WO2018041836A1

WO2018041836A1 - Method for producing and inserting a wire winding

Info

Publication number: WO2018041836A1
Application number: PCT/EP2017/071671
Authority: WO
Inventors: Günter DREIER
Original assignee: Grob-Werke Gmbh & Co. Kg
Priority date: 2016-08-29
Filing date: 2017-08-29
Publication date: 2018-03-08
Also published as: DE102017119838A1

Abstract

The invention relates to a method for producing a wire winding and inserting said wire winding into a component, wherein a winding head is fanned out. The invention further relates to a corresponding wire winding.

Description

"Method of Making and Inserting a Wire Wound"

The invention relates to a method for producing and introducing a wire winding in a plurality of grooves of a component, in particular a stator or rotor of an electric motor. The invention further relates to an associated wire winding.

Electric motors usually require a stator and / or a rotor, which can each be referred to as a component. At least one such component of an electric motor typically has a wire package with a number or a plurality of wire windings. It is an object of the invention to provide a method of making and incorporating such a wire coil into a device. It is further an object of the invention to provide an associated wire winding.

This is inventively achieved by a method according to claim 1 and a wire winding according to claim 15. Advantageous embodiments can be taken, for example, the dependent claims.

The invention relates to a method for producing and introducing a wire winding into a plurality of slots of a component, in particular of a stator or rotor of an electric motor, the method comprising the following steps:

Forming at least one wire to form the wire winding such that at least some wire sections are immediately adjacent to one another,

at least partially connecting directly adjacent wire sections,

Fanning the wire winding in a region of unconnected wire sections, wherein the fanned-out section essentially forms a winding head in the arrangement of the wire winding in the component,

Transferring the wire winding into the device,

wherein the wire winding is transferred with the fanned-out area ahead into the device.

By joining the wire winding is stabilized, whereby the introduction can facilitate and / or the packing density can be increased. By a higher packing density in particular a higher efficiency can be achieved.

Between wire forming and joining or after bonding, the wire winding can be embossed. This can be another Stabilization can be achieved. When embossing, a number of winding heads can be formed. At least one of the winding heads can be fanned out.

By fanning the introduction into the grooves can be facilitated, since wires can be successively or independently introduced.

According to an advantageous embodiment, the wire is wound during molding orthocyclically.

In particular, the wire winding may be shaped to extend along a longitudinal axis. This longitudinal axis can advantageously be a longitudinal axis of the wire winding or a wire package containing the wire winding and a number of other wire windings. It can also be identical or parallel to a longitudinal axis of the component.

The wire winding is preferably shaped so that some or all of the immediately adjacent wire sections extend parallel to the longitudinal axis.

According to respective embodiments, the wire winding is shaped such that the immediately adjacent wire sections are sections of a single wire or sections of multiple wires. A wire winding typically corresponds to a phase of the electric motor.

By embossing, a particular shape can be achieved, for example, as will be described below. In particular, for example, during embossing, winding heads can be formed on each axial end relative to the longitudinal axis or on one of the ends.

The wire winding can form several, in particular two, winding heads in the arrangement of the wire winding in the component. For example, the winding heads can be formed by bending with respect to the longitudinal axis.

Advantageously, for example, during embossing, the winding heads are bent radially outward relative to the longitudinal axis at a first axial end and the winding heads are bent radially inwardly at a second axial end, which is opposite the first axial end, with respect to the longitudinal axis.

According to one embodiment, at least one winding head is fanned radially with respect to the longitudinal axis to the interior of a stator or radially to the outside of a rotor. Thereby, the design of the winding head can be advantageously adapted to inwardly facing grooves. The fanning can basically refer to all winding heads or to only a part of the winding heads.

The directly adjacent wire sections may preferably be connected to a line which is inclined with respect to the longitudinal extent of these wire sections, in particular between 40 ° and 50 °, preferably 45 °, whereby the adjacent winding head is fanned along this line. This facilitates the introduction even further.

According to one embodiment, the connection is made by pressing. For this purpose, tools can be used which maintain such a state, such as clamps or rubber bands. These can, for example, after insertion be removed. By pressing in particular a high degree of filling can be achieved.

