EP4186151A1

EP4186151A1 - Positioning device and method for positioning wire ends during the production of an electric machine

Info

Publication number: EP4186151A1
Application number: EP21749598.5A
Authority: EP
Inventors: Jörg JÖRG WALTHER; Holger UHLMANN
Original assignee: Pro Beam GmbH and Co KG
Current assignee: Pro Beam GmbH and Co KG
Priority date: 2020-07-24
Filing date: 2021-07-26
Publication date: 2023-05-31
Also published as: JP2023535095A; US20230299650A1; WO2022018303A1; DE102020119587A1; CN116802975A

Abstract

A positioning device (10; 50; 60) for positioning wire ends (14) during the production of an electric machine (12) has a positioning unit (13), which has an aligning element (22a) and a mating aligning element (22b) which are arranged above one another in two parallel planes (16, 18) and are movable relative to one another along a movement path (34), wherein they at least partly overlap or are able to overlap. The aligning element (22a) has at least one passage cutout (24a) and the mating aligning element (22b) has at least one mating passage cutout (24b), which are arranged and designed in such a way that a clear positioning passage (99) remains perpendicular to the two planes (16, 18) of the aligning element (22a) and the mating aligning element (22b), through which positioning passage the at least one wire end (14) can extend and the cross-sectional area of which can be changed by way of a movement of the aligning and the mating aligning elements (22a, 22b) with respect to one another. In order to cause as little damage as possible to the wire ends, the at least one passage cutout (24a) on the aligning element (22a) and the at least one mating passage cutout (24b) on the mating aligning element (22b) each have two straight edge sections (30a, 30b, 30c, 30d) which run at an oblique angle to the direction of the movement in the respective plane (16, 18).

Description

Positioning device and method for positioning wire ends in the manufacture of an electrical machine

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a positioning device for positioning wire ends when manufacturing an electrical machine.

The invention also relates to a method for positioning and processing wires in the manufacture of an electrical machine.

2. Description of the prior art In the manufacture of electrical machines, such as electric motors, generators and/or transformers, wires that are used as electrical conductors, for example in coils of stators and/or rotors, must be arranged and arranged in certain assemblies to be edited.

In contrast to the examples of such assemblies known from textbooks, commercially available electrical machines often use a large number of wires instead of a continuous single wire and optimized winding techniques are applied in order to generate the best possible electromagnetic field. The individual wires must then be connected to one another at their wire ends in order to create the desired winding. Flat wires such as hairpins or I-pins are increasingly being used nowadays, particularly in the winding of stators for electric motors.

Such flat wires typically have a curved mostly central portion as well as two wire ends and are designed in a precisely predetermined shape to the Make the stator winding as tight as possible. In one or more further process steps, the wire ends of the individual flat wires are then connected to one another.

In all process steps in which the wire ends are further processed, the wire ends must be positioned relative to each other with the greatest precision in order to avoid manufacturing errors. Such process steps, which require precise positioning, include steps such as stripping, cutting and/or joining the wire ends, with welding and soldering being the main things to think of when joining.

With regard to the positioning of the wire ends, however, it has been shown that due to the winding of the wires and the sometimes relatively large wire thickness, a considerable

Force is required to push the wire ends into a suitable position in order to be able to carry out the further process steps.

It is therefore known from the prior art to mount a multi-part clamping device on the assembly to be processed, such as a stator, with which the wire ends are positioned.

Clamping devices of this type comprise two disks which lie one on top of the other and can be rotated in relation to one another and which each have aligned openings for the passage of all wire ends. After the wire ends have been fed through the openings, the discs are twisted so that the wire ends are clamped between the now less overlapping openings.

However, it has been shown that very high forces are required to actuate the tensioning device, which can lead to damage to individual wire ends. In addition, the discs block as soon as one wire end shows dimensional deviations or misalignment and not all wire ends are completely enclosed. Other clamping devices known on the market, which use small sheet metal segments for clamping, require sheet metal segments arranged in at least three layers in order to bring the wire ends into position. This requires additional material expenditure as well a more difficult handling of the clamping device due to the many parts. In addition, with sheet metal segments of the same thickness, such clamping devices have a thickness that is 50% greater, since instead of just two layers, three layers are required to completely enclose the wire ends. When using such clamping devices, the length of the wire ends of the electrical machine must be greater by this amount.

Other clamping devices are designed as complex constructions with individual grippers for the respective wire ends. However, the large space requirement and the high costs are disadvantages here.

