WO2019040961A1

WO2019040961A1 - Method and device for automatically producing a component of a stator or rotor of an electric machine

Info

Publication number: WO2019040961A1
Application number: PCT/AT2018/060189
Authority: WO
Inventors: Andreas Falkner; Mladen-Mateo PRIMORAC; David SCHERRER
Original assignee: Miba Aktiengesellschaft
Priority date: 2017-09-01
Filing date: 2018-08-13
Publication date: 2019-03-07
Also published as: DE112018004837A5; AT520356A1

Abstract

The invention relates to a method and a device for automatically producing a component of a stator (1) or rotor of an electric machine. Rod-shaped conductor elements (3, 4) are positioned in a laminated core (2) of the stator (1) or rotor such that the first and second longitudinal ends (11, 12; 13, 14) protrude relative to the first and second end faces (7, 8), respectively, of the laminated core (2) and form respective first and second line protrusions (15, 16; 17, 18) relative to the laminated core (2). At least one first bending tool (25, 25') is attached to the first longitudinal ends (11, 12) of the conductor elements (3, 4). Additionally, at least one second bending tool (26, 26') is attached to the second longitudinal ends (13, 14) of the conductor elements (3, 4). A bending process is then initiated in order to bend first and second line protrusions (15, 16; 16, 17) and/or the first and second longitudinal ends (11, 12; 13, 14). The bending process is defined by simultaneously carrying out a first rotational movement of the at least one first bending tool (25, 25') in a first rotational direction (27) about the main axis (6) of the laminated core (2) and a second rotational movement of the at least one second bending tool (26, 26') in the second rotational direction (28) which is opposite the first rotational direction (27).

Description

Method and device for the automated production of a component of a stator or rotor of an electrical machine

The invention relates to a method and a device for the automated production of a component of a stator or rotor of an electrical machine, as specified in claims 1 and 9.

From JP2003259613A a manufacturing method for the electrical winding of the stator of an electric machine is known. In this case, a plurality of substantially U-shaped curved conductor elements is inserted into the receiving grooves of the hollow cylindrical stator laminated core. The protuberances of the leg ends of the U-shaped bent conductor elements projecting on one of the two end faces of the stator laminated core are then bent along the circumferential direction of the stator laminated core by means of concentrically arranged, disk-shaped bending tools, with projections immediately adjacent to one another in the radial direction of the stator laminated core the conductor elements are bent in opposite circumferential directions, so that crossing overhangs occur. By selectively electrically connecting the projections of the conductor elements, at least one winding extending in the circumferential direction of the stator laminated core is produced. This manufacturing process can be implemented only to a limited extent automated or only with relatively high technical complexity and only in compliance with close tolerances of the U-shaped curved conductor elements automated.

US 2,270,472 A discloses a method and a machine for manufacturing the rotor of an electric machine. The winding of the rotor is designed as a bar winding with crossed line ends for connection to the commutator of the rotor. Also, this method is only partially satisfactory in terms of achievable production cycle times. The object of the present invention was to overcome the disadvantages of the prior art and to provide a method and a device with which a possible functionally stable, precise and fast production of stators or rotors for electrical machines is possible. This object is achieved by a method and a device according to the claims.

By means of the method according to the invention, an automated or at least partially automated production of a stator or rotor of an electrical machine is made possible, or at least one corresponding semi-finished product or intermediate product can thereby be produced. According to one of the method steps of the manufacturing process, a substantially hollow cylindrical or cylindrical laminated core is provided with a plurality of stacked, a major axis defining laminations. The laminated core has a plurality of distributed in its circumferential direction, extending between a first and second axial end face of the laminated core receiving grooves for line sections of an electrical winding.

Furthermore, a plurality of rod-shaped conductor elements having a first and a second longitudinal end are provided, which rod-shaped conductor elements are provided for forming the electrical winding. A length of the rod-shaped conductor elements is greater than an axial length of the laminated core.

In a further method step, at least one of the rod-shaped conductor elements is inserted in a plurality or preferably in all receiving grooves, wherein the rod-shaped conductor elements are inserted or inserted into the receiving grooves starting from the first and / or second axial end face of the laminated core. In addition, the rod-shaped conductor elements are positioned such that their first and second longitudinal ends in each case protrude with respect to the first and second front ends of the laminated core and respectively define first and second line projections with respect to the laminated core.

Subsequently, the first and second conductor projections of the rod-shaped conductor elements are bent at least along circumferential directions of the laminated core to form a first and a second winding head opposite thereto of the winding of the stator or rotor to be produced. In the course of implementation or implementation of the bending process, at least a first bending tool is attached or attached to the first longitudinal ends of the conductor elements. In addition, at least one second bending tool is attached or attached to the second longitudinal ends of the conductor elements. Thereafter, the actual bending process or a part of the total bending process required for bending the first and second longitudinal ends or line süber states of the conductor elements is initiated or executed. In this case, a first rotational movement is performed by the at least one first bending tool in a first rotational direction about the main axis of the laminated core, and simultaneously or at least in phases simultaneously a second rotational movement of the at least one second bending tool in the opposite direction to the first rotational direction, second rotational direction executed.

