FR2773008A1 - Flat wire coil winding mechanism - Google Patents

Abstract

The method of winding out the wire and shaping with a block provides a high precision winding.

Description

State of the art
The invention relates to a method of manufacturing a shaped coil for an excitation winding, this coil having a meandering pattern with several turns surrounding the poles of the excitation field of an electric machine.

 The invention also relates to a device for implementing this method.

 In a known excitation winding intended for the stator of an electric machine (DE 195 49 180 A1) each turn of the excitation winding is a conductor in the form of a bundle composed of several wires of circular section, wound in parallel, and juxtaposed at the front face of the poles while being twisted with each other in the area between the poles. To manufacture the molded coil for this excitation winding which is then placed in the stator, for example, two round, parallel wires are passed, at the same time around different fingers of a winding drum, the two front edges of the winding drum are offset at the periphery and the number of which corresponds to the number of poles of the stator. Between the different successive fingers, pass the two parallel round wires, in a diagonal direction, that is to say by making an acute angle relative to the axis of the winding drum and the wires are turned in this area. with each other on 1800.

Advantages of the invention
The object of the present invention is to remedy the drawbacks of known solutions and to this end relates to a process defined above, characterized in that an insulated flat wire passes completely around a winding pin and passes in front of cells. forming provided on pocket openings provided on the winding spindle being offset from each other in a regular manner, these forming pockets being directed in the axial direction, and their number corresponds to half the number of field coils d 'excitement; and when the wire is passed over the openings of the cells, each segment of wire which generates the openings is pulled axially in the forming cells to the bottom of the cells to form along the inner contour of each cell, a loop of wire; the passage around and the retraction of the wire being repeated until the desired number of turns are wound on the winding spindle and at the end of the winding the wire is stripped and cut and the axially extracted winding of the winding spindle.

The invention also relates to a device for implementing the above method, characterized in that a winding cylinder rotating around its axis, driven step by step, comprises a coaxial winding spindle and a number of molded cells corresponding to the number of excitation poles, these cells being offset relative to each other by the same peripheral angle and are offset on the longitudinal segment of the winding spindle by being joined in rotation with this and each shaped cavity comprises at least one drawer sliding axially on the winding spindle, this drawer being able to penetrate by introduction of the segment of wire which occupies the opening of the cell, in the mold cell until '' at the bottom of the cell and the drive movement of the drawer is synchronized with the movement
The method according to the invention for the manufacture of a molded coil for an excitation winding offers the advantage of giving a molded coil with a high filling coefficient and thus a great form accuracy which is characterized by an excellent blocking in case of tremors. The great shape precision allows excellent heat dissipation. The process is fast and can be implemented completely automatically.

 The device for implementing the method according to the invention as defined above, offers the advantage of simplicity.

According to other advantageous features the flat wire is wound on the field on the spindle
winding,
for each subsequent introduction of the wire segment which
gender the opening of the forming cells the wire loop
which is formed again, is applied against the loop of
previous wire against the forming cell,
each wire loop formed in a forming cell is
blocked in the forming socket until the segment
of wire that follows in the winding operation is integrated
in the next forming cell introduced,
the wire is unwound from a wire winding to be straightened
se,
a round, insulated wire is unwound from a coil of wire to be
laminated and to give a flat and straightened wire,
the insertion of the wire segment into the forming cell
is done using a drawer the pocket associated with the pin
winding for penetration, being slidably mounted
axially and the length / width dimensions of the drawers
are set to be smaller than the interior dimensions
corresponding res of dimension forming cells
corresponding to the wire loops placed in the cells
forming,
after each passage of the wire around the spindle
the drawers associated with each pocket are changed
and,
- the changed drawers are provided with reduced dimensions in
length and width of a wire loop dimension per
compared to removable drawers,
the passage of the wire around the winding spindle is done
by blocking the start of the wire on the winding spindle and
by turning the winding spindle being connected soli
obviously to the forming cell,
a set of drawers is associated with each forming cell
whose number corresponds to the number of turns of
1 excitation winding,
- the length / width dimensions of the first game drawer
of drawers being reduced by the measurement of a wire loop
relative to the corresponding interior dimensions of
the corresponding forming cell and,
- the length / width dimensions of the next drawer being
each time decreased by the measurement of a loop of thread by
compared to that of the previous drawer,
the drawer set is mounted on a revolver head which after
each complete rotation of the winding spindle is
tour of a new switching step so that the drawer
directly following is aligned axially on the cell of
corresponding forming,
each drawer remains immersed in the associated forming cell
until the next drawer in the direction of rota
tion enters the following associated forming cell,
the turns are formed from an insulated flat wire and the
different turns are tightly applied one against
the other with their large sides wide by large section.

