EP4076781A1 - Dispositif et procédé pour cintrer des profilés électro-conducteurs destinés à des moteurs électriques (technologie hairpin) - Google Patents

Dispositif et procédé pour cintrer des profilés électro-conducteurs destinés à des moteurs électriques (technologie hairpin)

Info

Publication number
EP4076781A1
EP4076781A1 EP20837986.7A EP20837986A EP4076781A1 EP 4076781 A1 EP4076781 A1 EP 4076781A1 EP 20837986 A EP20837986 A EP 20837986A EP 4076781 A1 EP4076781 A1 EP 4076781A1
Authority
EP
European Patent Office
Prior art keywords
profile
bending
engagement sections
engagement
sections
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP20837986.7A
Other languages
German (de)
English (en)
Inventor
Markus Werner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Original Assignee
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV filed Critical Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Publication of EP4076781A1 publication Critical patent/EP4076781A1/fr
Pending legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D7/00Bending rods, profiles, or tubes
    • B21D7/10Bending rods, profiles, or tubes by abutting members and flexible bending means, e.g. with chains, ropes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D11/00Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
    • B21D11/06Bending into helical or spiral form; Forming a succession of return bends, e.g. serpentine form
    • B21D11/07Making serpentine-shaped articles by bending essentially in one plane
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H02K15/0435Wound windings
    • H02K15/0478Wave windings, undulated windings