SUMMARY OF THE INVENTION

The object of the present invention is therefore to specify a positioning device for positioning the wire ends when producing an electrical machine, which takes some of the disadvantages mentioned above into account. In particular, the positioning device should be able to ensure the positioning of the wire ends with improved process safety.

According to the invention, this object is achieved by a positioning device for positioning wire ends when producing an electrical machine, comprising a) at least one positioning unit, which b) has an alignment element and a counter-alignment element, which are arranged in two layers one above the other and along a displacement path relative to one another are displaceable, whereby they are at least partially superimposed or can be superimposed, c) wherein the alignment element has at least one through-hole and the counter-alignment element has at least one counter-through-hole, which are arranged and designed in such a way that a clear positioning passage is perpendicular to the two layers of the alignment element and the counter alignment element remains, through which at least one end of the wire can extend and whose cross-section, in particular its cross-sectional area, can be changed relative to one another by shifting the alignment and counter-alignment elements, wherein d) the at least one through-hole on the alignment element and the at least one counter-through-hole on the counter-alignment element each have two straight edge sections, which in the respective position run obliquely at an angle to the direction of displacement.

The inventors have recognized that for improved positioning of the wire ends it is important in which direction the alignment element and the counter-alignment element are shifted relative to one another with regard to two straight edge sections of the through-hole and the counter-through-hole.

In principle, the positioning units of the positioning device according to the invention work with two mostly essentially plate-shaped (possibly also curved) alignment elements, the alignment element and the counter-alignment element. Cooperating through-holes and counter-through-holes are provided on these, which together provide a clear positioning passage through both alignment elements in a closed position.

The through-holes in turn have at least two straight edge sections, which can rest as end faces of the alignment elements on the wire ends to be positioned when the wire ends to be positioned, which are often present as individual wire end groups of two or more wire end groups to be positioned, through the respective Passage recesses and counter passage recesses are performed. The edge sections of an alignment element are arranged in relation to one another in such a way that they converge roughly in the opposite direction to the displacement direction of the alignment elements. This means that the clear positioning passage is reduced by the displacement of the two alignment elements against each other. If the displacement path is selected in such a way that the direction of the displacement path runs at an oblique angle, i.e. not parallel and not perpendicular, to the two straight edge sections, a force acts on the wire ends, which force gradually moves them when the alignment elements move into the closed position moved to the desired location while still allowing the wire ends to slide along the edge portions.

The vertical end faces of the edge sections of the alignment element thus rest analogously to those of the counter alignment element on two opposite surfaces of the grouped wire ends. Through the interaction of the two edge sections of a through-hole with the two edge sections of the associated counter-through hole, the position of the wire ends is fixed towards the end of the positioning process.

The movement of the alignment elements of the first and second layer is thus carried out until the four surfaces of the wire end or the wire end group are surrounded by two sides of the through-holes in the two alignment elements and block further movement of the alignment elements.

In principle, the displacement of the two alignment elements relative to each other must have at least one directional component along the two layers arranged one above the other in order to bring about the displacement into a closed position. That is to say, the alignment elements could simultaneously also move obliquely towards one another in such a way that the layers of the two alignment elements move towards one another. However, the displacement path will preferably run completely parallel to the two layers of the alignment elements.

The tangent to the displacement path can be viewed as the direction of the displacement path. By choosing the oblique angle, the wire ends can be precisely positioned with just two layers of aligning elements. The device can therefore be made significantly lighter and flatter, and the total applied force required for positioning can be reduced. In addition, a plurality of positioning units can preferably be provided, so that less force has to be applied to position an equal number of wire ends within a positioning unit, since the number of through-holes required per positioning unit can then be reduced. In particular, however, any dimensional deviations that occur in the wires to be processed can also be compensated for. Improved heat dissipation and a compact design of the device can reduce material consumption by wires of the electrical machine.

Both the positioning of the wire ends relative to one another, e.g. pressing two wire ends together, and the positioning of the wire ends relative to other wire ends or other components of the electrical machine can be regarded as positioning of the wire ends.

In principle, it is not important for the invention whether the counter-alignment element is displaced relative to a stationary alignment element or vice versa, since the two alignment elements only have to be displaceable relative to one another. Particularly advantageously, the positioning unit can even be mounted in a floating manner in relation to the wire ends, so that both alignment elements move relative to one another during the displacement and the positioning unit arranges itself over a large number of wire ends with respect to the component of the electrical machine. Provision is preferably made for the displacement path to be rectilinear.

