WO2018224604A1

WO2018224604A1 - Semifinished product for an electrical coil and method and device for producing same

Info

Publication number: WO2018224604A1
Application number: PCT/EP2018/065064
Authority: WO
Inventors: Markus Bergmann; Mirko Bach
Original assignee: Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V.
Priority date: 2017-06-09
Filing date: 2018-06-07
Publication date: 2018-12-13
Also published as: DE102017209792B4; DE102017209792A1

Abstract

The invention relates to a semifinished product for an electrical coil and to a method and to a device for producing said semifinished product. The method according to the invention for producing a semifinished product for an electrical coil, by means of which an electrical coil can be produced reproducibly economically, reliably, and in a simple way whilst achieving an increased filling factor or useful filling factor, comprises the steps: step A: arranging an electrically conductive wire (1) in wave form; step B: connecting at least two mutually spaced sections of the wire (1) arranged in wave form; step C: reshaping the wire (1) arranged in wave form, forming at least one reshaped region by changing the cross-sectional shape of the wire.

Description

Semi-finished product for an electrotechnical coil and method and apparatus for producing the same

The present invention relates to a semifinished product for an electrotechnical coil and to a method and an apparatus for producing this semifinished product.

So far coils are wound from round wire, which leads due to the conductor shape to the lack of space, especially in conical coils, or produced by casting, which is a very expensive process.

According to EP 2 387 135 A2, the achievable torque density of permanent-magnet synchronous machines with a tooth coil winding largely depends on the ratio of total copper cross-sectional area to groove area, the so-called slot fill factor. An increase in the fill factor allows for a constant torque of a flatter construction of the stator or a broadening of the teeth to relieve the magnetic circuit.

A significant geometric limitation in the prior art in the limited possibilities for using different winding cross sections: Usually, round wires are used for the windings, in which even with optimal utilization always a non-usable space between the individual windings remains. The necessary insulation, the wire entry and the discrete distribution of the conductors also limit the filling factor. In addition, since the groove fill factor ultimately achieved is only properly estimated in the electromagnetic design and can not be calculated due to the ignorance of the later actual execution of the motor, the motors tend to be due to the higher masses required (copper windings and laminations of the stator and the rotor). too heavy and (too) big.

The essential technical manufacturing difficulty is the application of the windings on the tooth.

In summary, it can be stated that with today's conventional method of producing coil windings there are technical and economic limits of groove filling with individual windings. A groove fill factor of 70% is already a very good value, the technically and economically feasible limits are currently around 75% to 80% (Source: Müller, Vogt, Ponick: "Calculation of electrical machines", p. 168, 6. Edition, Wiiey-VCH, Weinheim, 2008. ") The method known from EP 2 387 135 A2 makes it possible to produce coils by casting while fulfilling the abovementioned requirements, but is less economical than a forming manufacture of coils (no lost form, etc.).

According to EP 2 387 135 A2, the prior art comprises several conventional manufacturing methods. One method of machining is the needle winding technique, in which the wires are passed individually through the window between two teeth. This requires a certain clearance, which must be considered constructively and has a negative effect on the fill factor. Another possibility is the so-called "instillation" of windings into the groove window across the tooth, but this is a process that is carried out manually and therefore correspondingly cost-intensive.Furthermore, EP 2 387 135 A2 discloses a coil casting technique with which Although it is possible to increase the filling factor, which is considerably more uneconomical than a coil to be deformed (lost shape, etc.), the patent DE 10 2013 012 659 A1 and DE 10 2014 000 636 A1 disclose production methods which only make the wire cross section Based on DE 10 2013 012 659 A1 and DE 10 2014 000 636 A1, new restrictions arise in the economy, which include a geometrical desired shape of the wire section for the effective region and the left-hand input form of the wire for the region the winding head of the electrotechnical coil demand Need to produce larger numbers of engines.

With all o.g. Property rights is also called no deliberate difference in the size of the cross-sectional area of the conductor between the winding head and effective range of the coil.

Substantial industrial property rights are for this purpose inter alia US 2005/0258704 A1 and WO 01/54254 A1, as well as WO 2012/072695 A2 and DE 103 15 361 A1. However, these stated methods reach their limits in terms of productivity and continuity.

Starting from the above-described prior art, it is the object of the present invention to provide a semifinished product for an electrotechnical coil and a method and an apparatus for producing this semifinished product, with which an electrotechnical coil to achieve an increased Füllfaktorors or Nutfüllfaktors can be produced economically and reproducibly in a reliable and simple manner. To achieve the object, the method according to the invention for producing a semifinished product for an electrotechnical coil according to claim 1 comprises the following steps:

Step A: Arrange an electrically conductive wire in waveform.