According to one embodiment, the bonding is done by gluing.

Preference is given to compressing the immediately adjacent wire sections before or during gluing or bonding. This can increase the density of wires.

For bonding, the wire winding can be at least partially immersed in an adhesive bath.

It can also be sprayed for gluing an adhesive, in particular by means of a dispenser.

The bonding is preferably carried out by means of a baking adhesive. This can be easily applied and cured by heating.

According to one embodiment, the baking adhesive is already applied to the wire before the method is carried out.

According to a development, an insulating paper is introduced into each groove before transferring the wire package. This insulation can be improved and damage during insertion can be avoided.

According to one embodiment, only that winding head, which is arranged at an axial and non-fanned end with respect to the longitudinal axis, is connected or glued and / or immersed in an adhesive bath.

According to one embodiment, wire sections extending axially between the winding heads with respect to the longitudinal axis extend, bonded or / and immersed in the adhesive bath.

Preferably, the insulating paper is backklebergetränkt. This allows a simple application or application of the baking adhesive.

Preferably provided with baking adhesive sections of the

Wire bundles cured by heat treatment, preferably at 200 ° C.

Preferred are portions of the wire package during the

Heat treatment pressed, in particular by means of a number of heated jaws.

According to one embodiment, portions of the wire pack are cooled during the heat treatment to prevent curing of the baked adhesive. This can be selectively prevented at certain sections curing, so that the corresponding sections remain flexible or separated.

The wire winding can be fixed for transfer to a holding device and then introduced with this. This allows a simple automated introduction.

The holding device is preferably pushed axially for transferring with respect to the longitudinal axis in the component.

According to one embodiment, after the transfer, the winding heads are bent radially at an axial end with respect to the longitudinal axis, in particular radially to the outside of a stator or radially to the interior of a rotor. The winding heads may be bent after transfer using a backstop and / or a bending tool. This allows the formation of a final form.

The wire winding is preferably inserted into the grooves of the device with a winding head fanned to the inside of a stator or to the outside of a rotor, so that wire portions of the winding head are successively inserted into the groove. This allows a particularly simple introduction.

The grooves of the component according to an embodiment in cross-section planar legs adjacent to a respective slot opening.

The grooves of the component are tapered according to a further embodiment in cross-section at a respective slot opening, in particular by respective Nutzähne.

The invention further relates to a wire winding for forming a coil of a rotor or stator of an electric motor, wherein the wire winding has areas in which adjoining extending wire sections are at least partially interconnected, and

wherein the wire winding is fanned out in a region of unconnected wire sections, such that the wires of the fanned section are spaced apart from one another by a greater distance than the wires in the interconnected sections, in particular the spacing between the wires in that section toward an end of the wire winding increases

and wherein the wires in the fanned-out region are deflected in the same direction out of a plane of the wire winding, wherein in the fanned-out region the wires are in particular fanned out so that the width of the fanned-out region is smaller than the width of a slot slot of a component into which the wire winding is to be introduced.

Such a wire winding can be used particularly advantageously with the method according to the invention, for example in order to introduce it into a component. A slot slot may be, for example, a slot of a groove mentioned above.

As a wire, in particular a round wire or a flat wire can be used.

Preferably wire sections are also stiffened when connecting. This facilitates the introduction.

The wire winding can be wound with a wire or with a plurality of wires. The wire winding typically corresponds to a phase of the electric motor.

In particular, the wire winding may be part of a wire bundle having a number or plurality of wire windings, with the wire windings of the wire bundle being co-threaded. It is also possible to introduce several wire packages or wire windings at the same time or one after the other in order to introduce all the necessary wire windings.

Unconnected winding heads can be connected, in particular bandaged or glued, in particular after the transfer. This will give them a definitive and / or permanent form. The winding heads can in particular be pressed together during connection.