Although, in principle, curved or meandering displacement paths are also conceivable, a linear movement of the alignment element relative to the counter-alignment element represents a simpler construction.

Provision is preferably made for the two straight edge sections of the at least one through-hole and/or the counter-through hole to run perpendicular to one another. As a result, the straight edge sections can lie optimally on wire ends with a rectangular or square cross-section. During the positioning process, the vertical end faces of the edge sections of the alignment element can lie flat against two surfaces of the wire ends to be positioned. The edge sections of the counter alignment element bear against the two remaining surfaces of the wire ends to be positioned.

Above all when using wire ends with a round or other (for example hexagonal) cross-section, the edge sections can also run towards one another at a different angle. In particular, the straight-line edge sections do not have to directly adjoin one another. For example, at an imaginary intersection of the edge sections, the through-hole can have a concavely curved connection point, in which, for example, minor injuries to the edges of the wire ends can be accommodated.

Provision is preferably made for the through-hole and/or the counter-through hole to be a through-hole.

Since the two alignment elements of the first and second layers work together for the positioning, it is basically not necessary for the through-hole and/or the counter-through hole to have a completely closed circumference. I.e. the through-holes can be arranged at the edges of the alignment elements. However, a through opening has the advantage that higher forces can be exerted with the same thickness of the respective alignment element. In addition, areas around the clear positioning passage can optionally be better covered.

Each passage opening can thus have two edge sections which are preferably at right angles to one another. The openings can be rectangular, square, triangular or drop-shaped, for example. The two straight edge sections can be connected by a rounded corner. The shape and/or size of the openings can be adapted to the shape or size of the wire ends. A positioning unit can comprise recesses and/or openings of different sizes and shapes. The alignment element and the counter-alignment element can comprise un differently sized and/or differently shaped openings.

The number of recesses and/or openings per alignment element and/or per clamping unit can vary.

Provision is preferably made for the through-hole and/or the counter-hole to be designed in such a way that the positioning hole completely encloses at least one group of wire ends.

This ensures safe positioning. The through-hole and/or the counter-hole recess preferably enclose the wire ends in such a way that, apart from the clear positioning passage, there is no further clear passage through the two alignment elements when the positioning unit is in a positioning position/closed position. In particular, no clear passage remains around the wire ends within the outer limits of the alignment element and the counter-alignment element.

The through-holes of the two alignment elements are preferably designed in such a way that the gap between the wire and the alignment element when closed is a maximum of 0.1 mm. Wires with shape deviations lead to larger distances.

It is preferably provided that the displacement along the displacement path is generated by a force element.

Such a force element can be an active force element such as an actuator, eg a hydraulic or pneumatic piston, an electric motor or the like. However, a passive force element such as a spring or an elastic block of material can also serve as the force element. The power element can also include a lever mechanism. Above all, the passive force element can press the two alignment elements in the closed position/positioning position in the basic state. An opening actuator, which works actively against the spring force of the passive force element, can then be used for opening. the The device is thus preferably normally closed (normally closed, NC), that is, the force element exerts a force in the basic state in order to keep the alignment elements closed.

The displacement of the alignment element relative to the counter-alignment element of a positioning unit is preferably caused by a common force element. One force element is thus positioned per positioning unit in such a way that the edge sections of the through-holes in the two alignment elements, which are at right angles to one another, move toward one another.

Provision is preferably made for the positioning unit to work as a tensioning unit, in that the at least one end of the wire is clamped between the alignment element and the counter-alignment element.

Although the wire ends can also be positioned by resting on just one of the two alignment elements, the wire ends are optimally held in position by clamping. The positioning device thus becomes a clamping device. Above all, the force element will be designed in such a way that the at least one end of the wire is clamped between the alignment element and the counter-alignment element.

The force element can also have a maximum force limiter in order to limit the load on the wire ends.

The fact that the positioning device can comprise a plurality of positioning units also contributes to the fact that the maximum force of each positioning unit can be kept smaller.

Provision is preferably made for the positioning device to comprise a plurality of positioning units which are arranged in a ring around a center and the direction of displacement is not directed towards the center. This means that the positioning force that acts on the wire ends is not directed to the center either. Due to the angle between the direction of displacement and the straight edge portions of the through holes, the wire ends become simultaneous aligned in both radial and tangential directions. The direction of the force causing the displacement is oblique to the edge portions.

Provision is preferably made for the direction of displacement to have an angle of more than 0° to approximately 70°, in particular between approximately 10° and approximately 45°, to the radius of the ring-shaped arrangement.