Step B: bonding at least one bonding means to at least two spaced apart portions of the waved wire.

Step C: Forming the waved wire to form at least one deformation area by changing the cross-sectional shape of the wire.

By arranging the wire in a wave form a flat clutch is formed, which is fixed by the connecting means in its planar shape. In this state, a local change in the cross-sectional shape of the wire to form one or more forming areas can be done in a particularly simple manner. Then, a winding of the wave-shaped wire can be made such that the forming areas are aligned exactly or substantially parallel to the winding axis, so that the forming areas are not additionally curved during winding. In the subsequent rewinding of the wave-shaped wire from the wound state, the linear or non-curved state of the deformation regions is maintained.

The present invention enables the relatively simple production of uniform or conical coils with constant or changing conductor cross-sectional shape with the same surface area of the conductor and aims at the use of the advantages of forming production (no / little material loss) and the concomitant shortening of process chains by the Elimination of manufacturing and processing steps.

It may be advantageous if the method has at least one of the following additional steps:

Step D: conveying the waved wire in its extension plane, preferably in a conveying direction opposite to a laying direction of the wire.

Step E: Applying a coating of an electrically insulating material to the wire, preferably after step C and / or before step G.

Step F: Dry the coating. Step G: Winding the arranged in waveform wire, preferably such that the at least one forming area is aligned exactly or substantially parallel to the winding axis.

By the above steps, the wire for the final coil winding can already be largely prefabricated. The coating can avoid a short circuit between the possibly contacting coil windings, in particular if the coil windings are additionally compressed by exerting a compressive force along the winding axis.

Common practice has been e.g. according to EP 2 387 135 A2 the production and subsequent coating of the coils. The changeover of the process chain according to the method according to the invention is motivated by coating problems in connection with the forming. The process chain presented here divides the forming process into preforming and winding.

So far, forming, coating and winding of the coils is possible only without intermediate storage as a coil material. The present invention achieves an increase in productivity and transportability of preformed coated wire sections for coils to be wound.

However, it can also be useful if step A has at least one of the following substeps:

Step A1: providing the wire, preferably as an endless wire, preferably by extrusion, extrusion or unwinding from a coil, the wire preferably having a cross-sectional shape that is constant over the length, preferably a circular or rectangular cross-sectional shape.

Step A2: Laying the wire in a laying direction with alternately forming oppositely curved first and second loops, each with a formed between two successive loops forming section.

Step A3: Waveforming the wire using first and second holding means each having a plurality of holding portions arranged along a line, which are preferably formed identically and / or regularly spaced from one another, the lines along which the holding portions of the first and second Holding devices are arranged, preferably horizontally and / or parallel to are aligned with each other, wherein the sub-step A3 preferably comprises the following sub-steps:

Step A3-1: Forming a first loop by guiding the wire coming from the second holding device around a part of a holding section of the first holding device which is repelling it and back again in the direction of the second holding device, preferably forming a bend with a continuous bending radius and / or in one Angle in the range of 160 ° to 200 °, preferably in the range of 170 ° to 190 °, particularly preferably 180 °, without the wire crossing, wherein the wire preferably along the entire first loop or at least a part thereof bending inside of the Supporting portion of the first holding device is supported.

Step A3-2: Forming a second loop by guiding the wire coming from the first holding device around a part of a holding section of the second holding device and returning it towards the first holding device, preferably forming a bend with a continuous bending radius and / or in one Angle in the range of 160 ° to 200 °, preferably in the range of 170 ° to 190 °, particularly preferably 180 ° without the wire crossing, wherein the wire preferably along the entire second loop or at least a part thereof bending inside of the Supporting portion of the second holding device supported.

Step A3-3: applying a tensile stress to the wire such that the forming sections of the wire arranged between each two successive loops are stretched and extend along a straight line, wherein the forming sections are preferably exactly or substantially equally long and / or aligned parallel to one another are and / or regularly spaced from each other.

In this way, a plastic deformation of the initially linear wire in waveform can be achieved by simple means. The bending deformation of the wire is thereby facilitated by correspondingly shaped holding portions of the holding devices and by exerting a tensile force, preferably starting from the leading end in the laying direction of the wire. The bending radii of the wire in the region of the first and second loops and the resulting distances of the forming sections can be determined individually depending on the nature and thickness of the wire. Preferably, the curvature radii matched to the desired bending radii of the wire to the respective bending inner sides of the first and second loops of the holding portions of the holding means. By exerting a tensile force on the wire, the shape of the wire is favored. In particular, it is prevented that the wire sags under the influence of its own weight, so that the forming sections, as far as technically possible, are aligned parallel to each other in the smallest possible distances. The distance between two adjacent forming sections is preferably in the range of 100 to 1000% of the (undeformed) wire diameter, preferably in the range 200 to 500% of the (undeformed) wire diameter, more preferably in the range 300 to 400% of the (undeformed) wire diameter. The bending radii in the region of the first and second loops correspondingly correspond to half the distances between two adjacent forming sections. Each forming section preferably extends from a first loop to a subsequent second loop or from a second loop to a subsequent first loop.