Definitions

  • the present invention relates to an apparatus and a method for bending electrically conductive profiles.
  • the device comprises at least three engagement sections which can be brought into an engagement state for bending at least one such profile with the same, wherein at least two of the engagement sections can be moved while maintaining the engagement state in order to bend the at least one profile.
  • Such a bending device is known from WO 2015/132180 A1.
  • traction motors In the course of electromobility, an ever higher power density is required for traction motors. In addition, these motors have to be produced in large numbers in an automated manner.
  • One class of traction motors is based on distributed windings that are implemented using hairpins or shaped coils.
  • the bar windings consist of a large number of individual shaped bars of different geometries, which are bent into a V-shape, U-shape or S-shape and are known as flair pins.
  • the present invention is based on the object of providing a device and a method for bending electrically conductive profiles for electric motors which, while maintaining the state of engagement, enable the profile to be bent about various bending axes.
  • the object of the invention is achieved by the device according to claim 1 and the method according to claim 5.
  • the device disclosed herein for bending electrically conductive profiles comprises at least three engagement sections which can be brought into an engagement state for bending at least one such profile, with the at least one profile being bent at least two of the engagement sections can be moved while maintaining the A grip state, the engagement sections forming a kinematic chain and the A grip sections can be arranged and / or moved in at least two different planes.
  • the movement of one chain link usually causes the movement of an adjacent chain link.
  • the engagement sections represent, as it were, the links of the chain.
  • the chain can be changed in shape and defines the bending shape of the profile to be bent. In this way, several bends can be made one after the other at short time intervals without the engagement sections having to be repositioned with respect to the profile.
  • the respective engagement section is preferably firmly or non-positively connected to the profile. Due to the possibility of movement of the engagement sections in at least two different planes, bends in different bending planes in the engaged state of the engagement sections can be represented, ie the profile can be bent in the same clamping in several planes. Ideally, there is no relative movement between the engagement section and the profile in step B either. This applies above all to the outermost engagement sections, between which the profile can be firmly clamped.
  • the middle of the three engagement sections can support the profile, for example, on the inside of the bend and / or on the outside of the bend.
  • one of the engagement sections is preferably arranged in the center of curvature or on the bending axis of the bend, so that the profile is bent around the respective engagement section.
  • This is a guided bend in which the respective engagement section has a bending punch or forms at least one bending support so that the bending contour can be optimally designed and kinking of the profile can be prevented.
  • the kinematic chain preferably changes its shape in accordance with the curvature of the profile, ideally in such a way that the chain formed by the engagement sections is always aligned parallel to the profile.
  • the bending device can also have more than three engagement sections which form a kinematic chain, namely in particular three, four, five, six, seven, eight, new or ten.
  • the kinematic chain can be open or closed.
  • two adjacent engagement sections are movably connected to one another, preferably in an articulated manner, preferably via a joint, in particular a swivel joint or a ball joint or a sliding joint.
  • the joint preferably has one, two or three rotational degrees of freedom of movement and / or one or two translational degrees of freedom of movement.
  • a translational degree of freedom of movement can be used, for example, to adjust the distance between two adjacent handle sections.
  • at least one of the engagement sections is itself designed as a joint, e.g. as a swivel joint, universal joint, ball joint and / or as a sliding joint.
  • the engagement sections form a planar or spatial Koppelge gear and / or at least one of the engagement sections has its own drive.
  • the engagement sections are cyclically guided, for example, on a predetermined trajectory.
  • Spatial coupling gears always contain some joints with a degree of freedom f> l, or several degrees of freedom, such as ball joints.
  • Another aspect of the present invention relates to a method for bending electrically conductive profiles, in particular for producing shaped rods for electric motors (hairpins), using a bending device according to one of the preceding embodiments, comprising the steps:
  • Step A Establishing a state of engagement between the engagement portions and at least one such profile.
  • Step B Bending of the at least one profile by moving the movable engagement sections while maintaining the engaged state.
  • At least one of the engagement sections supports the profile in step B on the inside and / or at least one of the engagement sections supports the profile on the outside in step B.
  • the profile is preferably initially bent several times in the same bending plane, each at an obtuse angle.
  • step A three engagement sections offset from one another along the profile are brought into the engagement state with the same, with the middle of the three engagement sections being moved and / or relatively transversely to a line defined by the two outer engagement sections in step B is rotated (and the profile is contacted on the inside of the bend), the distance between the two outer engagement sections preferably being reduced.
  • the middle and / or one of the outer or all of the engagement sections can move in one or more bending planes or when rotating about one or more axes of rotation.
  • the line defined by the two outer engagement sections and / or the middle of the three engagement sections move relative to one another.
  • This feature is particularly suitable for bending the profile in a loop shape or in a wave shape, preferably in at least one bending plane.
  • step A it can be useful if the profile in step A is provided with a uniform or non-uniform cross-sectional shape. As a result, the intended outer contour of the profile can be produced more easily when installed.