Particularly preferably, the tangent to the displacement path has an angle of less than 70°, in particular an angle of 10° to 45°, to the radius of the ring-shaped arrangement. By selecting the angle, the proportion of force that is applied to the wire ends in the radial or tangential direction can be optimized and, for example, the compression of the longitudinal sides of two wire ends can be increased by increasing the proportion of force in the radial direction. Angles of 30° to 45° between the axis of displacement and the radius of the ring-shaped arrangement are particularly preferred, since the force components in the radial and tangential directions are approximately the same here.

Provision is preferably made for the plurality of positioning units to be controlled individually, in groups or all together by an opening mechanism.

This permits a process for positioning the wire ends, which is suitable for mass production, even when using a plurality of normally closed positioning units. In particular, the force applied by the opening mechanism can be adjusted individually in each case. In this way, neighboring positioning units can be activated independently of one another and do not influence one another. Influencing the force effect of the force element via the opening mechanism can also prevent the aligning elements and/or the wire ends from being damaged in the event of misalignments of the wire ends.

In general, therefore, each alignment element comprises at least one through-hole or opening, which is designed to enclose at least one wire end. A through hole or opening is preferably designed to include two or three wires. The number of passage recesses or openings in each layer preferably corresponds to the number of wire end groups to be positioned consisting of two or three wire ends. In a preferred embodiment, each alignment element comprises nine through-holes or openings. Each clamping unit positions and clamps as few wire ends as possible. This reduces the tension forces within one unit and reduces the risk of damage or unwanted deformation of the wires.

Independent of or in addition to the above inventive ideas, another aspect of the invention relates to a positioning device for positioning wire ends when manufacturing an electrical machine, comprising a) at least one positioning unit, which b) has an alignment element and a counter-alignment element, which are in two parallel positions arranged one above the other and can be displaced relative to one another along a displacement path, whereby they are at least partially superimposed or can be superimposed, c) wherein the alignment element has at least one through-hole and the counter-alignment element has at least one counter-through-hole, which are arranged and designed in such a way that a clear positioning passage remains perpendicular to the two layers of the alignment element and the counter-alignment element, through which at least one end of the wire can extend and whose cross section, in particular its cross-sectional area, through a displacement of the alignment and counter-alignment elements relative to one another can be changed, d) the alignment element and/or the counter-alignment element having a heat dissipation contact at least in the region of the through-hole (24a) or the counter-through-hole (24b). It is not only necessary for the most efficient power transmission possible that the closed alignment elements fit as precisely as possible on the wire ends (in particular also enclosing the wire ends), but also contributes to better heat transmission. Because when using the positioning device in processes with heat generation fertil at the wire ends, at least part of this heat must be able to be dissipated via the device in order to avoid damage to the workpiece to be machined, in particular a component of an electrical machine. This is because the wires to be processed often have a coating which melts and is damaged if the temperatures are too high. For good heat dissipation via the alignment element and/or the counter-alignment element, the contact surface as a heat dissipation contact between the wire and the alignment element must be as large as possible. The end faces of the alignment elements surrounding the wire ends must therefore be positioned as close as possible to the wire ends and adapted to their contour. They are also influenced by the thickness of the sheet metal used for the alignment elements.

In addition to the contact surface, the material of the device, in particular the alignment elements, also has a major influence on the heat balance, since materials with high thermal conductivity promote heat dissipation from the point of origin. Preferably, therefore, the heat dissipation contact is made of a more thermally conductive material than the steel commonly used for the alignment elements. The material of the heat dissipation contact preferably comprises copper, copper alloys, in particular CuCrZr, or aluminium, aluminum alloys, in particular AlZnMgCu. The heat dissipation contact can also be designed as a coating of the alignment elements on the entire surface or only parts thereof with a material with high thermal conductivity such as copper. It is also advantageous to apply several layers to a component, in particular a layer of graphite and a layer of copper. As a result, the thermal conductivity can also be improved.

According to a further aspect of the invention, a surface of the positioning device can have a diamond-like coating, at least in a partial area Carbon (Diamond-Like Carbon, DLC) included to avoid sticking of deposits from the processing of the wire ends. In particular, the surface can be that surface of the alignment element which points in the direction of the wires to be processed. In order to protect the machine element to be machined from deposits that form during machining and to make it easier to thread the wire ends into the openings of the device, the positioning device can include a base plate. The base plate can have a large number of openings, which have a larger circumference on the side facing the machine element than on the side facing the alignment elements. This closing disk can cover gaps and openings between the alignment elements and prevent contamination, such as welding spatter, from getting into the electrical machine.