However, it may also be useful if step B has at least one of the following substeps:

Step B1: Provision of at least one strand-shaped connecting means, preferably of metal or plastic, by extrusion or extrusion.

Step B2: connecting the at least one strand-shaped connecting means to a first section of the waved wire, preferably to a forming section.

Step B3: arranging the at least one strand-shaped connection means in the direction of the wire and / or transversely, preferably perpendicularly, to the first section of the waved wire, wherein preferably a plurality of strand-like connection means are spaced evenly from one another transversely or perpendicular to the laying direction of the wire.

Step B4: connecting the at least one strand-like connecting means to a second section of the waved wire, preferably with a forming section, preferably such that a plurality of strand-shaped connecting means are aligned parallel to each other and / or parallel to the laying direction of the wire.

Step B5: connecting the at least one strand-shaped connecting means to each further aligned portion of the undulating member Wire, preferably with each further forming section, which crosses the at least one strand-shaped connecting means in the direction of laying.

By the connecting means of the arranged in waveform wire is fixed in its planar extent. This proves particularly for the downstream step of forming the wire to form one or more forming areas by changing the cross-sectional shape of the wire as advantageous because it must be acted upon with force on the wire. This can cause the waveform of the wire to be disturbed and / or interrupted. This is precisely what is prevented by the connecting means. The connecting means thus has a stabilizing function, both during the promotion of the waved wire in its plane of extent and in a possible downstream winding and the corresponding rewinding from the wound in a flat state. After fulfilling its stabilizing function, the connecting means can be removed. From a practical point of view, the connecting means may be made of the same material as the wire. In this case, the connecting means is for example extruded extruded or unwound from a roll and placed in a plastic and deformable state with the wire in contact to enter into a cohesive connection with the wire when cooling. The connecting means can be materially and / or positively and / or non-positively connected to the wire. Preferably, the same type of connection is selected at each connection point.

However, it can also be advantageous if step C has at least one of the following substeps:

Step C1: Forming the wire to form at least one deformation area while maintaining the cross-sectional area of the wire, wherein the cross-sectional shape is preferably changed from a round or rectangular cross-sectional shape to an oval, rectangular or trapezoidal cross-sectional shape.

Step C2: forming the wire to form a plurality of deformation regions, each having the same length and / or the same cross-sectional shape.

Step C3: forming the wire to form a plurality of mutually objectionable forming regions within the same forming section of the wire, wherein the plurality of forming sections are preferably located between two adjacent connecting means. Step C4: Re-forming the wire to form a plurality of mutually objectionable forming regions within the same forming section of the wire, wherein the plurality of forming sections are preferably located on different sides of the same connecting means.

Step C5: forming the wire in several or all of the forming sections of the wire according to a repeating pattern, preferably such that several or all of the forming sections of the wire have identical forming sections.

Step C6: Reshaping the wire by changing the cross-sectional shape of the wire according to the German patent application DE 10 2016 224 837.5.

The deformation of the wire serves the vorgreiflichen change in the cross-sectional shape, so that the wire ideally takes the original cross-sectional shape in the undeformed state at a corresponding bend in the way of making the electrical coil. Corresponding techniques are described in German patent application DE 10 2016 224 837.5, the contents of which are incorporated by reference in their entirety in the disclosure of the present application.

However, it can also be useful if step G has at least one of the following substeps:

Step G1: Providing means for winding the waved wire so that the winding axis of the device is located below the waved wire.

Step G2: conveying the waved wire in the conveying direction in a plane parallel to the winding axis.

Step G3: rolling up the forward end of the waved wire in the conveying direction about the winding axis so that the at least one forming portion of the wire, preferably the forming portions of the wire, is / are aligned parallel to the winding axis.

Step G4: Fix the waved wire in a state wound around the winding axis. By these measures, the arranged in waveform wire can be arranged in a particularly compact coil shape, with an unintentional deformation of the parallel aligned to the winding axis forming sections can be avoided.