The invention further relates to a method for introducing a wire winding into a plurality of slots of a component, in particular a stator or rotor, of an electric motor, the method comprising the following steps:

at least partially connecting immediately adjacent wire sections, wherein the connection is by compression, and

Transferring the wire winding into the device,

wherein the wire winding is embossed between the molding and the joining or after the bonding, wherein embossing on each with respect to the longitudinal axis axial end or on one of the ends, a number of winding heads are formed, wherein at least one winding head is fanned, in particular radially inwardly with respect the longitudinal axis, and wherein the wire winding is transferred with the fanned winding head ahead in the component.

This corresponds to a particularly advantageous process management.

The invention further relates to a component, in particular a stator or rotor, of an electric motor into which a wire winding has been introduced by means of a method according to the invention. It can be used with respect to the method to all described embodiments and variants.

Below a possible procedure is outlined. It should be understood that this may form an aspect of the invention both individually and that the aspects mentioned therein can be arbitrarily combined with each other and with other aspects disclosed herein. All such combinations are considered part of this disclosure.

1. Create coil

For example, an orthocyclic wound mandrel having one or more wires is manufactured. The wires may be round or have other shapes, e.g. be rectangular. The forming coil can be made highly productive with a flyer or linear winder. The coil can be made with a specially coated wire (baked enamel, for example, partial discharge optimized and / or optimized for slipping).

2. Form, bake and compress the bobbin

The coil is heated and pressed, for example with a mold. Due to the properties of the varnish and its heating, the coil in the lower winding head and in the straight part of the coil, which later lies in the groove, remains dimensionally stable after the process. The upper winding head continues to consist of non-baked, glued wires or has such and is therefore not dimensionally stable.

3. Fan the bobbin

The coil is now fanned out in the upper winding head. The fan length is determined by the slot opening dimension. Due to fanning, the coil in the upper winding head must or should be narrowed. The narrowing must or should be done so far until the width is smaller than the slot slot of the stator.

4. Position the coil (s) in the insertion tool.

The coils can be inserted and / or retracted. The coils are in particular in the two- or multi-stage tool positioned. Here are the most diverse

Coil arrangements can be realized. One stage covers in particular the laminated core. One step in particular pulls or pushes the coil (s) into the stator.

5. Insulate the stator

The stator is preferably insulated with a single-groove insulation. The insulation can be executed with or without enamel. At a later date, a cover slide can be introduced. As a possible alternative, the forming coil (s) can also be isolated. In particular, the stator is not isolated separately, the slot insulation entrains the coil.

6. Insert the coil (s) into the stator

The coil (s) are / are inserted into the stator. For this, the stator is placed on the tool (or the tool on the stator). Via a linear movement, the coils are now pushed into the stator. In this case, the fanned end of the coil preferably precedes. The caked and compacted part is pushed or pulled into the groove. After completion of the process, the caked and compressed wire is in the groove. The fanned-out part represents the winding head which must or should be shaped. Depending on the coil design, the joining process may be necessary once or several times until all the grooves are filled with the coils.

7. + 8. Form the winding head and cake

The fanned-out part in the winding head is shaped in particular by a shaped tool. If all the coils are joined at once, the head is preferably shaped into a final position as possible. If several insertion processes are required, different intermediate molding processes are typically necessary. When the wire is a baked enameled wire, the forming tool can also serve as a heating element to bake the wires at about 200 degrees. 9. Storing the stator

If you do not need to select the "Coil Insulation" version, you should now either immerse the cover slide or the stator or parts of it will be heated to the baking temperature of the baking lacquer, which will cause the stator to cake with the insulating paper and the wire The impregnation can also be omitted or it can be mechanically strengthened with significantly less effort, the entire stator.

In the drawing, the invention is shown schematically in particular in exemplary embodiments. Show it:

1 a partially wound wire,

Fig. 2 is a partially embossed and fanned out

wire winding

Fig. 3, the wire winding in an adhesive bath

Fig. 4a, the wire winding and a device before the

Transfer .