Regardless of the alignment elements, the base plate can also function as a heat dissipation contact. According to a further aspect of the invention, there is provided a positioning device for positioning wire ends of an electrical machine, in which the wire ends are present in groups of two or more wire ends, comprising a first layer comprising an alignment element A or a plurality thereof; a second layer comprising a mating alignment element B or a plurality thereof; each alignment element having one or more apertures adapted to enclose at least two wire ends; each opening having at least two edges which are at right angles to each other; the alignment elements are arranged in such a way that the wire ends to be positioned can be guided through the openings of one alignment element each of the first and of the second layer; whereby the force on each alignment element A and/or B can be controlled individually by an opening mechanism.

The electrical machine is preferably an electric motor, in particular a stator. The device according to the invention for positioning wire ends of an electrical machine is preferably used for a method for welding the wire ends.

The method according to the invention for positioning and processing wire ends in the manufacture of an electrical machine comprises the following steps: a) providing a positioning device according to one of the preceding claims; b) passing a wire end through the positioning passage; c) aligning the end of the wire by displacing the aligning element and the counter-aligning element relative to one another; d) processing the end of the wire, in particular with an energy beam.

The processing of the wire end in step d) preferably includes the welding of two or more wire ends with an electron beam.

In particular, the above considerations have in common that the two straight edge sections, which are provided both on the alignment element and on the counter-alignment element, preferably run in such a way that the edge sections run at an oblique angle to the direction of displacement, especially towards the end of the displacement path. As a result, a force that deviates from the perpendicular to the edge sections acts on the wire ends, especially at the end of the displacement. This causes a positioning force to act on the hairpins both in the radial and in the tangential direction in relation to an axis of rotation of the electrical machine. In particular, since the side surfaces of rectangular hairpins are directed radially and tangentially, according to the present invention, the direction of displacement can preferably run approximately diagonally to the straight edge sections. However, the direction of displacement can also deviate from the diagonal by approximately plus plus/minus 20°, preferably approximately plus/minus 10°.

With regard to the positioning device as a whole, the fundamental idea behind the invention can also be expressed by the fact that, in the case of a plurality of positioning units arranged in a ring, the direction of displacement of each individual positioning unit runs at an angle to the radial direction of the respective positioning unit, especially at the end of the displacement, with the Shifting direction also deviates from the tangential direction at the same time. The angle can in particular be between approximately 10° and 80°, in particular between approximately 30° and 60°, preferably between approximately 40° and 50°. Optimally, the angle is around 45°, because then the positioning force at the end is about the same in radial and tangential directions. With such a positioning device, all wire ends to be processed can be positioned at the same time, even if they are arranged in different radial directions.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention are explained in more detail below with reference to the drawings. These show: FIG. 1 a schematic illustration of a side view of a machine element and a positioning device;

FIG. 2 shows a schematic representation of a plan view of the positioning device according to the invention;

FIG. 3 shows a schematic representation of an alignment element; FIG. 4 embodiments of the openings in the alignment elements; FIG. 5a shows a positioning unit in the open state;

FIG. 5b shows a positioning unit in the closed state;

FIG. 6a shows a schematic representation of a side view of a further embodiment of a positioning device for positioning wire ends with lateral orientation;

FIG. 6b shows a schematic representation of a plan view of the positioning device for positioning wire ends with lateral orientation;

FIG. 7a shows a schematic representation of a side view of a further embodiment of a positioning device for positioning wire ends of a linear motor;

FIG. 7b shows a schematic representation of a plan view of the positioning device for positioning wire ends of a linear motor;

FIG. 8 is a plan view of a positioning unit with recesses.

DESCRIPTION OF PREFERRED EMBODIMENTS

1 shows a first embodiment of the device 10 according to the invention in a mounted state on a machine element 12. The machine element 12 shown purely by way of example in FIG. 1 is a stator of an electric motor.

A stator is typically formed from a winding of a plurality of wires 14 . In one embodiment, these wires are formed in a hairpin shape and are also referred to as hairpins. These hairpins consist in particular of a copper wire which, in the embodiment shown in FIG. 1, is designed as a flat wire with a rectangular cross section and is coated with an insulating lacquer.

Hairpins typically have a bent portion and two wire ends and are shaped to a precisely predetermined shape to make the winding of the stator as tight as possible. Due to the winding of the hairpins and the relatively large wire thickness considerable force is required to push the wire ends 14 into an appropriate position to perform high quality machining on the wire ends.

