MXPA05014176A - Method and device for forming wave windings for rotor and stator cores of electric machines - Google Patents

Abstract

The invention relates to a method and device for forming wave windings, comprising web sections that are interconnected by winding heads, and introducing said windings into rotor or stator cores of electric machines. The wave windings (10) are cut from a continuously formed wave winding strip (52) consisting of winding wire (56), which is laid alternately around the external lateral surfaces of forming projections (50) by a wire guide (54) during the forming process. Said projections are offset in relation to one another on the periphery of two axially adjacent rotating discs (46, 48). Whilst the wave winding strip (52) is entrained on the periphery of the discs (46, 48), the distance between a forming projection (50) in the first row and the following forming projection in the other row is increased, in such a way that the external lateral surfaces of the forming projections (50) form the winding heads (14) of the wave windings (10). The wave windings (10) that have been cut from the wave winding strip (52) are subsequently introduced into grooves (89) of a rotor or stator core, or a transmission tool (88) that is similar to a rotor, said grooves opening radially to the exterior.

Description

METHOD AND DEVICE FOR FORMATION OF WAVY WINDING FOR ROTOR AND STATOR NUCLEOS OF ELECTRICAL MACHINES DESCRIPTION OF THE INVENTION The invention relates to a method and a device for the formation and introduction of corrugated winding with bridge sections connected by winding ends in rotor or stator cores of electrical machines in which the corrugated windings are cut, in each case with an amount a set of corrugations, of a continuous winding ribbon of winding wire winding with rectangular or round cross-section which is placed during the forming process by an alternating wire guide on the outer side faces of shaped protrusions arranged in the periphery of a forming element operable in rotational form, and then the corrugated windings, cut from the corrugated winding tape, are introduced in radially open slots to the outside of a rotor or stator core or a transfer tool similar to a rotor and are eventually displaced from the slots of the tool of transfer similar to a rotor towards the grooves opened radially towards the interior of a core of rotor or stator.

It has been known for a long time, for example, from EP 1 012 951 Bl, EP 0 604 797 A2 and US 5 881 778, to produce wave windings, particularly wave windings distributed for the production of alternators for automotive vehicles, by means of a nozzle of winding rotating by a template or of a template that spins in front of a fixed winding nozzle and axially inserting the annular corrugated winding thus produced in a stator. A method for the formation and introduction of corrugated windings with bridge sections connected by winding ends into a transfer tool similar to a rotor in which the corrugated windings are cut from a winding tape is also described in US 4,864,715. continuously formed wavy wire winding. The winding wire is placed during the process that forms the corrugated winding belt by forming rollers driven alternately by the right side face respectively left in a series of shaped protrusions configured in a driven conveyor chain in circulating form. At the end, the undulated windings are displaced from the radially open slots to the outside of the transfer tool into radially open slots into a rotor or stator core. In this method, the operation of complicated and difficult forming of each of the individual corrugations of the corrugated winding by four wire guides which are respectively applied one after the other in the form of pusher-driven forming rollers is disadvantageous. In addition, the formation of the winding ends is imprecise, since in its plastic deformation only the tension of the pulling winch for the winding wire of the prepared wire is available. With the aim of obtaining as little as possible a filling factor as high as possible from the stator slots and simultaneously obtaining well-ventilated winding ends that produce comparatively little noise, they have been created - according to EP 1 120 881 A2 - stators with a multiplicity of rectangular grooves in cross section, open radially in the interior, into which the corrugated windings of rectangular winding wire are inserted in such a way that, in the cross section of a groove, the cross sections by the winding wire they form a row that extends along the slot and fill the cross section of the slot. The difficulty in producing such a stator is that the thick rectangular wirewhose width corresponds to the width of the groove, it is difficult to deform with conventional winding and inserted methods and the winding ends that normally protrude on the front side by the stator core are added to generate an excessive radial width, due to the multiplicity of the coil windings that overlap at the periphery, and due to the poor deformability of the winding wire which is practically impossible to reduce with conventional winding forming tools. The invention is therefore based on the object of offering a device and a method that allows to produce undulated windings in a simple manner also with comparatively thick winding wire and to introduce them into rotor or stator cores. Based on the method described in the US document 4,864,715, the above objective is solved according to the inventive proposal, as far as the method, because the winding wire is placed in an alternating manner around the external lateral faces of respectively a shaped projection disposed axially next to each other in a row over the periphery of two discs operable in a rotary fashion, or in two rows on the periphery of a roller operable in a rotary manner and displaced from each other, being that in the region of angle at which the corrugated winding tape is dragged on the periphery of the respectively, of the roller, the axial distance between a forming projection of one of the rows and the next forming projection of the other row is increased by a measure of lime that the outer side faces of the forming projections form the winding ends of the undulated windings. The invention offers the advantage that the winding wire is placed, in a single integrated process, continuously in the form of a corrugation fixed by stops and then adopts the desired undulating shape under tension by plastic deformation. In total, only two very simple forming processes are required, namely, in addition to the bending of the referred wire, to form the corrugated winding belt, only the bending of the corrugated winding cut to the length of the corrugated winding tape to form a ring with the relatively large radius of curvature of the annular arrangement of the corrugated winding in the rotor or stator core. The device proposed for the inventive embodiment of the new method comprises a forming device for the formation of a corrugated winding belt and an installation for introducing corrugated windings cut in radially open grooves to the outside of a rotor or stator core or a rotor-like tool, wherein the forming installation comprises forming protrusions evenly distributed over the periphery of a rotary forming element and a winding wire can be placed in an alternatingly wavy manner around the outer lateral faces of the protrusions of forming that follow one after the other in the periphery, the shape of the