  • the profile forms a symmetrical polygon, preferably an equilateral triangle, when the bending process is completed in step B, preferably in the bending plane, and / or if the profile has at least two parallel legs.
  • This shape corresponds to the classic U-shape or V-shape of an electrically conductive shaped rod for electric motors (hairpin).
  • the profile to be reshaped is preferably contacted and / or fixed in step B exclusively by the engagement sections.
  • step B it can prove to be practical if the profile in step B is bent one or more times in a first bending plane by movement and / or rotation of the movable engagement sections first in a sub-step B1, and finally in a sub-step B2 one or more times in at least one other bending plane is bent.
  • the profile can be deformed in several bending planes in one clamping.
  • step B it can prove to be helpful if the profile is bent over in step B by moving and / or rotating the movable engagement sections in order to reduce resilient restoring forces.
  • the device and the method are also suitable for forming multi-layer conductors or several electrically conductive profiles at the same time.
  • the main advantage here is that there are no tolerance problems in the individual manufacture. This lowers production costs, improves quality and, ultimately, economic use.
  • Fig. 1 is a schematic view of the steps of the method according to the invention according to the first exemplary embodiment of the invention using the bending device according to the invention, wherein in view (a) a profile to be bent is shown in a linear arrangement, which is clamped at the end between engagement sections, wherein in View (b) shows the profile after bending the first arch in the first plane of curvature, and in view (c) the profile after bending the second and third arches in the first plane of curvature is shown, with view (d) showing the profile from a different perspective tive shows and wherein in view (e) the profile is shown after cranking or bending in a second plane of curvature.
  • Fig. 2 shows schematically a five-link kinematic chain which is formed by the bend-inside and end-side engagement sections of the bending device according to the invention according to FIG Chain in a stretched or linear arrangement accordingly
  • Fig. la shows, where view (b) shows the chain in a simply curved arrangement according to Fig. lb, in which the middle engagement section is offset from a line that runs or is defined by the two adjacent engagement sections to the outside of the bend, and where view (c) shows the chain in a multiple curved arrangement according to FIG. 1c, in which the outer one of the inner bend engaging portions is offset from a line that extends or is defined through the middle and the respective outer engaging portion to the outer bend is.
  • Fig. 3 is a schematic view of the steps of the method according to the invention according to the second exemplary embodiment of the invention using the bending device according to the invention, with view (a) illustrating step A of the method according to the invention, in which the engaging sections of the bending device with an endless profile in one linear state can be brought into an engaged state, while the views (b) to (d) illustrate step B of the method according to the invention, in which the endless profile and while maintaining the state of engagement with the A handle sections is curved in a loop or wave-like manner, wherein in view ( b) it can be seen how a group of central engagement sections is offset transversely to a line defined by outer engagement sections in order to bend the previously straight profile in a loop shape, view (c) showing how the endless profile is used to cancel the resilient restoring forces of the Profile is arched, and where view (d) shows the state after completion of step B of the method according to the invention.
  • Fig. 4 in view (a) a four-layer winding for slotless air-gap windings or four electrically lei tend profiles, which are bent according to the method according to the invention and using the inventive device, in an installed state, and in view (b) a top view of the Winding from view (a).
  • FIG. 5 shows a photographic illustration of a multilayer winding according to FIG. 4.
  • An electrically conductive profile 2 as a semi-finished product is shown in view (a) with the kinematic chain ld of the bending device 1 according to the invention formed from the engagement sections la, lb, lc in the starting position.
  • the profile 2 extends along a straight line.
  • the end engagement sections la clamp the profile 2 at the end or clamp it so that the profile 2 is not relative to the can move both end engaging portions la.
  • the engagement sections lb are, for example, designed as Rol len and arranged on the intended bending inside of the profile 2.
  • the handle sections lc hold the profile 2 during the subsequent bending process on the inside of the bend-side engagement sections lb in contact and prevent buckling or bulging of the profile 2.
  • end-side engagement sections la and the inside-bend-side engagement sections lb as well as the biegeaussenseiti gene engagement sections lc form a circumferential or bulging.
  • closed kinematic chain ld which is symbolized by a dashed line.
  • the kinematic chain 1d of the bending device 1 is transferred from the linear starting position shown in view (a) into a curved configuration according to view (b). Due to the state of engagement between the engagement sections la, lb, lc and the profile 2, the curved configuration of the kinematic chain ld is transferred to the profile 2.
  • the middle of the inside of the bendable engaging section lb is offset relatively transversely (and towards the bend outside) to a line defined by the adjacent engaging section lb in order to serve as a bending punch in the position of the bending axis.
  • the bend around the central bend-inside engagement section lb takes place in the first bending plane X-Y (see coordinate system in view (c)), preferably at an angle of 90 °.
  • the kinematic chain 1d of the bending device 1 is then converted from the single-curved configuration shown in view (b) into the multiple-curved configuration according to view (c).
  • each of the handle sections lb adjacent to the middle bend inside engagement section lb is displaced relatively transversely (and to the outside of the bend) to a line defined by the middle engagement section lb and the corresponding outer engagement section la to be in the position of the bending axis as Bending punch to serve.
  • the bends of the second and third arcs around the engaging portions lb adjacent to the middle inner bend-side engaging portion lb are preferably each made at an angle of 45 ° and in the same first bending plane X-Y as the preceding bend of the first arch.
