DE102022130543A1 - Method for replacing conductors in the production of a flat wave winding - Google Patents

Abstract

A method is used to exchange conductors in the production of a flat wave winding (10) from at least two wires (14 a to d), which are fed to a flat winding template (18) by means of a wire feeder (16), the wires (14 a to d) in the direction of the longitudinal extent of the template (18) laterally displaced relative to the supplied wires and gradually transformed into the wave winding (10) by rotating the template (18) to form roof-shaped winding heads (12) and an exchange of wires in is carried out during the winding process. In order to be able to integrate the conductor exchange into the process in a process-reliable manner, it is proposed that the wires (14 a to d) in the wire feed be guided in individual wire guides (22 a to d), with at least one individual wire guide (22 a) intended for the wire exchange being included in each case the guided wire (14 a) is lifted out of the plane of the other individual wire guides (22 b to d) and displaced laterally relative to the other individual wire guides (22 b to d) before returning to the plane of the other individual wire guides (22 b to d ) is moved back.

Description

According to the preamble of claim 1, the invention relates to a method for exchanging conductors in the production of a flat wave winding from at least two wires, which are fed to a flat winding template by means of a wire feed, the wires alternating in the direction of the longitudinal extent of the template relative to the supplied ones Wires are shifted laterally and are gradually formed into the wave winding by rotating the template to form roof-shaped winding heads and an exchange of wires is carried out in the course of the winding process.

Such a procedure is from the WO2017089455A1 known. The exchange of individual wires in pairs is already generally described there, but no ways are shown as to how this could be carried out.

Basically, a winding with swapped conductors is already out of the box WO 2016/075215 A1 known, but it is not described how such a winding could be produced economically.

Basically, there is a demand from the electric motor industry that the winding schemes should not be designed to be continuous, but rather with conductors that are swapped once or at recurring intervals.

The object of the present invention is to create a method that enables the winding scheme to be changed in the manufacturing process of a wave winding using a template.

According to the invention, the object is achieved by a method of the type mentioned at the outset, in which the wires in the wire feed are guided in individual wire guides, with at least one individual wire guide intended for wire exchange being raised with the guided wire from the level of the other individual wire guides and laterally relative to them other individual wire guides before it is moved back into the plane of the other individual wire guides.

The solution according to the invention offers the advantage that individual conductors can be brought into an almost arbitrary position relative to the remaining conductors before they are wound onto the template. The process can be easily integrated into known winding processes and can also make use of existing facilities if necessary.

The displacement process can be repeated for another wire if this is dictated by the winding scheme.

After the offset, the newly arranged wires can be shifted relative to the wire feed before the actual winding on the template in order to achieve pre-shaping to form the roof shape of the winding heads to be formed.

In one embodiment, which allows almost any freedom when displacing the wires, it is provided that the individual wire guides are displaced in order to release a point between them or at one end to which the individual wire guide intended for wire replacement is moved. With this embodiment, almost any winding scheme is possible, since the wires can be swapped in almost any order before winding on the template. The disadvantage is the higher construction effort required to swap the individual wires, since the individual wire guides must have individual displacement devices.

For a recurring exchange sequence, in which, for example, a front or rear wire is moved to the other end of the supplied wire package, it is provided that the individual wire guides are laterally displaced together at least one individual wire guide before lifting the wire intended for the wire exchange and in this case in The individual wire guide leading in the direction of displacement is then moved to the other end via the individual wire guides remaining in the plane.

In this embodiment, the winding scheme can have any number of holes q with at least one or more conductor crossings.

• 1-2→2-1→1-2 usw.

bzw. bei einer Lochzahl q=4:

• 1-2-3-4→2-3-4-1 →3-4-1-2→4-1-2-3→ 1 -2-3-4 usw.

Possible conductor crossings for a number of holes q=2:

• 1-2→2-1→1-2 etc.

or with a number of holes q=4:

• 1-2-3-4→2-3-4-1 →3-4-1-2→4-1-2-3→ 1 -2-3-4 etc.

The wire that lies above the other wires can be made with any excess length in the form of a loop in the crossing arch, which will be discussed in more detail later.

The individual wire guides to be moved can be anchored together on a movable base plate.

In a further development of the method it is provided that the displacement of the at least one individual wire guide intended for wire replacement is carried out using a gripper. The gripper can, for example, lift the individual wire guide to be relocated from a detachable holder on the base plate and place it at the desired location. To move wires from one end to the other end of the supplied wire package, only the movable base plate and a gripper are required, which could also grip and move several individual wire guides at the same time, if this is desired for a specific winding scheme.