projections corresponding to the shape of the front contacts of the corrugated windings to be produced, and is characterized in that the rotary forming element comprises two rotating discs respectively a row or a rotary roller with two rows These are disposed in a displaced manner relative to each other, of protruding shaped protrusions on the disc periphery respectively roller, whose axial distance can be modified during a rotation of the discs respectively of the roller, and also comprises a guide of wire guided in such a manner that it can deposit the winding wire in an alternating wavy manner around the outer side faces of the forming projections respectively belonging to the one or the other row respectively and follow one another in sequence. This device offers the advantage that it is independent in principle from which wave shape, length and relative position each have the corrugated windings that must be introduced into a rotor or stator core. It is, therefore, applicable to a large number of different winding designs. If the corrugated windings are to be inserted into a rotor or stator core with slots open towards the inside, that is to say, the rotor-like transfer tool is applied to an external stator or the rotor of an external armature motor or generator, mentioned in the foregoing, for radially displacing outwardly the windings produced first in the tool for transferring the slots thereof to the grooves of the outer stator or the external armature rotor. Advantageous refinements of the above-mentioned method and of the new device are indicated in the dependent claims. Next, an exemplary embodiment of the invention is explained by the attached drawing. They show: Fig. 1 a corrugated winding in front of a bar-shaped magazine and lateral guide rails; Fig. 2 twelve undulated windings inserted in the bar-shaped magazine according to Fig. 1 which are then inserted together in a rotor or stator core or in a transfer tool similar to a rotor; Pig-3 a view from above on an installation consisting of several partial devices for forming and introducing corrugated windings in stator cores; FIG. 4 a side elevational view of an installation for the continuous forming of a corrugated winding belt with a stamping installation connected; Fig. 5 a top view of a forming installation and the embossing installation according to Fig. 4; Fig. 6A, B, C side views from the left in relation to Fig. 4 of the installation to form a corrugated winding tape, wherein the components of the installation are shown in different states during the formation of a corrugated winding; Fig. 7 a view from above on the wire guide that is part of the installation for forming a corrugated winding tape; Fig. 8 a simplified side view of a rotor or stator core or of a rotor-like tool with radially open slots to the outside in collaboration with the bar-shaped magazine shown in Fig. 1 and 2 and guiding organs for guiding the transferring the corrugated winding of the loader to the rotor core or stator respectively the rotor-like tool; Fi - 9 a schematic view from above on the bar-shaped magazine and the guide members in section according to FIG. 8, where for graphic reasons the undulated windings lying in the slots of the magazine are also represented, - Fig. 10 A partial cross section simplified by a transfer tool similar to a rotor in a concentric position adopted during the transfer of corrugated windings to a stator core and Fig. 11 a longitudinal section simplified by the transfer tool according to Fig. 10. The corrugated winding 10 shown in Fig. 1 has, depending on the amount and capacity of the grooves of the rotor core or stator, that they must be equipped with a certain amount of corrugations that are formed by bridge sections 12 and winding ends 14 in the form of a gable roof. The contact ends of the corrugated winding are designated with the number 16. In the case of the example, the corrugated winding 10 shown occupies every sixth slot of a stator core, with the bridge sections 12 extending through the grooves of the coil. The stator and the winding ends 14 in the form of a pitched roof protrude from the stator core on the front side. Between two stator grooves occupied by the corrugated winding 10, in the exemplary embodiment, five stator grooves in which other similar corrugated windings 10 are inserted are free. In total, they can be present, for example, in the slots 18 of a stator core 20, shown in FIG. 10, open radially inwardly and rectangularly in cross section, respectively eight layers respectively beds - by which is meant here a wire bed in a slot 18. This amount, however, is only an example of embodiment. The slots 18, rectangular in cross section, could also be filled respectively with four wire beds of a thicker rectangular wire. Depending on the type of motor respectively generator and the selected winding, other quantities of beds can also be presented, whereby also two or more wire beds in a slot can be formed by a single winding 10 corrugated in one piece. This occurs, for example, in the case of a so-called distributed corrugated winding, in which the bridge sections are located in two or more beds in the same stator slots, but the winding ends protrude from one or more beds in the same. the same front side of the core, while the winding ends of the respectively other beds protrude on the opposite side of the stator core. Another possibility for filling several wire beds in a groove with a single corrugated winding is to take advantage of a corrugated winding according to Fig. 1 so long that it extends several times over the circumference of the stator core after being inserted therein. The advantage of the winding ends in the form of a gable roof becomes evident if one imagines, based on Fig. 1, that it is inserted in those grooves, which are directly to the right in each case of the grooves. occupied by the bridge sections 12 of the first corrugated winding 10, a second corrugated winding in the bar-shaped magazine 22, shown there, after the first corrugated winding 10. The third corrugated winding is then placed, in turn, in the adjacent grooves adjacent to the right and thus the fourth, fifth and sixth corrugated windings. In the end it is found that it is always necessary to carry only the left legs of the winding ends 14 in the form of a gable roof on the right legs of the winding ends of the previously inserted undulated windings, but the right legs no longer they have to cross any previously placed undulated winding. It will further be detected that all defined crossing points in which a left leg passes over a right leg of a previously inserted undulated winding, respectively form the only crossing point at this point. Therefore, it is only necessary to globally or locally raise the left legs of the winding ends, which must be crossed, at the crossing points and then lower them again at the level of the bridge sections, so that all the sections of bridge and respectively half of the winding ends in the form of a gable roof of the six windings, placed one after the other, are located without difficulty in the same wire bed in the grooves. The raising and lowering locally of one half of the roof to two waters, to pass it over one or several halves of roof to two waters of undulated windings previously placed, - can be done by stamping the corrugated winding before placing it in the loader 22 in the form of a bar. It is understood that, as an alternative, it is also possible to lower half of the