Another independent aspect of the invention relates to a device for producing a semifinished product for an electrotechnical coil, in particular for carrying out the method according to one of claims 1 to 6, comprising:

A device for arranging an electrically conductive wire in waveform, preferably comprising at least one of the following features:

A coil from which the wire can preferably be unwound continuously.

First and second holding means each having a plurality of holding portions arranged along a line, wherein the lines along which the holding portions of the first and second holding means are arranged are preferably aligned horizontally and / or parallel to each other, wherein the holding portions of the first holding means and / or the holding portions of the second holding device are preferably evenly spaced from each other.

A wire laying tool configured to alternately form, in the laying direction of the wire, a first loop around a holding portion of the first holder and a second loop around a holding portion of the second holder such that each forming portion of the wire extends between two successive loops.

Means for connecting the connecting means to at least two spaced-apart portions of the waved wire.

A device for forming the arranged in waveform wire to form at least one forming area by changing the cross-sectional shape of the wire.

It may be useful if the device has at least one of the following features:

A device for conveying the wavy wire in its plane of extension, preferably a device for the simultaneous conveyance of the shark teabschnitte of the first and second holding devices in the conveying direction along the respective line along which the holding portions of the respective holding device are arranged, preferably continuously or discontinuously, more preferably in the conveying direction and / or against the laying direction of the wire.

A device for applying a coating of an electrically insulating material to the wire.

A device for drying the coating.

A device for winding the waved wire, wherein the device is preferably designed as a reel and is rotatable about an axis parallel to the extension plane of the waved wire, the conveying direction of the wire exactly or substantially tangential to the circumferential direction of the Establishment runs.

Another independent aspect of the invention relates to a semifinished product for an electrotechnical coil, preferably produced by the method according to one of claims 1 to 6 and / or using the device according to one of claims 7 or 8, comprising:

An undulating, electrically conductive wire.

At least one connecting means connected to at least two spaced apart portions of the waved wire.

At least one forming area in which the waved wire is deformed changing its cross-sectional shape.

A further aspect of the invention relates to a method for producing a semifinished product for an electrotechnical coil, comprising the steps:

Step X: Arrange an electrically conductive wire so that at least two sections of the wire are arranged exactly or substantially parallel to each other.

Step Y: connecting at least one connecting means with at least two exactly or substantially parallel sections of the wire. Step Z: Forming the wire to form at least one deformation area by changing the cross-sectional shape of the wire.

The method of this aspect of the invention may be combined with all of the embodiments disclosed herein. Further preferred embodiments of the present invention are achieved by combining the features disclosed in the claims, the drawings and the description.

Brief description of the drawings

Show it:

Figure 1 is a schematic plan view of an apparatus for producing a semifinished product for an electrical coil.

FIG. 2 shows a perspective schematic side view of the device according to the invention according to FIG. 1.

Detailed Description of the Preferred Embodiment

Figure 1 shows a schematic plan view of an inventive device 10 for producing a semifinished product for an electrical coil according to the preferred embodiment of the invention.

The apparatus 10 comprises a rectangular and flat working area 10A with a horizontal surface for arranging the wire 1 in waveform W and a reel / drum 10B following a shorter side of the rectangular working area 10A for winding the flat wire mesh along its laying direction L.

In the first working area 10A is an endless coil 1 1, from which a wire 1 of electrically conductive material such as copper or brass or an alloy is unrolled and a transversely to the laying direction L reciprocating wire laying tool 12 is supplied.

Along the rectangular and horizontal working area 10A extend on both sides thereof first and second retainers 13a and 13b having a plurality of regularly spaced holding portions (not shown) which serve to lay the electrically conductive wire 1 in waveform W. The holding sections are each on train chains (not shown), which rotate in a plane perpendicular to the sheet level and can are moved simultaneously in stepwise or continuously in the conveying direction F to each other.

Using the first and second holding means 13a and 13b, the wire is now waved by alternately forming first and second loops 1a, 1b using the first and second holding means 13a, 13b (after fixing the leading end of the wire 1) , So that in each case a straight extending forming section 1 c between two successive loops 1 a, 1 b is arranged, which extends from one of these loops 1 a, 1 b to the subsequent loop 1 b, 1 a.

The formation of a first loop 1 a is accomplished by guiding the coming of the second holding device 13 b (ie from this direction) wire 1 around a part thereof rejecting a holding portion of the first holding means 13 a and back toward the second holding means 13 b with a continuous bending radius and a bending angle of 180 °, so that the wire 1 does not cross.

Essentially mirror-symmetrically, the formation of a second loop 1 b is accomplished by guiding the wire 1 coming from the first holding device 13a (ie from this direction) about a part of a holding section of the second holding device 13b which is repelling it and back again in the direction of the first holding device 13a with a continuous bending radius and a bending angle of 180 °, so that the wire 1 does not cross and the respective adjacent forming sections 1 c are aligned horizontally and parallel to one another at regular intervals and perpendicular to the two holding devices 13a and 13b.