Drawing
The method according to the invention is described below using a device shown in the drawing, used to manufacture a molded coil for an excitation winding of an electric machine. Thus - Figure 1 is a perspective view of a molded coil
produced according to the method, - Figure 2 shows a detail seen in perspective of a stator
an electric machine with a molded coil,
place according to Figure 1, - Figure 3 is a perspective view of a molded coil
obtained by another process and corresponding to another
exemplary embodiment, - Figure 4 is a perspective view of a grif stator
polar fes of an electric machine with a soft coil
lée set up as shown in Figure 3, - Figure 5 is a schematic view of a device fa
connection of the coils molded according to Figures 1 and 3, - Figure 6 shows a detail of a schematic view in pers
pective of a device winding cylinder
winding of the device of Figure 5, - Figure 7 shows a detail in perspective view of the dis
positive winding of the device according to Figure 5, the
winding cylinder removed.

Description of the exemplary embodiments
Figures 1 and 3 show in perspective the two molded coils 10, 10 'for the excitation winding of an electric machine; these coils correspond to the extent that it is a flat, insulated wire in the form of a meander and which traverses the excitation winding according to several turns; the various windings of flat wires are superimposed with their large surfaces, that is to say their wide sides. While the meander shape of the coil 10 of FIG. 1 is substantially rectangular, that of the coil 10 ′ according to FIG. 3 has a more sinusoidal plot for the different curves of the meanders. The two coils 10, 10 'are designed for a six-pole stator.

 The stator 11 partially shown, in perspective in Figure 2 for a motor starter motor, is an example of an electric machine; this stator comprises a hollow cylindrical housing 11, formed of lamellae, with three excitation poles 12 forming one body as well as three excitation poles 12 ′ which slide with the engagement feet in the lamella housing 11; only two of the excitation poles 12 ′ are shown in FIG. 2. In the peripheral direction of the lamella housing 11, there is an alternation of a fixed pole 12 and a removable pole 12 ′. As shown in a sketched manner in FIG. 2, the shaped coil 10 is slid into the lamellar housing 11 after extraction of the removable excitation pole 10 '; each second loop of the six meanders of the coil 10 is applied around the fixed excitation pole 12.

Then, the three excitation poles 12 ′ are put in place which then come into the three other loops of the meanders of the coil 10 so that the excitation winding generally traverses the excitation poles 12, 12 ′ and the turns.

 In the case of the pole-claw stator 13 known according to FIG. 4 which consists of two stator halves, use is made of the coil formed 10 ′ according to FIG. 3 which is put in place when the stator halves are released; then the two stator halves are brought together so that, as in Figure 2, the excitation winding runs through the different claw poles according to a meandering path.

 The shaped coils 10, 10 ′ are produced using the device shown diagrammatically in FIG. 5; the manufacturing process takes place in a fully automatic manner. Winding wire 14 is received as a round wire, isolated on a spool in a wire drum 15; it is extracted from the wire drum 15 and pulled by a rolling device 16 which laminates it to form an insulated wire, almost flat. The winding wire 14 which is then flat, is directed into a straightening device 17 passing through a stripping device 18 and a separation device 19. Finally, it arrives in a winding device 20. The advance of the winding wire 14 is provided by a drive device 21.

 The heart of the winding device 20 is a winding cylinder 22 rotating around its axis. This cylinder is driven step by step (Figure 6). This cylinder has a coaxial winding pin 23 and several cells 24 equiangularly offset in the peripheral direction over a length segment of the winding pin 23 while being integral in rotation with the latter.

The number of shaping cells 24 is defined by the number of meandering loops required for the formed coil 10, 10 '; this number corresponds to half the number of planned excitation poles. In the case of a six-pole stator according to FIG. 2 or according to FIG. 4, the number of shaping cells 24 existing is equal to three. As indicated in FIG. 6 for a shaping cell 24, a drawer 25 is associated with each shaping cell 24; this drawer slides axially on the winding spindle 23 and penetrates substantially along a connection by shape in the cell 24. The shape of the cells 24 gives the shape of the meandering loops of the coils 10, 10 '.