cross-gable roof or raise a half one half of a roof to two waters and lower the other a little. From Fig. 1 and Fig. 2 it is also seen that a winding of the double circumference length can be folded and folded in the middle such that two bridge segments respectively lie one on top of the other and the winding ends are disposed on each other. opposite way. As an alternative, it would also be possible to place one of two identical undulated windings of simple circumferential length in the opposite direction on top of each other and electrically connect it at one end with it. This also results in a corrugated winding distributed with two bridge sections in each groove and with winding ends arranged directly in the opposite direction. If the corrugated windings 10 have the double circumferential length, then it is possible to proceed during the positioning in the grooves of the bar-shaped magazine 22 in such a way that the six corrugated windings forming a wire bed are placed first, in the sequence described above, only with half its length. The sequence is then inverted in the second half of the length of the magazine 22 in the form of a bar, so that the winding wire inserted at last with its first half is placed as first in the second half of the magazine 22, the corrugated winding second to last as second, etc. In this way it is achieved that, at the winding ends of the second wire bed in the stator, the wire crosses are located in the other half of the roof of two waters. In addition to such bends, electrical connections and alternations of sequences, it consists of placing the undulated windings in the grooves of the magazine 22 the additional option of bending upwards individual undulations of an already placed undulated winding and re-folding it to its original position in the slots of the charger 22 after placing one or more additional undulated windings, whereby at a certain point a modification of the sequence of the undulated windings placed one on top of the other is achieved. Fig. 2 shows the very uniform distribution of the winding ends of a multilayer winding. Fig. 3 shows, in top view, an overview of a complete production facility for winding and inserting corrugated windings into stator cores. In this case, two forming devices working in parallel are designated with 24 and 24 ', in which respectively a winding wire pulled from a respective 26' roll 26 'is formed in continuous mode to produce a corrugated winding tape, of the which are obtained the corrugated winding sections shown in Fig. 1 and 2. With 28 respectively 28 'is designated in Fig. 3 respectively a stamping station in which the winding ends of the corrugated winding are formed by dies and dies in such a way that can happen next to each other in different planes. In addition, the corrugated windings 10 of the corrugated winding strip produced in continuous mode to the respectively required length can be cut at this station and the connection terminals 16 are stretched. At the next station, designated 30 respectively 30", the undulated windings 10 are placed in the sequence and arrangement provided in the slots of the magazine 22 in the form of a bar and, namely, with as many wire beds in each slot as they are inserted. together in a single process step in the grooves of a rotor or stator core or of a transfer tool similar to a rotor.According to Fig. 3, a transport system with pallets carrying respectively a magazine 22 in shape is being provided. Once a magazine 22, according to Fig. 2, has been loaded with corrugated windings, the corresponding pallet 32 respectively 32 'is transferred to the transfer station shown at 34, and another pallet 36 respectively 36' it replaces in the charging station 30 with a charger 22 in the form of an empty bar In the transfer station 34 the corrugated windings of the charger 22 are transferred in the form of a bar, in the case of the example, first to a transfer tool similar to a rotor with radially open grooves to the outside. For details, reference is made below to Fig. 8 and 9. The loaded transfer tool, driven by a rotating table, then performs a pivoting movement to an insertion station 38, in which the rotor-like tool is inserted into the cavity of a stator core in such a way that the grooves thereof, open radially inward, are aligned with the slots of the transfer tool, so that radially displaceable pushers can push the corrugated windings of the tool Transfer radially to the grooves of the stator core. The rotating table 40 then drives the stator core, in a pivoting motion, to a compression station 42 in which the group of undulated windings, first placed, is pushed or pulled further out in the radial direction and compressed. the ends of winding. The fully wound stator core of the rotating table 40 is then transported to an exit station 44 and there withdrawn or delivered. If a second or several groups of corrugated windings must still be housed in the stator core, then the partially coiled stator core is placed once more to the insertion station 38 and loaded with the second or the other corrugated winding groups. A compression step in the compression station 42 then follows again, before the stator core is withdrawn at the output station. It may be convenient to form the undulated windings formed in the forming installation 24 'with somewhat narrower winding ends than in the forming installation 24 and to introduce into the transfer station 34 and the insertion station 38 in alternating mode first a group of corrugated winding of the forming installation 24 and then a group of corrugated windings of the forming installation 24 ', by means of appropriate transfer tools, in the stator core. With the winding ends of different width the different radii of the corrugated windings can be taken into account after their introduction into the stator core. Figs. 4, 5 and 6A, B and C show the installation 24 of more detailed forming and Fig. 4 and 5 also also the embossing installation 28. The main components of the forming device 24 are two discs 46, 48 placed axially next to one another which are in continuous rotation with forming projections 50 projecting respectively from the circumferential face. The disks 46, 48 cooperate during the continuous production of a corrugated winding belt 52 with a wire guide which is housed, rotatably in steps about a horizontal axis, immediately adjacent the periphery of the disks 46, 48. The shape of the winding wire supplied from the reservoir 26 to the corrugated winding belt 52 is better understood from the simplified schematic representation in FIGS. 6A, 6B and 6C. At the beginning of the continuous forming step, the front end of the winding wire, designated 56 according to FIG. 6A, is momentarily tightened in a forming projection 50 of the left disk 46 or otherwise clamped and placed as a loop around the web. the proximal projection 50, which follows in the direction of rotation, of the right disc 48. When then the wire guide 54, consisting of a carrier 55 rotatably housed, for example in the form of a disc or a bar, and drive pins 58, 60 projecting axially towards the discs 46, 48 and which are placed in diametrically opposite direction near the outer periphery, start to rotate according to the directional arrow 62, then in the case of the example according to Fig. 6A, it encounters the trailing pin 58 against a winding wire 56 coming from the reserve 26 and begins to form a bond in its periphery. Simultaneously, the trailing pin 58 also carries