It is advantageous in the method steps selected here that the torques exerted on the laminated core, which can be relatively high when forming a large number of conductor elements projecting from the laminated core, can at least partially equalize or, ideally, completely or almost completely compensate. In particular, thereby acting on a positioning or holding device for the laminated core forces or torques are much lower than is the case with only one-sided deformation of the conductor ends with respect to the laminated core or at a staggered, successive deformation of Conductor ends on the first and on the second front end of the laminated core occurs. This even if, in a multi-row, in particular two-, four- or six-row arrangement of conductor elements in the radial direction respectively successive, concentric layers or rows of conductor elements are bent in opposite directions each concentric row. Above all, due to the different circular diameters between the concentric rows or layers of conductor elements, varying degrees of torsional or bending moments are required, which must be absorbed by the positioning or holding device for the laminated core, while the corresponding bending tools have the corresponding bending forces the leaders and / or leaders over each other.

A particular advantage of the measures according to the invention lies in the fact that the corresponding production method enables a relatively high degree of automation of the production process. Mainly by the fact that rod-shaped conductor elements are used, whose mutually opposite longitudinal ends or front ends protrude in relation to the laminated core, respectively, is an optimally implementable, automated technology advantageous manufacturing method allows. In particular, this makes it possible to use functionally particularly reliable or relatively fail-safe and also rapid automation measures with which the shortest possible cycle times can be achieved. For example, in connection with the insertion step of the conductor elements in the laminated core functionally stable or highly available and fast-working automation measures can be implemented. After the resulting torsional forces or torques relative to the laminated core are as low as possible or depending on the design of the winding or depending on the geometry of the opposite winding heads of the winding either zero, almost zero, or relatively low, can be relatively slender or filigree and thus also cost-optimized holding or positioning devices for the stator or rotor, in particular with respect to the laminated core, are used. In addition, any peak loads on individual disks of the laminated core can thereby be avoided or reduced, so that the desired geometry or the planned structure of the laminated core is not adversely affected in the course of clamping or holding the laminated core or is affected as little as possible. Especially when glued together, electrically insulated from each other laminations is a destruction of the bond or damage to the insulation between the

To avoid laminations with the highest possible reliability or to hold back, which requirements can be met by the specified measures also optimized. Another method is defined by simultaneously or approximately simultaneously starting the first and second rotational movements and terminating the first and second rotational movements at the same or approximately the same time. As a result, the forces or torques that occur in relation to the laminated core at any time during the bending process are compensated for or at least partially compensated. In particular, the rotational movements of the relative to the laminated core opposite each other

Bending tools started or ended at the same time or almost at the same time. Due to the mutually opposing rotational movements carried out simultaneously on both ends of the laminated core. tions of the first and second bending tool, the resulting rotational forces are minimized or canceled relative to the laminated core. This especially because the radial distance of the first longitudinal ends or conductor projections of the conductor elements with respect to the main axis is identical or nearly identical to the radial distance of the second longitudinal ends or line süber states of these conductor elements with respect to the main axis.

Furthermore, an approach is advantageous, which is characterized by covering a same amount of rotation angle of the at least one first and the at least one second bending tool. As a result, identical rotational or peripheral speeds can be selected for the first and the second bending tool lying opposite to each other.

A practicable procedure is also defined by the fact that a first and a second movement drive are provided for the first and the second bending tool, wherein the first and the second movement drive are controlled such that same or approximately the same drive torques are present at the same time opposite or opposite directions act. This also makes it possible to achieve an absolutely present equilibrium of forces or a largely fulfilled equilibrium of forces with respect to the laminated core, and consequently makes the holding and positioning device for the laminated core simpler or relatively filigree.

A further advantageous method measure is defined by bringing the main axis of the laminated core into a horizontal orientation or by maintaining a horizontal orientation of the main axis of the laminated core before the bending process or during the bending process of the longitudinal ends of the conductor elements is carried out. It is thereby achieved that in each case the same or almost equal weight forces are exerted on the side of the stator or rotor to be produced, in particular of its laminated core and of its conductor elements on the first and the second bending tool. As a result, the achievable precision or quality can be favorably influenced. In addition, thereby the mechanical structure of the two opposing bending devices can be simplified or can be better absorbed as compared to a vertical orientation, the required support or counter moments of the bending devices or applied. In particular, this can be withstood with a relatively simple mechanical base frames or supporting elements high torsional forces or a precision affecting distortion and excessive torture of the bending station can be avoided during the execution of the bending process.