In order to avoid a buckling of the wire 1 in the region of the first and second loops 1 a, 1 b, the wire 1 is preferably in the entire bending region of the first and second loops 1 a, 1 b inside bending on the respective holding portions of the first and second holding device 13a, 13b supported.

The shape of the wire 1 in waveform can be supported by, for example, by the wire laying tool 12, a tensile stress is applied to the wire 1, so that the wire 1 spans and the loops 1 a, 1 b closely around the respective holding portions of the holding means 13 a and 13b and that the forming sections 1 c are taut and do not sag under the effect of their own weight. In this state, the first and second loops 1 a, 1 b and forming sections 1 c each formed identical to each other and extend exactly in a horizontal plane. The wire 1 comprises a plurality of shafts, each consisting of a first loop 1 a, a second loop 1 b and arranged therebetween forming section 1 c. All waves have the same shape and are the same in length and width.

The thus formed, flat Drahtgelege with the arranged in waveform W wire 1 is conveyed by a symmetrical drive of the holding means 13a, 13b in a direction opposite to the wire-laying direction L conveying direction F. In this case, the conveying is continuous or discontinuous, wherein the conveying speed is matched to the production speed of the wire laying tool 12, so that each wave 1 newly generated by the wire laying tool 12 is conveyed by the length of a shaft in the conveying direction F.

In step B of the method according to the invention, cross-connections are now made between the wire 1 arranged in the form of a wave W by connecting strand-shaped connecting means 2 to sections of the wire 1 which are subject to one another. A corresponding device 14 for the provision of connecting means 2 provides in the present example, three each formed as a continuous strand connecting means 2, which extend parallel to each other and parallel to the conveying direction F and parallel to the holding means 13a and 13b and are arranged at regular intervals from each other. Preferably, the connecting means 2 are made of the same material as the wire 1, but have a smaller cross-sectional area. Preferably, each strand-shaped connecting means 2 is provided by the device 14 in an endless form and in a plastic state, so that by slight exertion of pressure on the connecting means 2 in the direction of the wire 1 to be connected therewith, optionally exclusively under the influence of gravity, a cohesive connection between the connecting means 2 and the wire 1 can be achieved. The first connection means 2 (in the conveyor direction F on the left) extends in each case (in the conveying direction F on the right) just next to the first loops 1a perpendicular to the mutually parallel forming sections 1c. The second connection means 2 (in the conveyor direction F further to the right) extends at a slightly greater distance from the second loops 1b perpendicular to the mutually parallel forming sections 1c. The third connecting means 2 extends centrally at half the distance between the first and second connecting means 2 perpendicular to the mutually parallel forming sections 1 c. In step C, the conveyed in the conveying direction F and arranged in waveform W wire 1 is subjected to forming to form a plurality of forming regions 3 by changing the cross-sectional shape of the wire 1, more specifically to form a total of four forming regions 3 for each forming section 1 c. In each forming section 1 c two forming regions 3 are arranged between the first and the third connecting means 2, and two forming regions 3 are respectively arranged between the second and the third connecting means 2. In these forming regions 3, the cross-sectional shape of the wire 1, for example, changed from round to oval, rectangular or trapezoidal vorgreiflich, so that in a subsequent bending of the wire 1 in each of these forming regions 3 by way of manufacturing the electrical coil after the successful bending again the output cross section the transformation is present. A method for vorgreifllichen change of the cross-sectional shape of an electrical conductor with displacement of the centroid of the cross-sectional shape away from the profile axis with subsequent bending to the return displacement of the centroid of the cross-sectional shape in the direction of the profile axis is known from German Patent Application DE 10 2016 224 837.5. The contents of German patent application DE 10 2016 224 837.5 are incorporated by reference herein in their entirety, so that they form part of the disclosure of the original application documents of the present application.

Optionally, the flat wire layer is coated in step E prior to winding, for example, by an electrically insulating layer of plastic or the like, and dried in step F.

In step G, the winding of the flat wire mesh in the working area 10B of the device 10 then takes place with a corresponding device or drum 16 about a winding axis X parallel to the surface of the working area 10A of the device and arranged below it in the conveying direction F and counter to the wire laying direction L. At the end facing away from the wire laying tool 12, the wire 1 arranged in the wave form W is rolled up such that all the first loops 1a and all the second loops 1b lie one above the other at different axial ends of the winding in the radial direction with respect to the winding axis X and all the forming sections 1 c are aligned exactly parallel to the winding axis X, so that they are neither bent nor kinked by the winding. The necessary deformation of the wire 1 for transfer from the flat state, as it is produced in the section 10A of the device 10, in the wound or rolled up state, as for the storage and transport of the semifinished product is produced in the working area 10B of the device 10 is accomplished by bending deformation of the edge arranged on the first and second loops 1 a, 1 b.