For this purpose, a multi-part positioning device 10 is mounted on the element 12 to be machined Statorele. The positioning device 10 has a base plate 20 as the bottom layer, which serves as a delhilfe for the wire ends 14 to be inserted. In addition, the base plate 20 protects the stator from contamination caused by machining and gives the positioning device 10 stability.

Above the base plate 20, the positioning device 10, as can be seen from FIG. The alignment elements 22a, 22b can be formed from metal sheets with a thickness of approximately 1-5 mm.

The alignment elements 22a of the first layer 18 and the counter-alignment elements 22b of the second layer 16 are arranged symmetrically in a ring around a center 28 which, when the positioning device 10 is in the assembled state, coincides with a central axis of the stator 12 . The alignment elements 22a and 22b essentially have the shape of a cake segment, with an area around the center 28 remaining free and the tip of the cake segments thus missing. The alignment members 22a and 22b have a plurality of through openings 24 to receive the wire ends 14 of the stator 12 to be positioned.

Alternatively, the through-openings 24a, 24b can also be designed as through-holes 24a, 24b, which are open on one side, for example by the alignment elements 22a and 22b comprising fingers pointing towards the center 28, as shown in FIG. 8, on which the through-holes 24a, 24b are arranged laterally .

FIG. 3 shows a single positioning unit 13 in detail. It can be seen that the positioning unit 13, in addition to the alignment element 22a and the alignment element 22b, also has a passive power element 26 has. In this embodiment, a spring was selected as the passive force element 26, which elements 22a and 22b provides the force 34 for a displacement of the alignment elements 22a and 22b in order to close the positioning unit 13.

The passive force element 26 is positioned in such a way that the straight edge sections 30a, 30b of the through-openings 24a, which are at right angles to one another, and the two straight edge sections 30c, 30d of the counter-through opening 24b in the two alignment elements 22a and 22b approach one another move.

Each opening 24a, 24b of the alignment elements 22a, 22b here has at least two straight edge sections 30a, 30b, 30c, 30d, which are at right angles to one another. The mutually perpendicular edge sections 30a, 30b of the alignment element 22a of the first layer 18 lie against two surfaces of a group of two or more wire ends 14 during the positioning and clamping process.

In this embodiment, a through-hole 24 has a rectangular shape, which has three strongly rounded corners and one less rounded corner.

The edge sections, i.e. end faces of the alignment elements 22a, 22b, which adjoin the less strongly rounded corner, rest against the wire ends 14 in the closed state.

In this embodiment, the two edge portions 30a and 30c are arranged parallel to the tangents 70 of the circumference of the positioning device 10. FIG. If the wire ends 14 of the electrical machine 12 to be processed are arranged differently, the through-openings 24 of the alignment elements 22a, 22b must also be adapted.

The through openings 24 of the alignment elements 22a, 22b can be configured in different shapes (see FIG. 4). In addition, the through-openings 24 of the alignment element 22a can differ from those of the counter-alignment element 22b.

Figure 4a shows a rectangular opening 24. The rectangular opening 24 may be rounded at all corners (Figure 4b), or at only two (Figure 4c). In one embodiment the opening 24 has only one corner with two adjoining straight edge sections 30a, 30b and is otherwise teardrop-shaped (see FIG. 4d). The adjoining edge sections must be long enough to enclose two sides of the wires 14 . The vertical end faces of the openings 24 of the alignment element 22b of the second layer 16 lie opposite the vertical end faces of the alignment element 22a of the first layer 18, respectively.

The alignment elements 22b of the second layer 16 can move on the same linear axis 34 of the alignment elements 22a of the first layer 18, but in opposite directions, during positioning and clamping. But they can also be fixed.

The linear axis 34, along which the displacement path of the alignment elements 22a, 22b runs, is defined by two elongated holes 35. It would be conceivable here to design the elongated holes 35 in a curved manner, so that the displacement path no longer runs in a straight line.

The linear movement of the alignment elements 22a, 22b of the first and/or second layer 18, 16 is carried out until the four surfaces of the group of wire ends 14 are enclosed by two sides of the openings 24 in the two alignment elements 22a, 22b and block further movement of the alignment members 22a, 22b.

FIG. 5a shows a clamping device in the open state.

The number of openings 24 corresponds to the number of pairs of wire ends 14 to be positioned.

The alignment elements 22a of the first layer 18 can be displaced linearly with respect to the alignment elements 22b of the second layer 16. The displacement takes place at an oblique angle to the edges 30.