Also advantageous is a variant of the method in which two or more conductor elements which are lined up in the radial direction to the main axis are arranged at least in some of the receiving grooves to form two or more concentric layers or ring arrangements of conductor elements, the longitudinal ends of all the conductor elements within a radial inner layer or ring assembly by means of the associated bending tools simultaneously or at least phased simultaneously bent or rotated by a defined rotation angle in opposite directions. At the same time, or at least for the most part at the same time, the longitudinal ends of all the conductor elements of an immediately adjacent, radially outer layer or ring arrangement are bent simultaneously or at least in phase at the same time by a defined angle of rotation into mutually opposite directions of rotation by means of the further, associated bending tools.

As a result, oppositely directed or oppositely bent longitudinal ends or line projections are created between directly adjacent concentrically arranged layers or ring arrangements of conductor elements, which allow an advantageous connection to a meandering or circumferential direction of the laminated core extending winding or partial winding. In addition, a compensation or at least largely compensation of the torques acting on the laminated core is made possible.

An advantageous procedure is defined in that the at least one first and the at least one second bending tool are rotated in accordance with a desired offset angle of the conductor elements plus a springback compensation angle. This can be compensated in an advantageous manner, an elastic resilience of the line projections or the longitudinal ends of the conductor elements, so that the longitudinal ends at the end of the bending process at the planned position, at least with respect to the circumferential direction of the laminated core. In addition, the required cycle time for the bending process can be kept as low as possible. According to a practicable procedure, it can also be provided that in the course of attaching the at least one first bending tool and / or the at least one second bending tool to the respectively adjacent longitudinal ends or line projections, the conductor elements are displaced in the axial direction of the laminated core in the receiving grooves and corresponding to one predefined plan or setpoint are positioned. As a result, not only high precision but also the fastest possible production of the stator or rotor can be supported. In particular, the resulting cycle time can be kept as short as possible by this measure. The device according to the invention for the automated production of a component of a stator or rotor of an electric machine comprises on the one hand a support frame for mounting at least one first bending tool. This at least one first bending tool is provided for attachment to first longitudinal ends of electrical conductor elements, which are inserted into a laminated core of a stator or rotor to be produced. The at least one first bending tool is arranged to bend the first conductor projections of the electrical conductor elements with respect to the laminated core. In addition, at least one first movement drive for the controlled generation of rotational movements of the at least one first bending tool is formed. At least one electronic control device is provided for the controlled activation of the at least one first movement drive. It is essential that at least one second bending tool is mounted on the support frame for the at least one first bending tool or on an additional support frame. This at least one second bending tool is provided for attachment to the opposite second longitudinal ends of the plugged into the laminated core of the stator or rotor to be produced, electrical conductor elements. This at least one second bending tool is arranged to bend the second conductor projections of the electrical conductor elements with respect to the laminated core. The electronic control device is further configured to carry out a bending operation for simultaneous or predominantly simultaneous bending of the first and also the second conductor projections of the conductor elements, this bending process also being carried out by executing a first rotational movement of at least one of the first bending tools in a first direction of rotation, and defined by an at least temporarily simultaneous execution of a second rotational movement of at least one of the second bending tools in the opposite direction to the first direction of rotation, the second direction of rotation. The measures according to the invention make it possible to construct a device or plant which can be automated simply and in a relatively stable process for the production of a semi-product or intermediate product of a stator or rotor. In particular, this allows a machine-simple, reliable, precise and fast production of a stator or rotor or an optimized assembly of the electrical winding can be achieved.

Furthermore, it may be advantageous if the at least one first bending tool has at least two bending tools with different diameters, and that the at least one second bending tool has at least two bending tools corresponding to the diameters of the first bending tools, and that bending tools lying opposite each other with corresponding diameters of the control device activated simultaneously or almost simultaneously operated. This allows a rational and at the same time precise production can be achieved. In addition, in this case, the torques acting on the opposite end faces of the laminated core can be compensated or at least largely compensated.

Another embodiment is characterized in that the at least one first bending tool and / or the at least one second bending tool are adjustable with respect to their distance relative to each other. As a result, a simple introduction of a laminated core with frontally protruding therefrom conductor elements in the device allows. By adjusting the distance between the at least one first bending tool and the at least one second bending tool, the prepared laminated core together with the conductor elements inserted therein can simply be tensioned or picked up and released again after execution of the bending process.

A further possible embodiment is characterized in that the at least one first bending tool and / or the at least one second bending tool are adjustable relative to each other along their mutually aligned rotational or rotational axes in their distance. By limiting the relative mobility of the two opposing bending tools on their mutually aligned rotation or rotation axis, a high manufacturing accuracy can be achieved with the simplest possible mechanical structure. Finally, the electronic control device of the specified device can be designed to implement or control the method measures described above. Due to the predominantly software or programmatic feasibility of the corresponding process measures a high flexibility and at the same time a high level of functionality of the specified device can be achieved.