In this wound state, the wire 1 arranged in waveform W can be easily stored and transported to its destination. By transfer from the wound or rolled up state into a flat state, the coil can be completed on site, since the measures necessary for the intended application, including the deformation of the wire 1 in the forming regions 3, have already been made. Before the production of the electrical coil from the prepared semi-finished product, the connecting means 2 can be separated and removed, since they primarily have the function to fix the planar arrangement of the wire mesh and in particular before winding / rolling the same a displacement of the forming sections 1 c with respect to the winding axis X to prevent. After the return transfer of the wire 1 from the wound or rolled-up state into the planar state, the connecting means 2 are generally expendable.

As a result, the following advantages can be realized by the preform formation according to the invention for an electrotechnical coil in forming technology with the following features:

The highly productive production process for semi-finished products of such a coil according to the invention relates in particular to the forming production of the preform of an electrotechnical coil made of current-conducting materials.

In contrast to the conventional and single-coil oriented solutions, which require a longitudinal orientation, the wire central axis is ideally rotated by 90 ° before winding, according to the inventive method, in order to achieve a packing of endless wire with cross-sectional shape.

The principle of Nähgewirkeherstellung is analogously transmitted to an electrically conductive wire 1, but no thread in the holding devices 13a, 13b is inserted, but wire material.

The holding devices 13a, 13b have holding sections (not shown) which are suitable for wire reception and positioning / fixing and in which the wire 1 can be suspended and formed into loops 1a, 1b. The continuous or quasi-continuous or incrementally driven holding devices 13a, 13b guide the wire 1 to one or more effective regions / machines or downstream devices 14, 15 and 16.

At least one device 15 for reshaping the wire 1 is used for section-wise shaping while changing the cross-sectional shape of the wire 1 in one or more deformation regions 3.

A device for applying a coating can be integrated and / or a device for tempering / drying the wire material (not shown).

For fixation of the wire 1 arranged in wave form W, a device 14 for connecting the wire 1 to a connection means 2 or a "sewing device" can be provided.

At the end, the resulting forming or Umformnähdrahtgelege can be wound on a reel 16.

The most important advantage of the invention is the economy of production with low use of production means (see coil in casting has lost core). Furthermore, the use of relatively inexpensive semi-finished products (ie round wire) can be used.

According to the principle of the invention, the preform of complete coil windings can be produced on the endless conductor. The continuous production sequence results in a very high productivity. Due to the compact arrangement of the flat wire mesh in the wound state, long-prepared wire sections can be transported and compactly stored for further processing. According to an advantageous development, the coating of the wire 1 can be applied directly after the forming. The coating can be done externally by handling in the form of a coil; Coil width and coil winding length need not correlate.

Instead of a wire 1 having a circular or round cross-sectional shape, it is also possible to use a wire 1 with a polygonal, in particular rectangular, cross-sectional shape as semifinished product.

Furthermore, the invention applies to coated materials in which a subsequent necessary isolation step is eliminated. The invention is not bound to a coil form, it can straight, convex, concave or conical coils and rotationally and non-rotationally symmetric coils are made from this preform.

The preform is produced by forming. By grinding samples (destructive material testing) on turns cross-sections can be detected whether a coil or its preform has been produced by forming.

The technical field of application of the invention are coils for electric motors which are mass-produced.

LIST OF REFERENCE NUMBERS

1 wire

1 a First loop

1 b Second loop

1 c forming section

2 connecting means

3 forming area

10 device

1 1 wire spool

12 wire laying tool

13 holding device

13a first holding device

13b Second holding device

14 connection device

15 forming device

16 rewinder / reel

A Area for carrying out process step A (wire laying in waveform)

B Area for carrying out process step B (cross connections)

C area for carrying out process step C (reshaping)

D Area for carrying out method step D (winding)

E Area for carrying out process step E (coating)

F conveying direction

L laying direction

W waveform

X winding axis

Claims

claims

1 . Method for producing a semifinished product for an electrotechnical coil, comprising the steps: a. Step A: arranging an electrically conductive wire (1) in waveform (W). b. Step B: connecting at least one connecting means (2) to at least two spaced-apart portions of the wire (1) arranged in waveform (W). c. Step C: forming the waveform (W) arranged wire (1) forming at least one forming area (3) by changing the cross-sectional shape of the wire (1).