In the case of the rectangular meandering shape of the coil 10 according to FIG. 1, the free length / width dimensions of the cells 24, that is to say the depth of the shaping cells 24 and their width in the direction of rotation define the dimensions of the meander loops. The drawer 25 which almost penetrates by a connection by the shape into the shaping cell 24 thus has appropriate dimensions length / width which is the dimension of a loop 141 (Figure 6) relative to the corresponding free dimensions of the forming cells 24. Each wire loop 141 is formed by the axial sliding of the slide 25 in the shaping cell 24; the drawer 25 applies the segment of wire which covers the opening of the cell to the bottom of the cell and thus presses the winding wire 14 against the side walls and against the bottom of the shaping cell 24. As the coil 10 must have several turns, each subsequent wire loop 141, smoothed in the shaping socket 24 and which applies internally against the wire loop 141 previously introduced, must use another drawer 25 of smaller dimension the length / width dimensions of the next drawer 25, each time reduce the measurement of a loop of wire 141 compared to the dimensions of the previous drawer 25. All the drawers 25 associated with a cell 24 are carried by a revolver head 26 which rotates step by step so that the next drawer 25 is always aligned with the shaping cell 24. Figure 7 shows in perspective the arrangement revolver heads 26 for the coil to be shaped according to FIG. 1 in the winding device 20. Each of the three revolver heads 26 is associated with a shaping cell 24.

As the coil 10 of the embodiment of Figure 1 has six windings, each revolver head 26 has six drawers 25a-25f. The revolver heads 26 are driven by belt drives 27.

The device shown in Figures 5 to 7 allows for the coil formed 10 according to Figure 1
The winding wire 14, extracted from the wire drum 15 is rolled flat and straightened, is applied on the field, that is to say with its narrow lateral surface on the winding spindle 23 and is fixed with the start wire on the winding cylinder 22. The winding cylinder 22 is then rotated using a stepping motor 28 shown in Figure 5; the winding wire 14 passes in front of the openings of the shaping pockets 24. The drawer 25a which moves axially makes it possible to introduce the winding wire 14 by forming the wire loop 141 in the first forming cell 24. During that the slide 25a is in the shaping cell 24, the winding cylinder 22 is continued to rotate until the winding wire 14 is in the next shaping cell 24 .

 The drawer 25a of the revolver head 26, following forms in the next shaping pocket 24, a loop of wire 141; then the slide 25a again emerges from the first forming cell 24 and returns to its basic position on the revolver head 26. The winding cylinder 22 continues to rotate; the drawer 25a of the second revolver head 26 remains in the second forming cell 24 and rotates therewith until the opening of the third forming cell 24 is occupied by the winding wire 14.

By introducing the drawer 25a into the third revolver head 26, the wire loop 141 is thus formed in the third forming cell 24; at the end of the input movement of the drawer 25a of the third revolver head 26, the drawer 25a of the second revolver head 26 is again extracted from the second forming cell 24.

 At the end of a complete rotation of the winding cylinder 22, a winding of the forming reel 10 has been completed. During the next winding of the second turn of the reel 10, at the start of the operation, all the revolver heads 26 are tilted so that all the cells 24 now face the drawer 25. When the winding cylinder 22 continues to rotate, the operations described above are repeated and each time in place of the drawer 25a, the drawers 25b slide into the pocket-shaped openings of the shaped pockets 24 occupied by segments of wire, like loops of wire 141 which are slid into the shaping cells 24; the loops then apply firmly in each shaping cell 24 against the wire loop 141 which is already there. After six rotations of the winding cylinder 22 with six changes of slide 25 for the three revolver heads 26, the winding reel 10 was finished with six turns.

As soon as the length of winding wire necessary for the shaping reel 10 runs through the stripping device 18, the winding wire 14 is stripped at this location and then it is cut in the separation device 19 at the location stripped, to be separated from the remaining parts of winding wire 14. The formed coil 10, the winding of which is finished, is then extracted from the winding pin 20 and placed in the stator according to FIG. 2.

 To manufacture the reel formed 10 ′ according to FIG. 3, it suffices to modify in the device described above, the shape of the cells 24 and of the drawer 25. The number of drawers 25 existing on the revolver heads 26 depends on the number of windings required in the coil 10 '.