the winding wire around a forming projection 50 of the left disk 46, on whose peripheral face it is held by a pusher 64, pushed axially forward against the forming projection, which is arranged in the center of the carrier 55 or extending clamped against passing through the carrier 55. The pusher is preferably formed at its free end with a retaining shoulder 66 which pushes the wire a sufficient distance over the forming projection 50. Therefore, in the step shown in FIG. 6A, a loop is formed simultaneously on the forming projection 50 of the disk 46 and on the drive pin 58 respectively. As the rotary movement of the wire guide 54 continues in the direction of the directional arrow 62 and with simultaneous rotation of the discs 46 and 48 in the direction of the directional arrow 68, they increase the wrapping angles of both loops, as shown in FIG. shows in the intermediate stage represented in Fig. 6B. There, the vertical pivots 58 and 60 are located approximately one above the other in front of the disc 46. The pusher 64 is removed from the disc 46, because meanwhile the wire loop in the projection 50 of the disc 46, which has rotated a little more, is subject only. In order to avoid that in the step according to FIG. 6B, the winding wire 56 rests against the next projection shoulder 50 of the disk 46, which follows the forming projection 50 that is forming the loop, a guide sheet 70, shown in FIG. Fig. 4, which guides the winding wire 56 above the next forming boss 50. Once the wire guide 54 has continued to rotate and has reached the position according to FIG. 6C, a projection 50 for forming the disk 48 is located axially immediately opposite the drive pin 58. The rotary movement of the guide 54 of wire is interrupted briefly and a ripper 72, which is shown in Fig. 4 and 7, slides the wire loop, seated on the pin 58, pulling it axially away from it and placing it on the shaped boss 50 that is in front of him. Simultaneously or immediately thereafter, the pusher 64 advances again in the axial direction and pushes the wire 56 on top, that is, in front of the shoulder 50 for forming the disc 46 in the direction of movement, over which it was guided just a moment before by the guide blade 70, so that now this shaped protrusion forms the next loop. Next, the processes described above are repeated when the driving pin 60 arrives with the continuation of the rotation to that position, in which the drive pin 58 is located in FIG. 6A. As shown in the drawing, the projections 50 formed on the two discs 46 and 48 are disposed one with respect to the other aligned to interstice, the intermediate distance measured at the circumference between a projection 50 being in one of the discs and the projection 50 of the immediately following shape of the other disk is approximately as large as the diameter of the winding wire 56.

The continuous rotary movement of the discs 46 and 48 is adjusted to the discontinuous rotary movement of the wire guide 54 in such a way that a wire loop is transferred sequentially to each forming projection 50 of both discs 46, 48. in total there is the tape 52 of continuous corrugated winding. In order to obtain for the wire guide 54 a rotary movement with brief interruptions respectively at that stage in which the wire loops are slid by the traversing pins 58, 60 above the forming projections 50 of the disk 48, it can be use an intermittent movement mechanism, for example, in the form of a Maltese cross mechanism. The wire winch for the wire of the wire reserve 26 contains a wire brake. The winding wire 56 is therefore under tensile tension during the formation of loops around the forming projections 50, and already before placing the wire loop on the forming projections 50 a certain waveform is present respectively a zigzag form. However, the tensile stress would normally not be sufficient to give a precise shape, with its angles and straight intermediate paths, to the winding ends in the form of a gable roof, even if the forming projections 50 have a cross section corresponding to the winding ends 14. In order to achieve the desired shape of the winding ends 14, it is therefore envisaged to provide the forming projections 50 in both peripheral rows in the disks 46, 48 in the region of the periphery, in which the The wavy winding tape 52 of the loop forming point to the point of the outlet of the discs 46, 48, is first enlarged by a certain measurement, which is sufficient to achieve a comparatively high tensile tension which is necessary for the formation of the winding wire, and then reduced again. If the forming projections 50 are arranged on a wide roller so as to be displaceable in the axial direction in a controllable manner, then the roller can rotate uniformly along a straight axis. But if, instead, instead of a wide roller, two discs 46, 48 are used, it is not necessary that the forming projections 50 perform a relative axial movement, since it is sufficient to accommodate the discs 46, 48 in such a way that firstly, during the rotary movement, the distance between two obliquely formed shaped projections carrying the corrugated winding tape is increased and then reduced again. In the simplest case, the rotary axes can, for this purpose, be tilted laterally outward in decline. Then the distance between the two discs 46, 48, and with this between the obliquely formed shaped projections 50, is larger up, down smaller and at the point of loop formation approximately as large as at that point where the tape 52 of corrugated winding is disengaged from the disks 46, 48. In the path from the loop forming point to the detachment point, therefore, the intermediate distance as desirable increases, and then decreases again. Of course, other housings can also be selected for the discs 46, 48, which produce a reciprocating movement of the discs with the aforementioned effect. Finally it is noted that, for the production of the winding ends 14, it is not necessary to use forming projections 50 with a corresponding cross-sectional shape. The latter could be replaced, for example, by three pivots that are housed in those points where the outer corners of the forming projections 50 are located. The production of the pivots is more economical than the production of the forming projections 50. It is understood that the forming projections 50 may have another appropriate contour for the winding ends instead of a cross-section in the form of a gable roof. The equivalent is true for the provision of pivots that can be applied as an alternative. Approximately at the point of the circumference of the discs 4648, opposite the point of loop formation, in the case of the example, a protective sheet, disposed in the interspace between the discs 46, 48 can ensure that the corrugated winding tape 52 reliably detaches from the forming and forming projections 50. firstly forms a free-hanging loop 74, before the corrugated winding belt 52 is caught by driving pins 78 on the outer face of an endless conveyor driven conveyor 76 and transported to the embossing device 28. The free-hanging loop 74 varies during operation with respect to its length and forms an intermediate reserve which compensates for the uneven loosening speed, due to the periods of repose of the transport band 76, in relation to the uniform transport speed of the carriers. discs 46, 48. The loop 74 can possibly be supported with a flexible guide 80 which yields in the manner of a spring under load, in order to prevent an excessive