Fig. 4b a part of the device in cross section

Fig. 5 holding device

6 shows a part of the component with a part of

wire winding

Fig. 7, the wire winding, the device and the

Holding device after transfer, Fig. 8, the wire winding, the component and the

Holding device after bending a winding head,

Fig. 9a, the wire winding, the device and the

Holding device after further bending of the winding cop,

Fig. 9b a part of the device with incorporated

Wire winding,

In the figures, the same or corresponding elements are denoted by the same reference numerals and therefore, if not appropriate, will not be described again. The disclosures contained in the entire description are mutatis mutandis to the same parts with the same reference numerals or identical component names transferable. Also, the location information chosen in the description, such as top, bottom, side, etc. related to the immediately described and illustrated figure and are to be transferred to the new situation mutatis mutandis when a change in position. Furthermore, individual features or combinations of features from the illustrated and described different embodiments may represent for themselves, inventive or inventive solutions.

FIGS. 1 to 9b show a method according to an exemplary embodiment of the invention, in which a wire winding 10 is wound and transferred into a component 20, namely into a stator of an electric motor. The wire winding 10 shown here corresponds to a wire winding according to an embodiment of the invention. FIG. 1 shows a wire winding 10 which is currently being produced. This is formed from a wire 5, which is wound around a mold 7.

As shown, the wire 5 may be a round wire. However, it could alternatively be, for example, a rectangular wire or flat wire. It should be understood that a respective wire winding 10 can basically be wound from a single wire 5, but that a plurality of wires 5 can also be used for a wire winding 10.

The winding is presently orthocyclic as shown. In this case, no overlaps between sections of the wire 5 are formed.

FIG. 2 shows the wire winding 10 in a state in which it has been embossed. For embossing it can be clamped, for example, on a body, not shown. By means of this, the wire winding 10 can be formed so that a straight portion 12, a lower winding head 14 and an upper winding head 16 are formed. The straight section 12 is arranged between the lower winding head 14 and the upper winding head 16.

In each case, in the case of the straight section 12 as well as in the case of the winding heads 14 and 16, in each case a plurality of sections of the wire 5 lie parallel and immediately adjacent to one another.

As can be seen in Fig. 2, the lower winding head 14 has been bent outwards. The upper winding head 16, on the other hand, was bent inward. These data relate in particular also to a longitudinal axis to be defined below. The upper winding head 16 is fanned out. This takes place along a line which approximately assumes an angle of 45 ° to the straight section 12.

As a result of the fanning out, the lateral wire sections forming the upper winding head 16 are no longer parallel to one another. Rather, they form certain angles to the straight section 12 which, as shown, increase from top to bottom.

The fanning leads in particular to the fact that the introduction of the wire winding 10 in the grooves 22 of the device 20 is facilitated. In particular, the wire sections can be introduced at somewhat greater intervals and at least partially independently of each other.

FIG. 3 shows the wire winding 10 immersed in an adhesive bath 3. The adhesive bath 3 is formed by a baking adhesive which is located in a trough 2.

As shown, the wire winding 10 immersed in the adhesive bath 3 so far that the straight portion 12 and the lower winding head 14 are in the adhesive bath 3. These are soaked with the baking adhesive. An overlying section, which has a length dl and is formed essentially by the upper winding head 16, on the other hand remains outside of the adhesive bath 3 and is therefore not impregnated with the baking adhesive.

The applied in this way baking adhesive can be cured by heating. As a result, the respective wire sections are solidified and also connected to each other. This increases the dimensional stability and the strength of the interconnected wire sections. In the embodiment shown here, first the upper winding head 16 is fanned out, and then the wire sections are connected together. In particular and preferably, however, the order shown here can also be reversed, so that the wire sections or the straight section 12 are first connected to each other, for example by gluing, pressing or also by mechanical fixing, wherein subsequently the upper winding head 16 is fanned out. As a result, the wire winding 10 can be stabilized even before fanning.

FIG. 4 a shows the wire winding 10 before being introduced into a component 20. The wire winding 10 forms a wire package 9 together with another wire winding 10 a. The wire package 9 is intended to be introduced as a whole into the component 20.

The further wire winding 10a will not be described in more detail here, it is essentially formed like the wire winding 10 already described.

In the present case, the component 20 is a stator of an electric motor, in particular of an electric motor for an electric vehicle. It should be understood that this electric motor will not be discussed here otherwise. In particular, its further components are not shown here.

The upper winding head 16 is fanned out as already described, so that the wire sections are introduced successively into grooves 22 of the component 20.