In the embodiment shown in Figure 3, the spring is arranged as a force element 26 so that the direction of the force 34, which causes the displacement, and thus also the axis of displacement of the alignment elements 22a, 22b, an angle of 45 ° each has the edge portions 30a, 30b, 30c, 30d. In this embodiment, moreover, the edge portion 30b runs parallel to the radius of the positioning device 10, therefore the displacement also runs along an angle of 45° to the radius. The movement of the alignment elements therefore runs neither in order circumferential direction 38 nor radially 36 to the symmetrical arrangement. The direction 34 of linear movement is inclined at an angle to the edge sections 30a, 30b, 30c, 30d and does not pass through the center 28 of the symmetrical arrangement.

Because of the angle, a portion of the force acts on both edge portion 30a and edge portion 30b. As a result, the wire ends 14 are aligned both in the radial and in the tangential direction. This force causes the edge sections 30a and 30b and the edge sections 30c and 30d of the alignment element 22b to be pressed against the side surfaces of the wire ends 14 and enclosed in an opaque manner and precisely positioned (FIG. 5b).

This can be seen in FIG. 5b above all from a smaller cross-sectional area of a clear positioning passage 99 than in FIG. 5a through the passage openings 24a, 24b of the two alignment elements 22a, 22b.

Adjacent positioning units 13 work independently and do not influence each other. To open the self-sufficient positioning units 13, openers are used, which are moved centrally via a cam disk (not shown). The number of openers corresponds to the number of positioning units 13. In the inactive state, the force element 26 or the force elements 26 are permanently closed. This means that the spring force of the force element 26 acts permanently on the wire.

Each positioning unit 13 positions and tensions the smallest possible number of wire ends 14. As a result, the positioning forces within a positioning unit 13 are kept as low as possible. The positioning force of a positioning unit 13 therefore does not lead to damage or unwanted deformation of a large number of wire ends 14 in the event of a fault.

FIG. 6 shows a further embodiment of the device according to the invention. This positioning device 50 positions wire ends 14 which are not as shown in FIG 1 must be processed from above on a stator 12, but from the side. The end faces of the wire ends 14 to be processed thus show radially outwards.

The positioning device 50 can have an alignment element in the form of a ring with lateral openings 24 or a multiplicity of alignment elements arranged in a ring. The second layer 16 is represented here by an alignment element 22b, which can also have the shape of a ring or a multiplicity of elements , but with a smaller radius. That is, the layers of the alignment elements 22a, 22b arranged parallel one above the other according to the wording of the claim can also be curved and arranged one above the other in the radial direction of the stator 12.

The outer wall surface of the ring is adjacent to the inner wall surface of the stator 12 . The wire ends 14 are passed through the openings 24 located in the wall surfaces. The shape of the openings 24 and the direction in which the alignment elements are displaced relative to one another correspond to the embodiments described in FIGS. 1-5. The displacement between the alignment elements 22a, 22b is in turn effected by at least one passive force element 26.

Figure 7 shows a positioning device 60 according to the invention for positioning wire ends of a linear motor 62. In this embodiment, the alignment elements 22a, 22b of the first layer 18 and the second layer 16 are not arranged in a ring around a center 28, but along a straight or curved path. FIG. 7 shows a large number of alignment elements 22a and 22b. However, the positions 16, 18 can also be represented by individual alignment elements 22a, 22b adapted to the course of the linear motor 12. The shape of the openings and the direction of displacement of the alignment elements relative to one another corresponds to that of the embodiments described in FIGS. 1-6.

The positioning method according to the invention works as follows:

The positioning device 10 is placed on an electric machine 12 and the wire ends 14 protruding therefrom are passed through the openings 24 in groups. The alignment elements 22a, 22b are clamped using an opening/closing unit in such a way that the direction of displacement of the alignment elements relative to one another runs at an oblique angle to the edge sections 30a, 30b, 30c, 30d. This aligns the wire ends 14 to a precise position. The electrical machine 12 can then be relocated together with the mounted positioning device 10 for further processing in a process chamber. The wire ends 14 are processed there.