2. The method according to claim 1, characterized in that the method comprises at least one of the following additional steps: a. Step D: conveying the wire (1) arranged in wave form (W) in its plane of extent, preferably in a conveying direction (F), which is opposite to a laying direction (L) of the wire (1). b. Step E: applying a coating of an electrically insulating material to the wire (1), preferably after step C and / or before step G. c. Step F: Dry the coating. d. Step G: Winding the wire (1) arranged in wave form (W), preferably such that the at least one deformation area (3) is aligned exactly or substantially parallel to the winding axis (X).

3. The method according to any one of the preceding claims, characterized in that step A comprises at least one of the following substeps: a. Step A1: providing the wire (1), preferably as an endless wire, preferably by extrusion, extrusion or unwinding from a coil (1 1), wherein the wire (1) preferably has a transverse length which is constant over the length. has sectional shape, preferably a circular or rectangular cross-sectional shape.

Step A2: Laying the wire (1) in a laying direction (L) with alternating formation of oppositely curved first and second loops (1 a, 1 b), each with a formed between two successive loops (1 a, 1 b) forming section (1 c).

Step A3: Waveforming the wire (1) using first and second holding means (13a, 13b) each having a plurality of holding portions arranged along a line, which are preferably formed identically and / or regularly spaced from each other, the lines along which the holding sections of the first and second holding devices (13a, 13b) are arranged, are preferably aligned horizontally and / or parallel to each other, wherein the sub-step A3 preferably comprises the following sub-steps: i. Step A3-1: Forming a first loop (1a) by guiding the wire (1) coming from the second holding device (13) about a part of a holding section of the first holding device (13a) facing away therefrom and back again in the direction of the second holding device (FIG. 13b), preferably with the formation of a bend with a continuous bending radius and / or at an angle in the range of 160 ° to 200 °, preferably in the range of 170 ° to 190 °, particularly preferably 180 °, without the wire (1) crossing over , wherein the wire (1) preferably along the entire first loop (1 a) or at least a part thereof on the inside of the support portion of the first holding device (13a) is supported. ii. Step A3-2: forming a second loop (1b) by guiding the wire (1) coming from the first holding device (13) around a part of a holding section of the second holding device (13b) facing away therefrom and back again in the direction of the first holding device (13). 13a), preferably forming a bend with a continuous bending radius and / or at an angle in the range of 160 ° to 200 °, preferably in the range of 170 ° to 190 °, particularly preferably 180 °, without the wire (1) crossing , where the Wire (1) preferably along the entire second loop (1 b) or at least a part thereof inside bending on the holding portion of the second holding device (13b) is supported. iii. Step A3-3: applying a tensile stress to the wire (1) so that the forming sections (1 c) of the wire (1) arranged between each two successive loops (1 a, 1 b) are stretched and extend along a straight line, wherein the forming portions (1 c) are preferably exactly or substantially equal in length and / or aligned parallel to each other and / or are regularly spaced from each other.

4. The method according to any one of the preceding claims, characterized in that step B comprises at least one of the following substeps: a. Step B1: Provision of at least one strand-form connection means (2), preferably of metal or plastic, by extrusion or extrusion. b. Step B2: connecting the at least one strand-form connecting means (2) to a first section of the wavy (W) arranged wire (1), preferably with a forming section (1 c). c. Step B3: arranging the at least one strand-form connecting means (2) in the laying direction (L) of the wire (1) and / or transversely, preferably perpendicularly, to the first section of the waved (W) wire (1), preferably several strandformige Connecting means (2) transversely or perpendicular to the laying direction (L) of the wire (1) are uniformly spaced. d. Step B4: connecting the at least one strand-form connecting means (2) to a second section of the waved (W) wire (1), preferably with a forming portion (1 c), preferably such that a plurality of strandformige connecting means (2) parallel to each other and / or parallel to the laying direction (L) of the wire (1) are aligned. e. Step B5: connecting the at least one strand-form connecting means (2) to each other in the direction of (L) following section of Waveform (W) arranged wire (1), preferably with each further forming section (1 c), the at least one strand-shaped connecting means (2) in the laying direction (L) crosses.