4b shows a part of the component 20 in a cross-sectional view. It can be seen that the component 20 has a plurality of grooves 22. These are inside directed. In the grooves 22 ultimately the wire winding 10 is to be introduced.

As can be seen in Fig. 4b, the grooves 22 are not provided here with straight legs, but have towards their respective inside opening towards a respective taper. This is achieved by laterally trained Nutzähne. However, the use of straight legs is possible.

For this purpose, a holding device 30 shown in Fig. 4a is used. On this, the wire winding 10 is applied.

Drahtpacket 9, component 20 and holding device 30 together have a common longitudinal axis 11. Along this longitudinal axis 11 extend the wire package 9, the component 20 and the holding device 30. Along the longitudinal axis 11 is also an introduction of the wire package 9 in the device 20, for this purpose, the holding device 30 is pushed axially along the longitudinal axis 11 in the device 20 ,

When introducing the wire package 9 into the component 20, the upper winding head 16 is initially introduced by the wire winding 10. This is as shown with respect to the longitudinal axis 11 bent radially inwardly.

Subsequently, the straight portion 12 is introduced. This is essentially designed so that it fills the grooves 22. In the radial direction, it assumes a length d4, which is shown in Fig. 4a.

Typically, in the state after the introduction of the wire package 9, the winding heads 14, 16 project out of the component 20 at the bottom or at the top. The same applies to the further wire winding 10a. Fig. 5 shows the holding device 30 separately in a perspective view. It can be seen that it is a substantially rotationally symmetrical body. Chamfers above and below take the shape of the wire winding 10 bill.

The wire winding 10 can be introduced into the grooves 22, for example, such that the wire winding 10 is located in two grooves 22, between which there are two further grooves 22, which are spanned by the wire winding 10.

Fig. 6 shows the device 20 with partially introduced wire winding 10 in a cross-sectional view. It can be seen that only a portion of the wire sections of the wire winding 10 are already in the groove 22 shown, with the rest is still outside. The wire sections can thus be introduced successively.

FIG. 7 shows a state after the introduction of the wire package 9 into the component 20. The holding device 30 is located radially inside the component 20.

The wire package 9 is completely inserted into the component 20. The lower winding heads 14 are radially outward and the upper winding heads 16 are radially inward. The straight sections 12 are located in the grooves 22.

Fig. 8 shows a state after the upper winding heads 16 have been bent outward by 45 °. For this purpose, a counter-holder 35 was used. The upper winding heads 16 are now aligned with the straight sections 12. Fig. 9a shows a state after the upper winding heads 16 have been bent outwardly by another 45 °. For this purpose, a bending tool 37 was used, which presses from above onto the upper winding heads 16. The upper winding heads 16 are thus bent radially outward with respect to the longitudinal axis 11, as well as the lower winding heads 14.

Fig. 9b shows a state in which the wire winding 10 has been completely inserted into the grooves 22. As shown, the wire coil 10 fills the illustrated groove 22 substantially completely. This allows a particularly high efficiency.

It should be noted that when immersed in an adhesive bath 3, only the lower winding head 14 can be immersed in the adhesive bath 3. In contrast to the embodiment described above with reference to FIG. 3, a section thus remains free of baking adhesive, this length typically being substantially greater than the length d 1 already mentioned above. For example, the straight portion 12 remains free of baking adhesive, so that it does not participate in a later curing is stiffened. Also, the upper winding head 16 remains free of baking adhesive.

The claims now filed with the application and later are without prejudice to the attainment of further protection.

If, on closer examination, in particular also of the relevant prior art, it appears that one or the other feature is beneficial for the purpose of the invention, but not crucial, it is of course already desired to have a formulation which is such a feature , in particular in the main claim, no longer having. Such a sub-combination is also covered by the disclosure of this application.

It should further be noted that the embodiments and variants of the invention described in the various embodiments and shown in the figures can be combined with one another as desired. Here, one or more features are arbitrarily interchangeable. These feature combinations are also disclosed with.

The referenced in the dependent claims refer back to the further development of the subject of the main claim by the features of the respective subclaim. However, these are not to be understood as a waiver of obtaining independent, objective protection for the features of the dependent claims.