  • the legs of the curved profile 2 are therefore ideally aligned parallel to each other.
  • View (d) corresponds to the front view of the state according to view (c).
  • View (e) illustrates the cranking by moving the engagement sections lb, while at the same time the cross-sections of the long Legs are screwed in (substep B2). This restriction corresponds to the angle of the stator grooves that are filled by the hairpin.
  • FIG. 2 illustrates the kinematic chain ld formed from the engagement sections lb for bending the first, second and third arches in a simplified schematic representation.
  • the engagement sections lb bending the first, second and third arcs are designed as rotary or ball joints which have one, two or three degrees of freedom of rotation.
  • Sliding joints are arranged between the swivel joints, by means of which the distance between the swivel joints can be changed.
  • An open kinematic chain ld can be formed, for example, by a two-armed robot, each arm corresponding to its own kinematic chain ld. In the state of engagement with the profile 2, the kinematic chain 1d can also be imagined similar to an exoskeleton.
  • a further bending device 1 designed as a kinematic chain, as shown in FIG. 3, is proposed for bending endless wire into wave windings.
  • the material of the Pro fils 2 is withdrawn from the right of a coil, smoothed by appropriate straightening devices and then ge according to view (a) with the engagement portions of the bending device 1 brought into an engagement state. After about half of the movement of the engagement sections, the shape according to view (b) is created. In order to compensate for the springback of the curved profile 2, the bending areas are arched over, as shown in view (c). After the spring back, the shape is in accordance with view (d). From here, the bending device 1 is moved back to the starting position according to view (a), which moves the curved wave winding by one pattern to the left. The process is repeated until the desired number of Flairpins has been reached.
  • the option of using a profile 2 with area-specific cross-sections is not shown instead of a profile 2 (conductor material) with a constant cross-section.
  • the conductor section which lies in the groove of the Blechpa ketes, can be trapezoidal and different for each winding ring.
  • the approach according to the invention consists in using a kinematic chain ld for the bending, which has a plurality of articulated engagement sections la, lb, lc in order to form all bends of the profile 2 in a sequence of partial movements without the profile 2 again to grasp.
  • the profile 2 to be bent for example an electrically conductive wire section, is sensibly picked up in the middle and from there both legs and their subsequent bends are bent at the same time. This enables the bending to be parallelized and the time required to be reduced considerably.
  • Additional engagement sections la, lb, lc or joints are to be provided for bends, twists (cranking) in further directions.
  • Another feature of the kinematics is the ability to adjust the distances between the engagement sections la, lb, lc or joints to one another. This allows the length between the individual bends on profile 2 to be adjusted. With this adjustment option, different hairping sizes can be produced. As a rule, the hairpins of a motor winding differ only in the distance between the parallel areas that act in the sheet metal groove. This is usually realized by different shank lengths between the first and second bend or by the bending angle.
  • the kinematic chain ld can be driven by individual drives in each engagement section la, lb, lc or joint or as a closed coupling mechanism. Mixed forms of the drive types mentioned are possible, please include.
  • the parallelization of the movements of the engagement sections la, lb, lc or the bending of the profile 2 leads to significant time savings and thus higher productivity.
  • the bending of wave windings can be done endlessly, with the shaped part of the profile 2 being laid down and hardly needing to be moved (in contrast to bending on a conventional automatic machine).
  • the possibility of adjusting the kinematic chain ld formed by the engagement sections la, lb, lc offers the possibility of adapting to the different winding rings of an electric machine and to different product sizes, so that the product flexibility is increased. This also enables the correction of varying semi-finished product properties to allow narrower shape and positional tolerances.
  • hairpins can also be shaped, the cross-sectional shapes of which are adapted in sections in order to optimally fill out sheet metal sections with trapezoidal grooves (parallel teeth), for example.
  • the bending device 1 shown is also able to bend or fold a sequence of conductors, which is characterized in that the cross-sectional shape is adapted in sections.
  • the present invention is particularly suitable for the production of curved profiles 2, in particular special from solid material, from hollow profiles or from profiles with different cross-sections for electric motors, generators, and for electrical machines in general.
  • 4 and 5 show four electrically conductive profiles 2 in different views in an installed state in which the profiles 2 are wound around teeth 3 as a four-layer winding for slotless air-gap windings.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'invention concerne un dispositif (1) pour cintrer des profilés (2) électro-conducteurs, notamment pour la réalisation de barres profilées destinées à des moteurs électriques (technologie hairpin), comprenant au moins trois sections de prise (1a, 1b, 1c) qui peuvent être mises en prise avec au moins un profilé (2) de ce type pour le cintrer, au moins deux sections de prise (1a, 1b, 1c) pouvant être mises en mouvement alors que l'état de prise est conservé, pour cintrer l'au moins un profilé (2). Pour permettre un cintrage du profilé autour de différents axes de cintrage alors que l'état de prise est conservé, les sections de prise (1a, 1b, 1c) forment selon l'invention une chaîne cinématique.
EP20837986.7A 2019-12-20 2020-12-17 Dispositif et procédé pour cintrer des profilés électro-conducteurs destinés à des moteurs électriques (technologie hairpin) Pending EP4076781A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102019220415.5A DE102019220415A1 (de) 2019-12-20 2019-12-20 Vorrichtung und Verfahren zum Biegen von elektrisch leitenden Profilen für Elektromotoren (Hairpin)
PCT/EP2020/086826 WO2021123023A1 (fr) 2019-12-20 2020-12-17 Dispositif et procédé pour cintrer des profilés électro-conducteurs destinés à des moteurs électriques (technologie hairpin)