extension of the corrugation ribbon 52 due to its own weight. The stamping station 28 has the function of deforming the winding ends 14 vertically relative to the plane of the corrugated winding belt 52 in such a manner that, in the state mounted on the stator core, the overlapped winding ends are not obstructed. the undulated windings 10 of the same wire bed, for example of the radially outermost wire bed, can be inserted as tension free as possible in their bed respectively position in the stator slots, so that it is not necessary to compress strongly the winding ends crossed during the insertion process, to deform them and so that the bridge sections of the corrugated windings 10 can assume their intended position in the stator slots. According to its purpose, the die 82 and the die 84 are dimensioned in such a way that one or more winding ends 14 can be stamped, upwards or downwards, totally or partially relative to the main plane of the stamping operation. Rib 52 of corrugated winding. In this way, all the winding ends 14 of a winding 10 can be formed simultaneously with a suitable number of dies in a single stroke. As an alternative there is the option of forming the winding ends 14 of a corrugated winding 10 with fewer dies 82 in several strokes. Normally the conveyor band 76 will stop during forming, during which the discs 46, 48 convey the corrugated winding tape 52 produced to the loose loop 74 which serves as intermediate reserve. If a large production capacity is required, then it is also possible to operate in a mobile manner the dies 82 and dies 84, in association with a longer transport band 76, so that they are displaced during the forming operation together with the web 76. of transport at the speed of this one. With such an operation mode, the freely hanging loop 74 is not required. In the embossing installation 28 there are, in addition to the dies 82, non-shown cutting tools that separate the corrugated winding tape 52 at predetermined points, to obtain undulated windings 10 of determined length. The wire ends of the cut corrugated windings are drawn by jaws not shown to obtain the connection terminals 16 shown in Fig. 1 and 2. Furthermore, in the embossing facility 28, or in another forming station, the bridge sections 12 of corrugated windings produced with round wire to obtain a rectangular cross section. After the embossing installation 28, another process position still follows, in which, automatically or manually, a long corrugated winding 10 is folded on itself in such a way that a corrugated winding distributed half the length is generated. As an alternative it is also possible to connect two windings 10 undulated one on top of the other to obtain a distributed undulated winding and electrically connect them at one end. There is also the option to cross two or more undulated windings, which must be arranged next to each other in different grooves, at points determined in such a way that in one section of their length one corrugated winding lies below the other corrugated winding, but in another section of its length above it. In the next operation step, the undulated windings 10, formed in the manner described in the foregoing, are placed in the loading station, designated 30 in Fig. 3, in the transverse slots of the bar-shaped magazine 22 respectively of rack, also shown in Fig. 1 and 2, as well as in Fig. 8 and 9. For this purpose a conveyor belt transports in the manner of the conveyor belt 76 one after another several wave windings 10, whose ends 14 of The windings are guided in this on the guide rails 86 shown in Fig. 1, in the bed respectively predetermined above or below the determined transverse grooves of the bar-shaped magazine 22. The corrugated windings 10 are then introduced by respectively raising or lowering the guide rails 86 or alternatively by lifting or loosing the bar-shaped magazine 22 respectively in the transverse grooves thereof. Of course, there is also the possibility of introducing the wavy windings 10 from above into the grooves of the bar-shaped magazine 22 and then to turn this together with the corrugated windings inserted to put it in the position according to Fig. 8. In Fig. 8 it is shown transferring the wavy windings of the bar-shaped magazine to a rotary cartridge respectively a transfer tool 88 similar to a rotor with slots 89 radially open to the outside. This operation is carried out in the transfer station designated 34 in Fig. 3. Instead of a transfer tool 88, a rotor or stator core with slots open radially to the outside may also be present. According to FIG. 8, for the transfer operation, the bar-shaped magazine 22 is aligned tangentially with respect to the transfer tool 88 similar to a rotor, respectively a rotor or stator core present in its place, the slots of bar-shaped magazine 22 and slots 89 of transfer tool 88 are oriented with their openings toward each other. In addition, the distance of the slots and the relative movement of the magazine 22 and of the transfer tool 88 are adjusted to each other such that, at the point of tangential contact, the two opposing slots are respectively aligned with each other. In the exemplary embodiment according to FIG. 8, during the transfer operation, the transfer tool 88 performs a counter-clockwise rotary movement about a stationary axis, while the bar-shaped magazine 22 is advanced in line straight from the right to the left along a linear guide not shown simultaneously with the circumferential speed of the transfer tool 88. While this coordinated movement occurs, two U-shaped guide members 90, 92, viewed from above, push the windings 10, possibly held up to this moment in the slots of the magazine 22 by guide rails corresponding to the guide rails 86, in the region of the tangential contact point and the region behind it in the direction of movement, causing them to come out of the slots of the magazine 22 and enter the respective opposite slots of the transfer tool 88. As the bar-shaped magazine 22 according to Fig. 1, 2 and 9 is narrower than the length of the bridge sections 12 of the corrugated windings 10 the U-shaped guide members 90, 92 can attack on both sides together to the bar-like magazine 22 in the outer regions of the bridge sections 12 as well as the winding ends 14 to move the bridge sections one after the other, of the slots of the magazine 22 and push them into the slots of the transfer tool 88. Instead of two guide members 90, 92, a single larger guide member could also be used. As an alternative there would be the option of providing pushers or pushers that push with one or two strokes respectively bridge sections held in a slot of the magazine 22 to the opposite slot of the transfer tool 88. The tangential arrangement shown in Fig. 8 of a bar-like magazine 22 in relation to a transfer tool 88 similar to a rotor is designed for the transfer operation with very simple drives. If there is a disposition to do without this, it is also possible to inventively use a loader 22 in the form of an upward or downwardly arched bar with a determined radius in relation to Fig. 8, because in this case too it occurs at the contact point of the transfer tool 88 a substantially tangential relative alignment and movement. In all cases, while the respective other component is fixed, the transfer tool 88 or the bar-shaped magazine 22 can be guided in a combinatorial movement in such a way that a rotational movement is presented which allows the transfer of the corrugated winding.