Claims (9)

CLAIMS 10) Method of manufacturing a shaped coil for an excitation winding, this coil having a meandering pattern with several turns surrounding the poles of the excitation field of an electric machine, characterized in that - an insulated flat wire (14) passes completely around a winding pin (23) and passes in front of forming cells (24) provided on pocket openings provided on the winding pin (23) being offset from each other in a regular manner, these forming pockets (24) being directed in the axial direction, and their number corresponds to half the number of excitation field coils, - and when the wire is passed ( 14) on the openings of the cells, each segment of wire which generates the openings is pulled axially in the forming cells (24) as far as the bottom of the cells to form along the inner contour of each cell, a loop of wire (141), - the pass age around and the retraction of the wire (14) being repeated until the desired number of turns are wound on the winding spindle (23) and at the end of the winding the wire (14) is stripped and cutting and extracting the winding axially from the winding spindle (23) 2 ") Method according to claim 1, characterized in that the flat wire (14) is wound on the field on the winding spindle ( 23). 30) Method according to any one of claims 1 or 2, characterized in that for each subsequent introduction of the wire segment which generates the opening of the forming cells (24), the wire loop (141) which forms new, is applied against the preceding wire loop (141) against the forming cell (24) 40) Method according to any one of claims 1 to 3, characterized in that each wire loop (141) formed in a forming cell (24) is blocked in the forming cell (24) until the wire segment which follows in the winding operation is integrated into the next formed forming cell (24). 50) Method according to any one of claims 1 to 4, characterized in that the wire (14) is unwound from a wire winding to be straightened. 60) Method according to any one of claims 1 to 4, characterized in that a round, insulated wire is unwound from a coil of wire to be rolled and to give a flat and straightened wire. 70) Method according to any one of claims 1 to 6, characterized in that the insertion of the wire segment in the forming cell (24) is done using a drawer (25), the pocket (24) associated with the winding spindle (23) for penetration, being slidably mounted axially and the length / width dimensions of the drawers (25) are fixed to be smaller than the corresponding internal dimensions of the forming cells (24), d 'a dimension corresponding to the wire loops (141) placed in the forming cells (24) 80) Method according to claim 7, characterized in that after each passage of the wire (14) around the winding spindle (23 ), the drawers (25) associated with each forming pocket (24) are changed and, - the changed drawers (25) are provided with reduced dimensions  in length and in width of a wire loop dimension  (141) relative to the removable drawers 90) Method according to any one of claims 1 to 8, characterized in that the passage of the wire (14) around the winding spindle (23) is done by blocking the start of the wire on the winding spindle (23) and turning the winding spindle (23) while being integrally connected to the forming cell (24). 100) Device for implementing the method according to any one of claims 1 to 9, characterized in that a winding cylinder (22) rotating around its axis, driven step by step, comprises a spindle coaxial winding (23) and a number of molded cells (24) corresponding to the number of excitation poles, these cells being offset relative to each other by the same peripheral angle and are offset on the longitudinal segment of the winding spindle (23) being connected in rotation with it and each shaped socket (24) comprises at least one drawer (25) sliding axially on the winding spindle (23), this drawer being able to penetrate by introducing the segment of wire which occupies the opening of the cell, in the molding cell (24), to the bottom of the cell and the drive movement of the drawer (25) is synchronized on the step-by-step movement of the winding cylinder (22). 110) Device according to claim 10, characterized in that each forming cell (24) is associated with a set of drawers whose number (25a-25f) corresponds to the number of turns of the excitation winding, - the length / width dimensions of the first drawer (25a) of the  set of drawers being reduced by the measurement of a loop of  wire (141) relative to the corresponding internal dimensions  dantes of the corresponding forming cell (24) and, - the length / width dimensions of the drawer (25b-25f) according to  being each time decreased by the measurement of a loop of  wire (141) relative to that of the previous drawer (25a  25e). 120) Device according to claim 11, characterized in that the set of drawers (25a-25f) is mounted on a revolver head (26) which after each complete rotation of the winding spindle (23) is turned a new no switching so that the drawer directly next is aligned axially with the corresponding forming cell (24). 130) Device according to any one of claims 10 to 12, characterized in that each drawer (25) remains immersed in the associated forming cell (24) until the next drawer (25) in the direction of rotation enters the following forming alveolus (24). 140) Coil formed for an excitation winding with an excitation field coil which rotates with several meandering turns around an electric machine, characterized in that the turns are formed from a flat wire (16) , isolated and the different turns are tightly applied against each other with their large sides wide and of large section.