For a better understanding of the invention, this will be explained in more detail with reference to the following figures.

In each case, in a highly simplified, schematic representation:

Fig. 1 is a hollow cylindrical laminated core with a plurality of received therein, rectilinear conductor elements in their not yet bent state, in perspective view;

Fig. 2a single process steps for producing a stator of an electric machine;

FIG. 2b shows a device for bending the conductor sections projecting in relation to a laminated core and a stator semi-finished product manufactured with this device with curved conductor sections projecting with respect to the laminated core.

By way of introduction, it should be noted that in the differently described embodiments, the same parts are provided with the same reference numerals or the same component names, wherein the disclosures contained in the entire description can be mutatis mutandis to the same parts with the same reference numerals or component names. Also, the position information selected in the description, such as top, bottom, side, etc. related to the immediately described and illustrated figure and these position information in a change in position mutatis mutandis to transfer to the new location. The term "in particular" is understood below to mean that it may be a possible more specific training or specification of an object or a method step, but not necessarily a compelling, preferred embodiment of the same or a compelling approach.

In Fig. 1 shows a possible embodiment of a stator 1 for forming an electric machine, not shown. However, it would also be possible to apply and to carry out the following description and embodiment of a rotor for forming an electric machine in a manner analogous thereto. The following description is therefore based only on a stator 1, but may also relate to a rotor.

The assembly and a plurality of production steps of the stator 1 can preferably be carried out automatically in a complex production plant in several production stations usually also fully automatically. In the following, not all of the overall required process or manufacturing steps for the creation of a ready-to-use stator 1 or rotor are described, wherein the additionally required manufacturing steps can be taken from the prior art.

Basically, the stator 1 comprises a laminated core 2 as well as a multiplicity of conductor elements 3, 4 to be accommodated therein for forming electrical coils or windings and for generating a magnetic rotating field as a result of a current loading of the coils or windings.

In the present embodiment, the individual conductor elements 3, 4 are shown in their undeformed starting position, in which they are formed as straight rods. The rods usually have a rectangular cross section up to a square cross section and a longitudinal extent and are formed from an electrically conductive material. In most cases, this is a copper material. Therefore, the conductor elements 3, 4 may also be referred to as profile bars and the electrical winding constructed therewith may be referred to as a bar winding. To form electrical coils or windings formed therefrom, a multiplicity of receiving grooves 5 are arranged or formed in the laminated core 2, in which in each case at least one of the conductor elements 3, 4, but preferably at least two of the conductor elements 3, 4, are received or is arranged or are. The receiving grooves 5 may extend in the axial direction of the laminated core 2 in a parallel orientation relative to a main axis 6 defined by the laminated core 2. But it would also be possible to choose a respect to the main axis 6 is not parallel arrangement of the grooves 5 with the therein male conductor elements 3, 4. In any case, the receiving grooves 5 extend in the direction of the main axis 6 in each case between the first end face 7 and the second end face 8 of the laminated core 2 spaced therefrom.

The receiving grooves 5 each have a conductor element 3, 4 accommodated on the cross-sectional dimension of the conductor element 3, 4 or in the case of several in the same receiving groove 5, each having a receiving groove cross-section adapted to the cross-sectional dimensions. The conductor elements 3, 4 per receiving groove 5 can - as exemplified - be arranged in the radial direction to the main axis 6 in a row. But it is also a matrix or array-shaped, in particular a series and column-like arrangement of conductor elements 3, 4 in the individual grooves 5 possible. The laminated core 2 is composed of a plurality of electrically mutually insulated individual sheets or laminations 2 'to the package. The laminated core 2 is bounded in the direction of its main axis 6 by the first end face at its first end face 7 and by the second end face spaced therefrom at its second end face 8. Preferably, the two end faces or front ends 7, 8 are arranged parallel to each other and extending in a direction aligned in the normal direction with respect to the main axis 6 level. In the present exemplary embodiment of a stator 1 of an electric machine, the laminated core 2 forms a hollow cylinder with an inner surface and an outer surface made of the stacked individual sheets or laminations 2 '. As already stated above, at least one of the conductor elements 3, 4 is arranged in each of the receiving grooves 5. However, it is also possible to provide several, in particular two, three, four, five, six or even more conductor elements 3, 4 per receiving groove 5. In particular, In particular, eight, ten, twelve or more conductor elements 3, 4 can be accommodated in each of the receiving grooves 5. As a minimal variant, a conductor element 3, 4 may be provided, but in this embodiment, in each case a receiving groove 5, two conductor elements 3, 4 are shown and described. Thus, the conductor elements 3 arranged in the radial direction on the inside form a first layer 9 and the conductor elements 4 arranged on the outside in the radial direction form a second layer 10. Individual or a few of the receiving grooves 5 can also remain empty or be implemented without inserted therein conductor elements 3, 4. The rod-shaped, preferably straight in the original state

Conductor elements 3 and 4 each have a first longitudinal end 11, 12 and in each case one opposite thereto second longitudinal end 13, 14. In this embodiment, the first longitudinal ends 11, 12 project beyond the first end face 7 and the second longitudinal ends 13, 14 project beyond the second front end 8 of the laminated core 2. The conductor elements 3, 4 thus form opposite the first end face 7 first line projections 15, 16 and opposite the second front end 8 second line states over 17, 18 from.