How many wave windings are transferred in a bar-like work cycle of the magazine 22 to the transfer tool 88 and to a stator or rotor core with radially open grooves therein depends on the specific case. Normally, two transfer operations will suffice. Fig. 10 and 11 show a partial cross section of the rotary cartridge respectively of the transfer tool 88 on a larger scale, as well as its longitudinal section during the radial insertion of the corrugated windings 10 into the grooves 18 open radially inside a core 20 of stator. For this operation of translation the stator core 20 is placed in that axial rotary position on the transfer tool 88 or this is inserted into the cavity of the stator 20, in which the grooves 18 open radially to the inside are aligned with the radially open grooves outside of the transfer tool 88. The undulated windings, seated in the grooves of the latter, are then displaced by lamella-shaped pushers 94, which are housed further in the same grooves, radially outwardly to the grooves 18 of the stator core 20. Fig. 10 shows, by way of example, a slot 18 in which four beds of corrugated winding wire have already been inserted in a pre-transfer operation, while four additional wire beds of corrugated windings are still seated in the slot 89 corresponding to the transfer tool 88 and which must be displaced by the associated pusher 94, in the next transfer operation, radially outwardly to the aligned stator slot. Another stator slot, rectangular in cross-section, has already been completely filled with eight wire beds of corrugated windings adjusted in their cross-section. There are several options for deploying and removing the pushers 94 radially with power cylinders or worm drives. A simple example of embodiment is shown in Fig. 11. It has pushers 94 in the form of lamellae which are guided in a displaceable but axially fixed manner in the grooves radially open to the outside of the transfer tool 88. To move them axially, a power cylinder or other drive displaces a centrally acting bar 96 in which are fixed conical or conical disks 98 whose parallel front and rear wedge faces, extending obliquely relative to the longitudinal axis, engage in the pushers 94 in the form of lamellae. Therefore, a movement of the upwardly acting bar 96, in relation to FIG. 11, causes the pushers 94 to open and thus move the undulated windings in the slots 89 of the transfer tool 88 toward the stator slots 18. By withdrawing the drive rod 96 downwards after the transfer operation, the pushers 94 are pulled radially inward again. As an alternative for the discs 46, 48 could also constitute bars, corresponding to disks with an infinite diameter, with shaped projections 50 fixed thereon, in a manner analogous to the referred roller, a bar with two rows of projections 50 displaceable transversely in collaboration with a wire guide 54, the forming facility for the corrugated 10 windings in ribbon form. In such a mode, all the other components and measures described could be applied or changed in a similar way.

Claims (36)

1. CLAIMS 1. Method for forming and introducing corrugated windings with bridge sections connected to winding ends in rotor or stator cores of electric machines in which the corrugated windings are cut with a certain amount of corrugations of a corrugated winding tape, formed continuously, of wire of winding with rectangular or round cross section which, during the forming operation, is placed by a wire guide in an alternating manner by the external lateral faces of some forming projections, arranged on the circumference of a rotationally operable forming element. , and then the cut corrugated windings of the corrugated winding tape are introduced into grooves open radially outwardly of a rotor or stator core or of a transfer tool similar to a rotor and are eventually displaced from the grooves of the tool. transfer similar to a rotor to open slots rad It can be inserted into a rotor or stator core, characterized in that the winding wire is placed in an alternating mode around the outer side faces of the forming projections disposed offset from each other in a row on the circumference of two discs respectively. can be rotationally actuated one axially next to the other or in two rows on the circumference of a roller operable in rotary mode, being that in the region of angle at which the corrugated winding tape is dragged on the circumference of the discs, respectively of the roller , the axial distance between a forming shoulder of one row and the next forming shoulder of the other row is increased such that the outer side faces of the forming projections form the winding ends of the corrugated winding. Method according to claim 1, characterized in that the winding wire in each forming operation is bent by pressure of at least one drive pin placed eccentrically in a carrier operable in rotary mode against the circumference of the wire and transverse forces exerted around a forming shoulder of the one row to form a first loop and around the driving pin to form a second loop which is slid over a forming shoulder of the other row. Method according to claim 1 or 2, characterized in that towards the end of the region of the angle at which the corrugated winding tape is dragged on the circumference of the discs respectively of the roller, the tension in the winding wire is reduced again by reducing the distance between the two rows of formed projections on the winding wire. . Method according to one of claims 1 to 3, characterized in that at least a part of the winding ends of the corrugated windings is formed in the form of a gable roof and then before insertion of the grooves of a bar-shaped loader at least one half of the gable roof is pushed at least partly by plastic deformation to leave the plane of the bridge sections adjacent to the winding ends. Method according to one of claims 1 to 4, characterized in that the continuously formed corrugated winding belt is guided at least between two forming stations and / or assembly stations as a loose loop that compensates for different transport speeds in the two forming or assembly stations. Method according to one of claims 1 to 5, characterized in that the corrugations adjacent to the cutting points of the winding wire are bent upwards and formed in contact terminals of the corrugated windings. Method according to one of the claims 1 to 6, characterized in that the bridge sections of several corrugated windings are placed in parallel transverse grooves of a bar-shaped magazine and carried thereon during transfer to grooves open radially outwards of a rotor or stator core or a transfer tool similar to a rotor. 8. Method according to one of claims 1 to 7, characterized in that the corrugated windings are essentially tangentially approached to a rotor or stator core or a rotor-like tool respectively with open radially outward grooves and their bridge sections inserted into the slots under pressure during a rotary movement of the rotor. rotor or stator core respectively of the transfer tool similar to a rotor and an essentially tangential relative movement, corresponding to the circumferential speed of the corrugated windings. The method according to claim 8, characterized in that after the housing of the corrugated windings, the transfer tool similar to a rotor is inserted into a rotor or stator core with grooves open radially inwards and the corrugated windings are displaced radially from the rotor. The slots of the transfer tool similar to a rotor to the grooves of the rotor core or stator. 