Features which have been disclosed only in the description or individual features of claims that comprise a plurality of features, at any time as essential to the invention to delineate the distinction from the prior art in the or the independent claim / claims are taken, even if such features have been mentioned in connection with other characteristics or achieve particularly favorable results in connection with other characteristics.

Patent attorney

Claims

Claims:

A method of manufacturing and inserting a wire coil (10) into a plurality of slots (22) of a device (20), particularly a stator or rotor of an electric motor, the method comprising the steps of:

Forming at least one wire (5) to form the wire winding (10) such that at least some wire sections are immediately adjacent to one another,

at least partially connecting directly adjacent wire sections,

Fanning the wire winding (10) in a region of unconnected wire sections, the fanned-out section in the arrangement of the wire winding

(10) in the component (20) essentially a winding head

(16) forms,

Transferring the wire winding (10) in the device (20), wherein the wire winding (10) is transferred with the fanned-out area ahead in the device (20).

2. The method according to claim 1, characterized in that the

Wire winding (10) is formed so that it extends along a longitudinal axis (11).

Method according to one of the preceding claims, characterized in that the wire winding (10) in the arrangement of the wire winding (10) in the component (20) several, in particular two winding heads (14, 16) and the winding heads (14, 16) by kinking be formed opposite the longitudinal axis (11).

Method according to one of the preceding claims, characterized in that the winding heads (14) at a first axial end with respect to the longitudinal axis (11) are bent radially outwardly and the winding heads (16) at a second axial end which is opposite the first axial end, with respect to the longitudinal axis (11) are bent radially inwardly.

Method according to one of the preceding claims, characterized in that at least one winding head (16) with respect to the longitudinal axis (11) is fanned radially to the interior of a stator or radially to the outside of a rotor.

Method according to one of the preceding claims, characterized in that the connection is effected by pressing or gluing.

Method according to one of the preceding claims, characterized in that prior to or during the gluing or bonding takes place a compression of the immediately adjacent wire sections.

8. The method according to any one of the preceding claims, characterized in that in each groove (22) before the transfer of the wire package (10) an insulating paper is introduced.

9. The method according to any one of the preceding claims, characterized in that only the one winding head (14), which is arranged on a relative to the longitudinal axis (11) axial and not fanned end, is connected or glued and / or in an adhesive bath (3 ) is dipped.

10. The method according to any one of the preceding claims, characterized in that the wire winding (10) is fixed for transfer to a holding device (30) and then introduced with this.

11. The method according to any one of the preceding claims, characterized in that the holding device (30) for transmitting with respect to the longitudinal axis (11) is pushed axially into the component (20).

12. The method according to any one of the preceding claims, characterized in that after the transfer, the winding heads (16) at an axial end with respect to the longitudinal axis (11) are bent radially, in particular radially to the exterior of a stator or radially to the interior of a rotor.

13. The method according to any one of the preceding claims, characterized in that the winding heads (16) are bent after transfer using a counter-holder (35) and / or a bending tool (37).

14. The method according to any one of the preceding claims, characterized in that the wire winding (10) with a for Inside a stator or to the outside of a rotor fanned winding head (16) is inserted in advance in the grooves (22) of the device (20), so that wire portions of the winding head (16) are successively inserted into the groove.

Wire winding (10) for forming a coil of a rotor or stator of an electric motor, characterized in that the wire winding (10) regions (12, 14), in which adjacent adjacent wire sections are at least partially interconnected, and

wherein the wire winding (10) is fanned out in a region of unconnected wire sections, such that the wires of the fanned section (16) are spaced apart from one another by a greater distance than the wires in the interconnected sections (12, 14), in particular the distance between the wires in this area (16) increase toward one end of the wire winding (10),

and wherein the wires in the fanned-out region (16) are deflected in the same direction out of a plane of the wire winding (10),

wherein in the fanned-out region (16) the wires are in particular fanned out so that the width of the fanned-out region (16) is smaller than the width of a slot slot of a component (20) into which the wire winding (10) is to be introduced.

Patent attorney