The conductor elements 3, 4, which are accommodated in the sheet-metal package 2 in the individual receiving grooves 5 and are still undeformed in the initial state, are provided in the region of each of the two prongs 7, 8 of the laminated core 2 at their longitudinal ends 11, 12; 13, 14 or with respect to their line projections 15, 16; 17, 18 in a subsequent manufacturing step entangled against each other or bent along the circumferential direction of the laminated core 2. Subsequently, longitudinal ends 11 of the first or inner layer 9 are selectively electrically connected to corresponding longitudinal ends 12 of the second or outer layer 10. The same can also be carried out with the respective second longitudinal ends 13, 14 in the region of the second front end 8 of the laminated core 2.

In a known manner, the conductor elements 3, 4 may be provided with an electrical insulation layer 19, with the exception of mutual contact regions formed thereon. This insulating layer 19 on the lateral surface of the rod-shaped conductor elements 3, 4 is preferably formed of plastic and may have been applied in a previous painting or dipping process. Furthermore, it may be advantageous if the individual conductor elements 3, 4 in addition to their electrical insulation layer 19 within the grooves 5 are also surrounded by a structurally independent, hollow-profile-like insulation element 20 preferably fully.

The feeding or the introduction of the individual conductor elements 3, 4 in the respective grooves 5 can be done stepwise or intermittently, with the laminated core 2 is preferably with its main axis 6 in a horizontal orientation. Since the typically still undeformed, originally linear or rod-shaped conductor elements 3, 4 are received longitudinally displaceable in the respective grooves 5, when transferring to a subsequent processing station or manufacturing station on the relative position of the conductor elements 3, 4 with respect to the laminated core 2 is considered or to make a predefined relative position of the conductor elements 3, 4 with respect to the laminated core 2 safe.

In a preferred before the transfer or passing to the subsequent processing o- or manufacturing station to be performed positioning step, the conductor elements 3, 4 in the axial direction with respect to one of the front ends 7, 8 of the laminated core 2 are still aligned. This can e.g. take place in that the laminated core 2, together with the conductor elements 3, 4 already accommodated therein, is transferred from its preferably horizontal charging position into a vertical positioning position, in which the main axis 6 of the laminated core 2 has a vertical longitudinal orientation. The laminated core 2 can be supported on a positioning approach, wherein the conductor elements 3, 4 preferably by gravity in the individual grooves 5 to a preferably circumferentially formed positioning with one of their longitudinal send 11, 12 or 13, 14 come to rest. The distance between the positioning projection and the positioning element is to be selected according to the required or predetermined projection of the ends of the conductor elements 3, 4 via one of the front ends 7, 8 of the laminated core 2. This transport position can e.g. be taken on a movable between each of the workstations workpiece carrier.

With the method steps given below, as also schematically illustrated in FIGS. 2a and 2b, an automated or at least partially automated production of at least one semi-finished product of the generic stator 1 or rotor for electrical machines can be achieved. The corresponding process steps therefore result a semi-finished or intermediate product of a stator 1, which semifinished product is to be supplemented or completed by further process measures.

In an initial step, a substantially hollow-cylindrical laminated core 2 with a plurality of laminations 2 'stacked on top of one another and defining a main axis 6 is provided. This laminated core 2 has a plurality of distributed in the circumferential direction, between the first axial end face 7 and the second axial end face 8 of the laminated core 2 extending receiving grooves 5 for line sections of an electrical winding to be produced. In the illustrated embodiment with a stationary running stator 1 of an electric machine or an electric drive motor, the laminated core 2 is designed as a hollow cylindrical body. However, it is also possible for a stator to have a substantially cylindrical body shape, the corresponding electric machine or the corresponding drive motor then being designed as a so-called external rotor motor with a hollow-cylindrical rotor.

In addition, a plurality of rod-shaped conductor elements 3, 4 are provided, which in the initial or original state, in particular in their insertion state relative to the laminated core 2, have a rectilinear or predominantly rectilinear shape, in particular have a rod shape. Depending on the length of the receiving grooves 5, these rod-shaped conductor elements 3, 4 can also have a helical or screw-shaped configuration, which is the case in particular in so-called obliquely-grooved laminations 2 or stators 1 or rotors. The rod-shaped conductor elements 3, 4 each have a first longitudinal end 11, 12 and a distal opposite, second longitudinal end 13, 14. This plurality of rod-shaped conductor elements 3, 4 are provided by predefined electrical interconnections or by subsequently to be produced connections for the construction of the electrical winding of the stator 1. A length 21 of the rod-shaped conductor elements 3, 4 is greater than an axial length 22 of the laminated core 2.