10. Method according to claim 8 or 9, characterized in that the corrugated windings are so long that they must be introduced during several revolutions of the rotor core or stator or of the transfer tool similar to a rotor with open radially outward grooves in these grooves. 11. Method according to one of claims 7 to 10, characterized in that the corrugated windings are respectively placed in one piece in several beds in the bar-shaped magazine. Method according to one of claims 7 to 11, characterized in that between two beds of a corrugated winding at least one bed of another corrugated winding is placed in another slot of the loader in the form of a bar. 13. Method according to one of claims 7 to 12, characterized in that at least one corrugation of a corrugated winding inserted in the bar-shaped magazine is folded so that it exits approximately 90 ° from the tape-shaped plane and after the placement of at least one additional corrugation is bent from back to the loader in the form of a bar. 14. Method according to one of claims 9 to 13, characterized in that after the introduction of several corrugated windings in a rotor or stator core with slots radially open to the inside, the winding ends of the corrugated windings projecting on the front of the rotor core or stator are displaced more radially towards outside and then additional wave windings are introduced into these grooves. Method according to claim 14, characterized in that the corrugated windings inserted into the grooves of the rotor core or stator in the first stage are formed with wider winding ends than the corrugated windings inserted in a second stage. Method according to claim 15, characterized in that the corrugated windings, introduced in the second stage in the grooves of the rotor core or stator, are formed with winding ends higher than the corrugated windings introduced in the first stage. Device for carrying out the method according to one of claims 1 to 16, comprising a forming device for the formation of a corrugated winding belt and an installation for introducing corrugated windings cut from it in grooves open radially towards the outside of a rotor or stator core or a transfer tool similar to a rotor, wherein the forming installation comprises forming bosses evenly distributed around the circumference of a rotary forming element and a winding wire can be placed in the form of undulations alternating around the external lateral faces of the forming projections that are followed in the circumference whose shape corresponds to the shape of the winding ends to be formed, characterized in that the rotary forming element comprises two rotating discs with respectively one row or a rotating roller with two rows of projections of protruding shape on the circumference of disc or roller, uniformly distributed on the circumference and arranged in displaced form relative to the respective other row, whose axial distance is changeable during a revolution of the discs respectively of the roller and a guided wire guide of Such that the winding wire can be placed in the form of corrugations in alternating mode around the outer side faces of the forming projections respectively belonging to one or the other row following one another. Device according to claim 17, characterized in that the free distance measured on the circumference between a forming shoulder of the one row and the next forming shoulder of the other row corresponds to the thickness of the winding wire. Device according to one of claims 17 or 18, characterized in that the lateral faces of the forming projections facing in opposite directions have, in the view from above on the circumference of disc or roller, respectively the shape of a roof of two waters. Device according to one of Claims 17 to 19, characterized in that in the circumferential section a corrugated winding travels in the disks respectively the roller, the axial distance between a forming projection of the one row and the next forming projection the other row can be first increased and subsequently decreased. Device according to claim 20, 26. Device according to claim 25, characterized in that each row of forming projections is fixed in a disk housed individually and reciprocally or obliquely so that the distance between the two rows in the section of circumference traveled by a corrugated winding increases first and then decreases, being that due to the distance increase the winding wire that is stretched tightly against the outer faces in the form of a gable roof of the forming projections can be formed with ends of Corresponding winding in the shape of a gable roof. Device according to one of Claims 17 to 21, characterized in that the wire guide is a carrier rotatably operable about a rotary axis essentially in transverse direction relative to the rotary axis of the discs respectively of the roller comprising at least one pivot eccentric drag and a pusher housed essentially on the rotary axis, axially displaceable in a controlled manner, being that the carrier with the or with the pin (s) of drag immediately revolutionizes next to the discs the roller in synchrony with the rotary movement of these and, in a first intermediate phase of a work cycle, the pusher can be moved towards the fed winding wire - in the space between the carrier and the discs respectively the roller and a forming shoulder of the one row, so that the winding wire is clamped in this formed protrusion for the formation of a first loop, and in a second intermediate phase, in which a forming projection of the other row is located axially in front of a driving pin, a scraper can be operated with which a second loop, formed from the winding wire in the second part, can be detached from the driving pin. the pivot of drag, to leave it in the projection of formed that is in front of him. Device according to claim 22, characterized in that the carrier rotates in that direction of rotation in that the driving pin, displaced with its circumferential surface against the winding wire, forms the first loop around a forming shoulder of the one row and simultaneously a second loop around itself. Device according to claim 22 or 23, characterized in that the carrier of the at least one driving pin rotates in an irregular manner, for example, it is driven by a Maltese cross mechanism. 