Method according to one of the preceding claims, characterized in that step C comprises at least one of the following substeps: a. Step C1: Forming the wire (1) to form at least one deformation area (3) while maintaining the cross-sectional area of the wire (1), wherein the cross-sectional shape is preferably changed from a round or rectangular cross-sectional shape to an oval, rectangular or trapezoidal cross-sectional shape. b. Step C2: Forming the wire (1) to form a plurality of deformation regions (3), which each have the same length and / or the same cross-sectional shape. c. Step C3: forming the wire (1) to form a plurality of mutually spaced Umformbereiche (3) within the same Umformabschnitts (1 c) of the wire (1), wherein the plurality of forming regions (3) are preferably between two adjacent connecting means (2). d. Step C4: deformation of the wire (1) to form a plurality of mutually spaced Umformbereiche (3) within the same Umformabschnitts (1 c) of the wire (1), wherein the plurality of forming regions (3) are preferably on different sides of the same connecting means (2) , e. Step C5: deformation of the wire (1) in several or all forming sections (1 c) of the wire (1) according to a repeating pattern, preferably such that several or all forming sections (1 c) of the wire (1) identical forming regions (3 ) exhibit. f. Step C6: Reshaping the wire (1) by changing the cross-sectional shape of the wire (1) according to the German patent application DE 10 2016 224 837.5.

Method according to Claim 2, characterized in that step G has at least one of the following substeps: a. Step G1: providing means (16) for winding the wire (1) arranged in waveform (W) so that the winding axis (X) of the device (16) is located below the wire (1) arranged in waveform (W). b. Step G2: conveying the wire (1) arranged in wave form (W) in the conveying direction (F) in a plane parallel to the winding axis (X). c. Step G3: rolling up the front in the conveying direction (F) of the arranged in waveform (W) wire (1) to the winding axis (X), so that at least one forming region (3) of the wire (1), preferably the forming sections (1 c ) of the wire (1) is aligned parallel to the winding axis (X). d. Step G4: Fix the wire (1) arranged in waveform (W) in a state wound around the winding axis (X).

7. Apparatus for producing a semifinished product for an electrotechnical coil, in particular for carrying out the method according to one of the preceding claims, comprising: a. A device (1 1, 12, 13) for arranging an electrically conductive wire (1) in waveform (W), preferably comprising at least one of the following features: i. A spool (1 1), from which the wire (1) can preferably be unwound continuously; ii. First and second holding means (13a, 13b) each having a plurality of holding portions arranged along a line, the lines along which the holding portions of the first and second holding means (13a, 13b) are arranged are preferably aligned horizontally and / or parallel to each other wherein the holding portions of the first holding means (13a) and / or the holding portions of the second holding means (13b) are preferably evenly spaced from each other; iii. A wire laying tool (12) which is formed to rotate in the laying direction (L) of the wire (1) alternately a first loop (1 a) about a holding portion of the first holding means (13 a) and a second loop (1 b) around a holding portion of second holding device (13b) to form, so that in each case a forming section (1 c) of the wire (1) between two successive loops (1 a, 1 b) extends. b. A device (14) for connecting a connecting means (2) with at least two spaced-apart sections of the arranged in waveform (W) wire (1). c. A device (15) for forming the arranged in waveform (W) wire (1) to form at least one forming area (3) by changing the cross-sectional shape of the wire (1).

8. The device according to claim 7, characterized in that the device has at least one of the following features: a. Means (13) for conveying the wire (1) arranged in waveform (W) in its extension plane, preferably means for simultaneously conveying the holding portions of the first and second holding means (13a, 13b) in the conveying direction (F) along the respective line, along which the holding sections of the respective holding device (13a, 13b) are arranged, preferably continuously or discontinuously, particularly preferably opposite to the laying direction (L) of the wire (1). b. A device for applying a coating of an electrically insulating material to the wire (1). c. A device for drying the coating. d. A device (16) for winding the waved (W) wire (1), wherein the device is preferably designed as a reel and is rotatable about an axis parallel to the plane of the waveform (W) arranged wire (1) axis, said Conveying direction (F) of the wire (1) runs exactly or substantially tangentially to the circumferential direction of the device (16). A semifinished product for an electrotechnical coil, preferably produced by the method according to one of claims 1 to 6 and / or using the device according to one of claims 7 or 8, comprising: an electrically conductive wire (1) arranged in waveform (W); at least one connecting means (2) connected to at least two spaced-apart portions of the waved (W) wire (1); and at least one forming portion (3) in which the waved wire (1) is deformed to change its cross-sectional shape.

Method for producing a semifinished product for an electrotechnical coil, comprising the steps: a. Step X: arranging an electrically conductive wire (1), so that at least two sections (1 c) of the wire (1) are arranged exactly or substantially parallel to each other. b. Step Y: connecting at least one connecting means (2) with at least two exactly or substantially parallel sections (1 c) of the wire (1). c. Step Z: Forming the wire (1) to form at least one deformation area by changing the cross-sectional shape of the wire (1).