In a preferably automated process step, the rod-shaped conductor elements 3, 4 in pairs or in groups, in particular in a multiple of two pieces, preferably in each of the grooves 5 are introduced. But it is also possible that individual of the grooves 5 less conductor elements 3, 4, or that individual grooves 5 have no conductor elements 3, 4. In the middle section 2a is a partially executed insertion process of the conductor elements 3, 4 can be seen or were the sake of simplicity, only one of the inserted into the laminated core 2 conductor elements 3, 4 shown. The introduction of the substantially rectilinear or unbent, rod-shaped conductor elements 3, 4 in the grooves takes place starting from the first or second axial end face 7, 8 of the laminated core 2. But it is also a combined insertion of individual conductor elements 3, 4, starting from the first front end 7 and individual conductor elements 3, 4, starting from the opposite, second front end 8 of the laminated core 2 possible. The insertion or insertion process is thus carried out in the axial direction to the laminated core 2, that is not just in the radial direction to the main axis 6 of the laminated core 2. In particular, the receiving grooves 5 usually have a taper of the clear cross section and the clear width in their the main axis 6 next allocated section on. This section or this end of the receiving grooves 5 is thus relatively narrow or narrow, but nevertheless designed to be open, in particular interrupted, as is known in principle from the prior art and can be seen by way of example from FIG. 2 a.

In a subsequent method step, the bar-shaped conductor elements 3, 4 introduced into the receiving grooves 5 are positioned such that their first and second longitudinal ends 11, 12; 13, 14 opposite the first and second front end 7, 8 of the laminated core 2, respectively. These protruding sections of the conductor elements 3, 4 define first and second line projections 15, 16, respectively; 17, 18 opposite the first and second front end 7, 8 of the laminated core 2. Individual conductor elements 3, 4 may have a comparatively greater length 21 than other conductor elements 3, 4 within the electrical winding to be formed. The comparatively longer running conductor elements 3, 4 can be provided in particular for the formation of winding connections or connection zones. After introduction and positioning of the conductor elements 3, 4 corresponding to the desired electrical winding concept, a defined bending or crimping of the first and second conductor projections 15, 16 and 17, 18 of the rod-shaped conductor elements 4, 5 takes place in the circumferential direction of the laminated core 2. In particular, the first and second winding heads 23, 24 (FIG. 2 b) of the electrical winding of the stator 1 or rotor are thus defined in their basic geometry or shape. In accordance with an expedient measure, in the course of this bending or forming process, the line projections 15, 16 or 17, 18 which originally projected linearly or largely rectilinearly out of the laminated core 2, are provided that at least one first bending tool 25, 25 'at the first longitudinal ends 11 , 12 of the conductor elements 3, 4 attached or attached. In addition, in particular offset substantially at the same time or slightly offset in time, at least one second bending tool 26, 26 'is attached or attached to at least one of the second longitudinal ends 13, 14 of the conductor elements 3, 4, as is roughly illustrated in particular in FIG. The at least one first bending tool 25, 25 'and the at least one second bending tool 26, 26' can in a conventional manner positively acting receiving pockets or driving elements for the longitudinal ends 11, 12; 13, 14 and front ends of the conductor elements 3, 4 have. But it is also possible that the bending tools 25, 25 ', 26, 26' are primarily based on a friction final principle or are based on another driver principle for controlled, plastic deformation of the conductor elements 3, 4.

In an effective manner, the at least one first bending tool 25, 25 'and / or the at least one second bending tool 26, 26' can also be used so that they have the respective associated longitudinal ends 11, 12; 13, 14 or line over states 15, 16; 17, 18 of the conductor elements 3, 4 move in the axial direction of the laminated core 2 in the receiving grooves 5 and position as planned or at the respective desired position relative to the front ends 7, 8 of the laminated core 2.