A winding scheme already mentioned provides that four wires, but 2 or 24 wires are also conceivable, are fed and the front wire is moved to the end of the fed wire package in regularly recurring sequences. The offset does not have to be carried out before each winding process of the winding template.

The method is also suitable for the simple windings already mentioned, in which two wires are fed and swapped in a regularly recurring sequence.

In a particularly preferred embodiment of the method, it is provided that after lifting the at least one individual wire guide intended for wire replacement, a length puller is introduced in the area between the individual wire guides and the template between the wires remaining in the plane and the at least one raised wire.

This length puller ensures that the already mentioned wire loop is formed for the wire that jumps over the other wires, so that it is not pulled against the other wires under load during winding and can damage them because the jumping wire has to travel a longer distance around areas of the winding head.

After insertion, the length puller is preferably moved in the direction of the template, with wire being drawn from a wire supply if necessary. This movement of the length puller allows it to be inserted into an area between the wires in which the distance between the raised wire and the wires remaining in the plane is greater.

In order to enable a larger length of wire to be drawn, it is provided that the length puller is moved in a direction away from the wires that are still in the plane and that wire is drawn from a wire supply.

In order not to impede the subsequent molding processes on the template and to avoid tracking of the length puller, it is preferred that the length puller is moved out of the area of engagement with the at least one raised wire before the at least one raised wire guide moves back into the plane of the remaining individual wire guides becomes

It is further preferred that the lengthener has a round shape or triangular shape or any other shape over which the wire passes. The length puller can also have a rotatably mounted roller over which the wire to be displaced runs.

• 1 einen Ausschnitt aus einem Wickelschema mit und ohne Lagentausch der Leiter;
• 2 eine Draufsicht und Seitenansicht der Drahtlagen aus 1 in Draufsicht beim Zuführen zur Wickelschablone;
• 3 eine Seitensicht der Drahtlagen bei einem Lagentausch;
• 4 a bis c in Draufsicht Verfahrensschritte zur Bewerkstelligung des Lagentauschs der Leiter;
• 5 einen vergrößerten Ausschnitt X aus 4 c;
• 6 eine Draufsicht entsprechend 5 mit einem positionierten Längenieher;
• 7 eine schematische Seitenansicht der Bewegungsabfolge des Längenziehers.

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 section of a winding diagram with and without changing the layers of the conductors;
• 2 a top view and side view of the wire layers 1 in top view when feeding to the winding template;
• 3 a side view of the wire layers when changing layers;
• 4 a until c Top view of process steps for exchanging the layers of the conductors;
• 5 an enlarged section X 4c ;
• 6 a top view accordingly 5 with a positioned lengthener;
• 7 a schematic side view of the sequence of movements of the length puller.

1 shows a section of a wave winding 10, namely a winding head 12, in which a layer exchange of wires 14 of the winding is provided in the right half in the sense of the illustration. As can be seen, one wire 14a jumps over the remaining wires 14b, c, and d. Such winding schemes are structurally specified in order to achieve optimal efficiencies of the electric motors produced with them.

Fig. 2 shows a top view of a wire feed 16, which in the example shown feeds four wires 14 a, b, c and d to a winding template 18. The The method used to produce a wave winding, which can then be inserted into the slots of a stator, is known and will not be discussed in more detail here.

In the right half of 2 The wire layer required for feeding is shown in order to remove the winding head with the skipping wire 1 to be able to wrap, the left half shows the conventional arrangement.

From the side view 3 It can be seen that the skipping wire 14 a, which crosses the remaining wires 14 b, c and d, should have a greater length in this area so that it can be wound when winding by turning the template 18 counterclockwise in the sense of 3 around a bending edge 20 cannot collide with the other wires.

In 4 a until c A process sequence is now described as to how the wires can be brought into the desired arrangement. For this purpose, the wires 14 a to d are each guided and held in individual wire guides 22 a to d, which are arranged on a base plate 24, which is movable overall relative to the wire guide in a direction parallel to the longitudinal direction of the template 18.

Based on the arrangement in 4a , which represents the initial position for winding a normal winding head without conductor replacement, the entire wire package is first displaced relative to the sections already lying on the template 18 by moving the base plate 24. On the template, the wires 14 a to d can be held stationary to the template using a suitable holding device.

After reaching an intermediate position (see Fig. 4b), the individual wire guide 22a of the foremost wire 14a in the direction of displacement is moved by means of a gripper 26 (see also 7 ) is lifted off the base plate and moved to the rear end of the wire package in the direction of displacement. The desired conductor replacement is thus basically accomplished; this is followed by a partial winding process in which, for example, the wires on the template 18 are displaced in the longitudinal direction of the template 18 relative to the wires in the wire feed 16, by the amount resulting after the template has been rotated by 180 degrees roof-shaped winding heads 12 to preform.

