy level of up to 0.98 can be achieved if the web width 408 is further reduced.

Furthermore, despite the high level of occupancy, a sufficient web width 408 can be ensured.

Sufficient heat dissipation via support elements 400 can be ensured during operation of the induction device 300.

The support element 400 can, for example, have a material thickness 428 of 4 mm and have a material such as aluminum.

Between the two casting materials or casting elements or casting resins 426 can be made according to 5 a plurality of support elements 400 may be arranged. These support elements 400 can be placed at the desired positions by the feed device 216.

Furthermore, at least one cover element or cover plate 450 can be provided or arranged, which is preferably provided in a region of a longitudinal end of the plurality of guide elements 410.

The support elements 400 form an open, flow-through structure, in the form of gaps 412 which form or represent the flow channels 436 for a flowing coolant between the individual pin groups 416 and the support elements 400.

Furthermore, it is possible to arrange 400 additional spacers between the support elements, so that a minimum distance between the support elements is ensured.

In particular, silicone or plastic rings or the like can be placed/arranged as spacers around a plurality of guide elements or pins 410 or groups of pins, on which a subsequent support element 400 rests or rests.

Advantageously, an open, flow-through structure can be formed by means of the support elements 400.

• - vor dem Absenken des ersten Stützelements 400 über die ausgerichteten Stiftgruppen 416 auf das abzusenkende Stützelement 400 aufgesetzt und mit dem Stützelement 400 gemeinsam aufrecht stehend abgesenkt,
• - nach dem Absenken des ersten Stützelements 400 und vor dem Absenken des nachfolgenden Stützelementes 400 zwischen die Stiftgruppen 416 und auf die Stege 406 oder Stegknoten 434 aufgesetzt und/oder
• - an das nachfolgende Stützelement 400 angeheftet, das dann nachfolgend mit den hängenden Stützelementen 400 über die bereits ausgerichteten Stiftgruppen 416 abgesenkt wird.

The support elements 400 are advantageously used when assembling the induction device 300

• - before lowering the first support element 400, it is placed on the support element 400 to be lowered via the aligned pin groups 416 and lowered together with the support element 400 in an upright position,
• - after lowering the first support element 400 and before lowering the subsequent support element 400 between the pin groups 416 and placed on the webs 406 or web nodes 434 and/or
• - attached to the subsequent support element 400, which is then subsequently lowered with the hanging support elements 400 over the already aligned pin groups 416.

Overall, it is understood that the information relative to gravity, such as "up", "down", "lower", "touch down", "upright", "hanging" etc. is only for illustrative purposes and to describe the elements shown in a specific position serve. This information is not to be understood as limiting with regard to the orientation of the induction device in use or during assembly and arises in an analogous manner with a different orientation, such as a vertical orientation of the induction device.

The two examples of 3 and 4 show that inserting or otherwise mechanically aligning the pins 410 would require many times the time and/or control effort compared to the adjustment via the polarized guide fingers, which are already arranged in the desired distribution grid.

In summary, the present invention represents an efficient and precise way to produce an induction device 300 with a large number of guide elements 410.

Reference symbol list

100

brake

200

Manufacturing device

202

Contact element

204

Counter element

206

Polarization device

208

Formation element

210

Base body

212

Guide finger

214

Diameter (guide finger)

216

Feeding device

218

carrier plate

220

Support and guide frame

222

Position sensor

224

Longitudinal axis

226

Fasteners

228

Support frame (from 200, 216)

230

field line

232

Control/control unit

234

Gripper unit

236

axis

238

(vertical) travel direction

300

Induction device

400

Support element

402

opening

404

Opening axis

406

web

408

Bridge width

410

Guiding element

412

space

416

Leader group (leader cluster)

418

Wall element

420

Width

422

Guide element width (diameter)

424

Main geometry

426

Cast resin

428

Material thickness

432

Spacers

434

Bridge knot

436

Flow channels

440

Row

442

Split

450

Cover element/cover plate

Claims (15)