Publications (1)

Publication Number Publication Date
EP4076781A1 true EP4076781A1 (fr) 2022-10-26

Family

ID=74130196

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20837986.7A Pending EP4076781A1 (fr) 2019-12-20 2020-12-17 Dispositif et procédé pour cintrer des profilés électro-conducteurs destinés à des moteurs électriques (technologie hairpin)

Country Status (3)

Country Link
EP (1) EP4076781A1 (fr)
DE (1) DE102019220415A1 (fr)
WO (1) WO2021123023A1 (fr)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102021128410A1 (de) 2021-11-01 2023-05-04 Aumann Espelkamp Gmbh Vorrichtung und Verfahren zum Herstellen einer Biegung einer Wellenwicklung für eine Spulenwicklung einer elektrischen Maschine
DE102022204823A1 (de) * 2022-05-17 2023-11-23 Zf Friedrichshafen Ag Verfahren und Vorrichtung zur Herstellung einer Wickelmatte für einen Stator oder einen Rotor eines elektrischen Motors
DE102022204826A1 (de) * 2022-05-17 2023-11-23 Zf Friedrichshafen Ag Verfahren zur Herstellung einer Wickelmatte für einen Stator oder einen Rotor eines elektrischen Motors

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DE380094C (de) * 1923-09-01 Ernst Bovermann Dipl Ing Vorrichtung zur Ausuebung des Verfahrens zur Herstellung von Biegungen, insbesondereDoppelbiegungen, an Rohren
DE1527313C3 (de) * 1965-06-21 1978-04-13 Rockwell Golde Gmbh, 6000 Frankfurt Vorrichtung zum Biegen von Profilen, Rohren o.dgl
US3955599A (en) * 1973-10-01 1976-05-11 Deep Oil Technology, Inc. Apparatus for bending a flowline under subsea conditions
US3952572A (en) * 1974-01-23 1976-04-27 Case Western Reserve University Beam bender
CN1181936C (zh) * 2000-02-17 2004-12-29 三樱工业株式会社 弯曲加工装置
DE102005032478A1 (de) * 2005-07-12 2007-01-18 Robert Bosch Gmbh Verfahren zum Herstellen einer Wicklung einer elektrischen Maschine
JP4506895B2 (ja) * 2008-04-07 2010-07-21 株式会社デンソー 波巻きステータコイルの製造方法
JP5389522B2 (ja) * 2008-12-15 2014-01-15 日特エンジニアリング株式会社 コイル成形方法及びコイル成形装置
JP5131561B2 (ja) * 2009-03-13 2013-01-30 アイシン・エィ・ダブリュ株式会社 コイル製造方法、コイル製造装置、及びコイル
FR2947968A1 (fr) * 2009-07-09 2011-01-14 Valeo Equip Electr Moteur Bobinage d'une machine electrique tournante
JP5348505B2 (ja) * 2010-05-13 2013-11-20 株式会社デンソー ステータコイルの製造方法及びそのステータコイルを用いたモータ
JP5292360B2 (ja) * 2010-06-10 2013-09-18 トヨタ自動車株式会社 モータ
TR201816474T4 (tr) * 2014-03-07 2018-11-21 Atop Spa Bobin elemanlarının oluşturulmasına yönelik aparat ve yöntem.
DE102015218379A1 (de) * 2015-09-24 2017-03-30 Zf Friedrichshafen Ag Stator
DE102016203167A1 (de) * 2016-02-29 2017-08-31 Zf Friedrichshafen Ag Vorrichtung und Verfahren zum Herstellen eines wellenförmig gebogenen Drahtsegments
DE102016012677A1 (de) * 2016-10-20 2018-04-26 Technische Universität Dortmund Vorrichtung und Verfahren zum Biegen von Profilen oder Stabmaterial, insbesondere unsymmetrischer und offener Profile oder Stabmaterial
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Also Published As

Publication number Publication date
DE102019220415A1 (de) 2021-06-24
WO2021123023A1 (fr) 2021-06-24

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