The conductor exchange can be carried out before each half-turn of the template 18, but of course this is not mandatory and can be adapted to the requirements of the winding scheme to be wound.

In order to promote the formation of the additional length of the wire 14a crossing the other wires, a length puller 28 is used which has a round head 30 which can be designed as a roller. This moves in a position in which the gripper 26 still holds the individual wire guide 22 a raised, in an area between the wire feed 16 and the template 18, in which the wires 14 a to d run freely, between those in the plane of the base plate 24 lying wires 14 b, c and d and the wire 14 a stretched at an angle α to these are retracted, the length puller 28 first being moved in a direction L1 towards the template 18 until it has reached under the crossing wire 14 a. The length puller 28 is then moved away from the non-crossing wires 14 b, c and d, the length puller 28 taking the crossing wire 14 a with it and pulling wire lengths from a wire supply (not shown) in front of the wire feed 16. Finally, the length puller 28 is moved to a rest position R, in which it does not disrupt the subsequent processes.

The process of forming a crossing with a skipping wire can be repeated if desired.

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

All features and advantages arising from the claims and the description, including constructive details, spatial arrangements and method steps, can be essential to the invention both individually and in a wide variety of combinations.

Reference symbol list

10

wave winding

12

winding head

14 a to d

Individual wires

16

Wire feed

18

Wrapping template

20

bending edge

22 a to d

Single wire guides

24

base plate

26

Grabber

28

length puller

30

Roundhead

R

Rest position length puller

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed 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.

Cited patent literature

• WO 2017089455 A1 [0002]
• WO 2016/075215 A1 [0003]

Claims (11)

Method for exchanging conductors in the production of a flat wave winding (10) from at least two wires (14 a to d), which are fed to a flat winding template (18) by means of a wire feeder (16), the wires (14 a to d) being alternately ) are shifted laterally in the direction of the longitudinal extent of the template (18) relative to the supplied wires and are gradually formed into the wave winding (10) by rotating the template (18) to form roof-shaped winding heads (12) and an exchange of wires in the course of Winding process is carried out, characterized in that the wires (14 a to d) are guided in the wire feed in individual wire guides (22 a to d), with at least one individual wire guide (22 a) intended for wire replacement being connected to the guided wire (14 a ) is raised from the plane of the other individual wire guides (22 b to d) and laterally displaced relative to the other individual wire guides (22 b to d) before being moved back into the plane of the other individual wire guides (22 b to d). Procedure according to Claim 1 , characterized in that the individual wire guides (22 a to d) are displaced in order to release a point between them or at one end to which the individual wire guide (22 a) intended for wire replacement is moved. Procedure according to Claim 2 , characterized in that the individual wire guides (22 a to d) are moved laterally together before lifting the at least one individual wire guide (22 a) intended for wire exchange and the individual wire guide (22 a) leading in the direction of displacement is then moved over the one in the plane remaining individual wire guides (22 b to d) are moved to the other end. Method according to one of the preceding claims, characterized in that the displacement of the at least one individual wire guide (14 a) intended for wire replacement is carried out by means of a gripper (26). Method according to one of the preceding claims, characterized in that four wires (14 a to d) are supplied and the foremost wire (14 a, b, c or d) is moved to the end of the supplied wire package in regularly recurring sequences. Procedure according to one of the Claims 1 until 4 , characterized in that two wires are supplied, which are swapped in a regularly recurring sequence. Method according to one of the preceding claims, characterized in that after lifting the individual wire guide (22 a) intended for wire replacement, a length puller (28) is placed in the area between the individual wire guides (22 a to d) and the template (18) between the in the plane remaining wires (14 b to d) and the at least one raised wire (14 a) are introduced. Procedure according to Claim 7 , characterized in that the length puller (28) is moved in the direction of the template (18) after insertion. Procedure according to Claim 7 or 8th , characterized in that the length puller (28) is moved in a direction away from the wires (14 b to d) that are still in the plane and wire is drawn from a wire supply. Procedure according to one of the Claims 7 until 9 , characterized in that the length puller (28) is moved out of the engagement area with the at least one raised wire (14 a) before the at least one raised wire guide (22 a) is moved back into the plane of the remaining individual wire guides (22 b to d). . Procedure according to one of the Claims 7 until 10 , characterized in that the length puller (28) has a round shape (30) or triangular shape or any other shape over which the wire runs.

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