Manufacturing device (200) for an induction device (300), in particular an induction device (300) for an electrodynamic brake (100), comprising - at least one polarizable contact element (202) - at least one polarizable counter element (204), which is arranged at a distance from the at least one contact element (202), - at least one electrical polarization device (206), which is designed to impose a magnetic polarity on the contact element (202) and the counter-element (204), the contact element (202) and/or the counter-element (204) comprising at least one formation element (208). or can be connected to the at least one formation element (208), wherein a plurality of guide elements (410) can be arranged between the contact element (202) and the counter-element (204) and by means of polarization of the contact element (202) and the counter-element (204). the at least one formation element (208) can be aligned. Manufacturing device (200). Claim 1 , characterized in that the at least one formation element (208) has a base body (210) with a plurality of guide fingers (212), the guide fingers (212) of the contact element (202) and / or the counter element (204) preferably being aligned parallel to one another are. Manufacturing device (200). Claim 2 , characterized in that a guide finger (212) of the counter element (204) is arranged axially aligned opposite each guide finger (212) of the contact element (202). Manufacturing device (200). Claim 2 or 3 , characterized in that the diameter (214) of the individual guide fingers (212) is equal to or smaller than the diameter (418) of a guide element (410) to be aligned, in particular is 5% to 20% smaller. Manufacturing device (200) according to one of Claims 2 until 4 , characterized in that the guide fingers (212) have two position patterns: - a basic shape and - a distribution grid, which represents the distribution or arrangement of the guide fingers relative to one another in the basic shape. Manufacturing device (200) according to one of Claims 2 until 5 , characterized in that at least part of the guide fingers (212) is manufactured by a constructive, additive manufacturing process, in particular on the base body (208) is manufactured by a structural, additive manufacturing process. Manufacturing device (200) according to one of the preceding claims, characterized in that a carrier plate (218) made of a magnetically non-conductive material is arranged on the contact element (202), in particular a carrier plate made of a current-conducting material. Manufacturing device (200) according to one of the preceding claims, characterized in that the contact element (202) and the counter-element (204) are movable relative to one another, in particular in the direction of a longitudinal axis (224) of the contact element (202) and the counter-element (204). Manufacturing method for manufacturing an induction device (300) for an electrodynamic brake (100), in particular using a manufacturing device (200) according to one of the preceding claims, comprising the steps: - Providing at least one support element (400) with a plurality of openings (402) in a predeterminable distribution grid, - introducing guide elements (410) into the openings (402) of the support element (400), characterized in that in an adjustment step, in particular before the introduction of the guide elements (410) into the openings (402) of the at least one Support element (400), at least a partial number of guide elements (410) are aligned by means of a magnetic force on the distribution grid of the openings (402) of the support element (400), so that each opening (402) of the support element (400) is assigned at least one guide element (410). is. Manufacturing process Claim 9 , characterized in that before the adjustment step, the guide elements (410) are aligned parallel to one another and set up on a support plate (218) in the longitudinal direction, in particular set up in a pre-formation. Manufacturing process Claim 9 or 10 , characterized in that the guide elements (410) are aligned on a carrier plate (408) arranged on the contact element (202) of the manufacturing device (200). Manufacturing process according to one of the Claims 9 until 11 , characterized in that at least one support element (400) having a distribution grid is brought up and lowered vertically over at least a portion of the guide elements (410) in order to insert the guide elements (410), while the portion of the guide elements (410) is on the contact element (202) the manufacturing device (200) is arranged aligned, in particular two or more support elements (400) are brought up and lowered vertically over at least a portion of the guide elements (410), while the portion of the guide elements (410) are arranged aligned on the contact element (202). Manufacturing process according to one of the Claims 9 until 12 , characterized in that the guide elements (410) are aligned at least temporarily by means of a magnetic force, in particular a magnetic flux, while the at least one support element (400) is brought up and / or lowered vertically over at least the partial number of guide elements (410). Manufacturing process according to one of the Claims 9 until 13 , characterized in that the guide elements (410) are fixed in at least one fixing step in at least one opening (402), in particular all openings (402), by at least one support element (400). Manufacturing process Claim 14 , characterized in that a pre-fixing step takes place before the at least one fixing step, in particular a pre-fixing step with a detachable or removable pre-fixing agent.

Images