25. Device according to one of the claims 22 to 24, characterized in that in order to change the height of the corrugated windings, the maximum axial distance between the two rows of forming projections and the eccentricity of the pivot (s) can be adjusted in a changing manner, depending on different core heights ( s) on the carrier. Device according to one of Claims 17 to 25, characterized in that a stamping device is provided between the forming device and the loading station for inserting the corrugated windings into a bar-shaped magazine. transport adapted to the corrugated winding, for example a conveyor belt of worm conveyance which can be controlled with positional precision with drive elements fixed on the external part at a distance from the bridge sections, as well as laterally next to the conveyor belt one or more dies and dies, which allow the stamping of at least a part of a winding end of a corrugated winding to be inserted in the loader of the plane of the adjacent bridge sections. Device according to claim 26, characterized in that the embossing device comprises cutting tools for cutting the corrugated windings at the length of the corrugated winding belt. 28. Device according to one of the claims 26 or 27, characterized in that between the forming installation and the embossing installation there is a loose guide for the corrugated winding tape formed, so that it can form a loop of changing length that serves as an intermediate reserve. Device according to one of claims 17 to 28, characterized in that the installation for inserting the corrugated windings into a rotor or stator core or a transfer tool similar to a rotor comprises a guide for the corrugated windings which is essentially arranged tangentially in relation to a rotor or stator core or a transfer tool similar to a rotor operable in a rotary fashion by means of a rotary drive respectively with grooves radially open to the outside, and there is the presence of a drive for the relative displacement of the corrugated windings with their winding ends connected by bridge and core sections or the transfer tool along the guide with a circumferential speed that corresponds to the speed of the rotor core or stator respectively of the transfer tool similar to a rotor, as well as organs of guide or push that allow the successive introduction of the bridge sections near the rotor core or stator respectively to the transfer tool in the slots open radially to the outside. 30. Device according to claim 29, characterized in that the guide comprises a bar-shaped magazine, movable in the longitudinal direction, with parallel transverse grooves in which several wave windings can be placed, which must be inserted together in a stage of operation in the core of rotor or stator or transfer tool similar to a rotor, with its bridge sections in the relative relative position. Device according to claim 30, characterized by guide members, arranged in a stationary manner, which make contact in the outer regions of the bridge sections and / or winding ends of the corrugated windings and which allow these to be displaceable to the grooves radially open to the outside of the rotor or stator core or to the rotor-like transfer tool, while rotating around a stationary axis and rolling in this in the bar-shaped loader passing next to it in the direction tangential or in a line parallel to it. 32. Device according to one of the claims 29 to 31, characterized in that the transfer tool similar to a rotor comprises, in the grooves radially open to the outside, pushers, guided in a radially displaceable manner, which can be deployed beyond the outer circumference, with which the corrugated windings housed in the grooves can be displaced into aligned grooves, radially open to the inside, of a concentrically arranged rotor or stator core for the transfer. Device according to claim 32, characterized in that the axially fixed pushers are provided with wedge surfaces and are displaceable radially by wedge or coniferous surfaces of a common drive element, displaceable in the axial direction. 34. Device according to one of the claims 30 to 33, characterized in that a loading station for the insertion of the corrugated windings into bar-shaped loaders comprises guide rails, movably housed which extend parallel to each other and with the projection loader next to it, which they serve as a guide for the winding ends of the corrugated windings, as well as in addition a conveyor belt guided in a circulating endless form, controllable with positional precision, comprising drag elements arranged on their external side at a distance from the bridge sections and a regulator drive for moving the guide rails from one position in front of the slot entries of the bar-shaped magazine to a position next to it, whereby the bridge sections of the corrugated windings can be inserted into the slots of the magazine . 35. Method for forming and introducing corrugated windings with bridge sections connected to winding ends in rotor or stator cores of electric machines in which the corrugated windings are formed as a belt respectively with a certain amount of corrugations of rectangular winding wire or round in cross section, the wire being placed in an alternating fashion around the external lateral faces of the forming projections, arranged in a row, linearly displaceable in the longitudinal direction of the row and then the corrugated windings cut from a stock of wire are introduced into slots open radially to the outside of a rotor or stator core or a transfer tool similar to a rotor and eventually displaced from the slots of the transfer tool similar to a rotor to slots open radially inward from a nu rotor or stator, characterized in that the winding wire is placed alternately around the external lateral faces of some shaped projections disposed respectively in a row in two parallel bars, operable linearly in the longitudinal direction in respectively one row or in a bar operable linearly in the longitudinal direction in two rows displaced from each other, and then the distance between a shoulder of formed one row and the next shaped shoulder of the other row is increased by a measure such that the outer side faces of Shaped projections form the winding ends of the corrugated windings. 36. Device for carrying out the method according to claim 35, comprising a forming installation for the corrugated winding formation and an installation for introducing undulated windings in grooves radially open to the outside of a rotor or stator core or a similar transfer tool. to a rotor, wherein the forming device comprises forming projections arranged in a row, linearly displaceable in the longitudinal direction of the row and a winding wire can be placed in an alternating form in an undulating manner around the outer side faces of projections of forming that follow one another, whose shape corresponds to the shape of the winding ends that must be produced, characterized in that the forming installation comprises for the corrugated winding two longitudinally displaceable rods in the longitudinal direction with respectively a series or a bar with two rows of shaped projections uniformly distributed, arranged in mutually offset relative to each other row, movable in transverse direction relative to the direction of movement, whose transverse distance with respect to the longitudinal direction of the rows can be modified, as well as a guide wire guided in such a manner that the winding wire can be alternately waved by an external lateral face of the forming projections following one another, respectively belonging to one or the other row.