In a preferred embodiment, the wire ends 14 are treated with an energy beam, in particular with an electron beam. Processing may include welding, cutting, and/or stripping wire ends 14 of insulation.

reference sign

10 positioning device

11 axis of rotation 12 machine element 13 positioning unit 14 wire ends 16 first layer 18 second layer 20 base plate 22 a, b alignment element 24 opening 26 elastic element 28 center of the arrangement

30 a, b, c d edge 34 direction of force

36 radial direction 38 circumferential direction 40 tangential direction 50 device for positioning wire ends in lateral alignment 52 machine element with laterally aligned wire ends

60 Device for positioning wire ends in a linear motor

62 linear motor

Claims

PATENT CLAIMS

1. Positioning device (10; 50; 60) for positioning wire ends (14) in the manufacture of an electrical machine (12), comprising a) at least one positioning unit (13), b) an alignment element (22a) and a counter-alignment element ( 22b) which are arranged in two parallel layers (16, 18) one above the other and can be displaced relative to one another along a displacement path (34), whereby they are at least partially superimposed or can be superimposed, c) the alignment element (22a) having at least one through-hole (24a) and the counter alignment element (22b) has at least one counter passage recess (24b), which is arranged and designed in such a way that a clear positioning passage (99) is perpendicular to the two layers (16, 18) of the alignment element (22a) and of the counter-alignment element (22b) remains, through which at least one end of the wire can extend and whose cross-section, in particular its cross-sectional area, through a e The displacement of the alignment and counter-alignment elements (22a, 22b) relative to one another can be changed, characterized in that d) the at least one through-hole (24a) on the alignment element (22a) and the at least one counter-through-hole (24b) on the ge alignment element (22b) each have two straight edge sections (30a, 30b, 30c, 30d) which, in the respective layer (16, 18), run at an oblique angle to the direction of displacement.

2. Positioning device according to claim 1, characterized in that the displacement path (34) is rectilinear.

3. Positioning device according to one of the preceding claims, characterized in that the two straight edge sections (30a, 30b, 30c, 30d) of at least one through-hole (24a) and/or the counter-through hole (24b) run perpendicular to one another.

4. Positioning device according to one of the preceding claims, characterized in that the through-hole (24a) and/or the counter-throughhole (24b) is a through-hole.

5. Positioning device according to one of the preceding claims, characterized in that the through-hole (24a) and/or the counter-through hole (24b) are designed such that the positioning hole (99) completely encloses at least one end of the wire.

6. Positioning device according to one of the preceding claims, characterized in that the displacement along the displacement path (34) by a Kraftele element (26) is generated.

7. Positioning device according to one of the preceding claims, characterized in that the positioning unit (13) works as a clamping unit by the at least one end of the wire between the alignment element (22a) and the element (22b Gegenausrichtele-) is clamped.

8. Positioning device according to one of the preceding claims, characterized in that the positioning device (10; 50) comprises a plurality of positioning units (13) which are arranged in a ring around a center (28) and the direction of displacement does not point to the center (28). is directed.

9. Positioning device according to claim 8, characterized in that the direction of displacement forms an angle of more than 0° to about 70°, in particular between about 10° and about 45°, to the radius (36) of the ring-shaped arrangement of the positioning units (13 ) having.

10. Positioning device according to one of claims 8 to 9, characterized in that the plurality of positioning units (13) can be controlled individually, in groups or all together by an opening mechanism.

11. Positioning device (10; 50; 60) for positioning wire ends (14) in the manufacture of an electrical machine (12), comprising a) at least one positioning unit (13), the b) an alignment element (22a) and a counter-alignment element (22b) which are arranged in two parallel layers (16, 18) one above the other and can be displaced relative to one another along a displacement path (34), whereby they are at least partially superimposed or can be superimposed, c) the alignment element (22a) having at least one has a through-hole (24a) and the counter-alignment element (22b) has at least one counter-hole (24b) which is arranged and designed in such a way that a clear positioning passage (99) is perpendicular to the two layers (16, 18) of the alignment element (22a) and of the counter-alignment element (22b) remains, through which at least one end of the wire can extend and whose cross-section, in particular its cross-sectional area, through ei ne displacement of the alignment and counter-alignment elements (22a, 22b) relative to one another can be changed, characterized in that d) the alignment element (22a) and/or the counter-alignment element (22b) at least in the region of the through-hole (24a) or the counter-through-hole (24b ) have a heat dissipation contact made of a more thermally conductive material.

12. A method for positioning and processing wire ends (14) in the manufacture of an electrical machine (12), comprising the following steps: a) providing a positioning device (10; 50; 60) according to any one of the preceding claims; b) passing at least one wire end (14) through the positioning passage (99); c) positioning of the at least one wire end (14) by shifting the alignment element (22a) and the counter-alignment element (22b) relative to one another; d) processing the at least one wire end (14), in particular with an energy beam.