It is essential that the bending process of the conductor elements 3, 4 or of its line projections 15, 16; 17, 18 with respect to the two front ends 7, 8 of the laminated core 2 with the respective associated bending tools 25, 25 'and 26, 26' simultaneously or at least approximately simultaneously executed. In particular, a bending operation is initiated and carried out, which by at least a phase-wise simultaneous execution of a first rotational movement of the at least one first bending tool 25, 25 'in a first rotational direction 27 and by a second rotational movement of the at least one second bending tool 26, 26' in a second direction of rotation 28 is marked. The second rotational movement of the at least one second bending tool 26, 26 'is carried out in the opposite direction to the first direction of rotation 27 or opposite, second direction of rotation 28. It is useful if the first and second longitudinal ends 11, 13 and 12, 14 of Conductor elements 3, 4 per layer 9 or 10 with respect to the opposite ends 7, 8 of the laminated core 2 are bent simultaneously or substantially simultaneously in opposite directions, which by the opposite rotational movements of the at least one first bending tool 25, 25 'and at least a second bending tool 26, 26 'is accomplished. At the same time or substantially simultaneously at least the predominant number of first conductor projections 15 of the inner conductor elements 3 at the first end face 7 of the laminated core 2 and at least the vast majority of second conductor projections 17 of the inner conductor elements 3 at the second front end 8 of the laminated core 2 are reshaped as planned or bent, in particular with respect to the end faces 7, 8 of the laminated core 2 angled at least once. The same applies to the second line projections 16, 18 of the conductor elements 4, which lie comparatively further in the radial direction. The conductor elements 3 of the inner layer 9 and the conductor elements 4 of the outer layer 10 are preferably bent in opposite directions, so that at the winding heads 23, 24 a crossed structure of the line projections 15, 16 and 17, 18 is formed, as best seen in the right portion of Fig. 2b.

The bending operation is thus expediently carried out in such a way that at least the predominant number of the conductor elements 3, 4 inserted into the laminated core 2 are or have a substantially Z-shaped profile with respect to their entire longitudinal extent, as shown schematically in FIG. 2b and by way of example. This can be done by the ever

Front end 7, 8 of the laminated core 2 formed pairs or groups of oppositely rotatable bending tools 25 and 25 'and 26 and 26' can be achieved.

The control engineering processes for the bending process are controlled or implemented by at least one electronic control device 29. The at least one control device 29 is coupled on the one hand with at least one first movement drive 30 for the at least one first bending tool 25, 25 'and further with at least one second movement drive 31 for the at least one second bending tool 26, 26' conductively connected or control technology.

The electronic control device 29 can be set up or programmed in such a way that a simultaneous or approximately simultaneous starting of the first and second rotational movement and termination of the first and second rotational movement to a same or approximately the same time takes place, so that the occurring forces or torques relative to the laminated core 2 are compensated or at least partially compensated. A schematically illustrated gripping or holding device 32 for the laminated core 2 thus has to be able to withstand only relatively small torsional forces or torques. In particular, by the forces exerted on the laminated core 2 or on the laminations 2 'summarily or resulting forces in the course of the bending process of the line projections 15, 16; 17, 18 relatively low.

The holding device 32 can be designed according to any known from the prior art mechanisms. For example, the holding device 32 may be designed in the manner of a forceps gripper, a multiple finger gripper, or even in the manner of a magnetic gripper or an electromagnetic holding device.

In this case, the first and second winding heads 23, 24 can be shaped essentially symmetrically, but their overhangs 15, 16 or 17, 18 can be bent in opposite directions. In particular, it can be provided that at least approximately the same angles of rotation 33, 34 - see arrows in FIG. 2b - are covered by the first and second bending tools 25, 26 with respect to the same layer 10 of the winding to be produced. The same applies to the conductor elements 3 of the radially inner layer 9 and their associated bending tools 25 ', 26'. The control or control of the respective twist angle 33, 34 is preferably also carried out by the at least one electronic, typically programmable logic controller 29th

The electronic control device 29 may also be adapted to drive the at least one first movement drive 30 for the at least one first bending tool 25 of the radially outermost layer 10 and the at least one second movement drive 31 for the at least one second bending tool 26 of the same, radially outermost layer 10 are driven so that the same or approximately the same drive torques are present at the same time, which act in opposite directions or in opposite directions. The same applies to the conductor elements 3 of the inner layer 9 and to the bending elements 25 ', 26' associated with the inner conductor elements 3. It is also expedient if in the course of carrying out the method according to the invention the main axis 6 of the laminated core 2 is moved in a horizontal orientation or if the horizontal orientation of the main axis 6 of the laminated core 2 is maintained before or during the bending process of the longitudinal ends 11, 12; 13, 14 of the conductor elements 3, 4 is executed. After the execution of the bending process then the at least one first bending tool 25, 25 'and the at least one second bending tool 26, 26' of the longitudinal ends 11, 12; 13, 14 of the conductor elements 3, 4 again removed or removed.

The at least one first and the at least one second bending tool 25, 25 ', 26, 26' are preferably designed in several parts, in particular formed by concentric nested, independently rotatable part tools or drive plates. This ever bending tool 25, 25 ', 26, 26' running combination or part tools at the axial ends 7, 8 of the laminated core 2 are rotatable in opposite directions, as is known from the prior art, to immediately adjacent layers , 10 of line projections 15, 16 and 17, 18 to be able to bend in opposite circumferential directions. As a result of the opposite rotational movement of a plurality of part tools per bending tool group 25, 26, the mutually entangled deformation of the line projections 15 and 16 or 17 and 18 that can be seen in the right half of FIG. 2b can be achieved. In particular, each layer 9, 10 and each front end 7, 8 of the laminated core 2 each be provided a bending tool, so that in the illustrated embodiment, two concentric nested sub-tools or drive plates define the first bending tool group 25, 25 'and two concentric with each other set sub-tools or drive plates define the second bending tool group 26, 26 '. In the course of carrying out the bending process, therefore, the first winding head 23 and the second winding head 24 of the stator 1 are formed simultaneously or substantially simultaneously. In particular, by the opposite or opposite bending operations, which are carried out at least approximately simultaneously with respect to the opposing front ends 7, 8 and preferably for all layers 9, 10 of the winding to be carried out, in Fig. 2b in the right half illustrated, prefabricated stator semi-finished produced. In the left-hand half of FIG. 2b, a bending device for automatically producing a component of a stator or rotor of an electric machine is schematically illustrated. This device comprises a support frame 35 for supporting or rotatably supporting the at least one first bending tool 25, 25 '.

This at least one first bending tool 25, 25 'is provided for attachment to first longitudinal ends 11, 12 of electrical conductor elements 3, 4, which are inserted into a laminated core 2 of a stator or rotor to be produced. The at least one first bending tool 25, 25 'is - as explained above - arranged for bending the first conductor projections 15, 16 of the electrical conductor elements 3, 4 relative to the laminated core 2.

The at least one first movement drive 30, for example a servomotor, is designed for the controlled generation of rotational movements of the at least one first bending tool 25, 25 '. The at least one electronic control device 29 is designed for the controlled activation of the at least one first movement drive 30.

On the support frame 35 for the at least one first bending tool 25, 25 'or on an additional support frame 36, the at least one second bending tool 26, 26' is mounted, in particular rotatably supported. The at least one second bending tool 26, 26 'is provided for attachment to the opposite second longitudinal ends 13, 14 of the inserted into the laminated core 2 of the stator or rotor to be produced, electrical conductor elements 3, 4. The at least one second bending tool 26, 26 'is designed to bend the second conductor projections 17, 18 of the electrical conductor elements 3, 4 with respect to the laminated core 2.

The electronic control device 29 is adapted to a bending operation for simultaneous or predominantly simultaneous bending of the first and also the second line projections 15, 16; 17, 18 of the conductor elements 3, 4 execute. This bending process is also characterized by an execution of a first rotational movement of at least one of the first bending tools 25, 25 'in a first direction of rotation 27, and by an at least temporarily simultaneously executing a second rotational movement of at least one of the second bending tools 26, 26' in the first direction of rotation 27 opposite, second direction of rotation 28 defined. It can be provided that the at least one first bending tool 25, 25 'at least two bending tools having different diameters, and that the at least one second bending tool 26, 26' at least two to the diameters of the first bending tools 25, 25 'corresponding bending tools 26, 26 ', as indicated in Fig. 2b by dashed lines. The opposing bending tools 25, 26 and 25 ', each having a corresponding diameter are simultaneously activated by the control device 29 or actuated approximately simultaneously to achieve the most comprehensive or extensive compensation of the resulting torques in relation to the laminated core 2 ,

It may also be expedient if the at least one first bending tool 25, 25 'and / or the at least one second bending tool 26, 26' are adjustable relative to one another with regard to their spacing 37. In particular, it can be provided that the at least one first bending tool 25, 25 'and / or the at least one second bending tool 26, 26' are adjustable relative to each other along their mutually aligned rotational or rotational axes in their distance 37

The embodiments show possible embodiments, it being noted at this point that the invention is not limited to the specifically illustrated embodiments thereof, but rather also various combinations of the individual embodiments are possible with each other and this possibility of variation due to the teaching of technical action by representational Invention in the skill of those skilled in this technical field.

The scope of protection is determined by the claims. However, the description and drawings are to be considered to interpret the claims. Individual features or combinations of features from the illustrated and described different embodiments may represent for themselves inventive solutions. The task underlying the independent inventive solutions can be taken from the description. All information on ranges of values in objective description should be understood to include these arbitrary and all sub-ranges thereof, eg the indication 1 to 10 should be understood to encompass all sub-ranges, starting from the lower limit 1 and the upper limit 10 that is, all portions begin with a lower limit of 1 or greater and end at an upper limit of 10 or less, eg, 1 to 1.7, or 3.2 to 8.1, or 5.5 to 10.

For the sake of order, it should finally be pointed out that for a better understanding of the construction, elements have been shown partially unevenly and / or enlarged and / or reduced in size.

REFERENCE NUMBERS

1 stator 30 first movement drive

2 laminated core 31 second movement drive

2 'laminations 32 holding device

3 conductor element 33 twist angle

4 conductor element 34 twist angle

5 receiving groove 35 supporting frame

6 main axis 36 support frame

7 first end face 37 distance

8 second front end

9 first shift

10 second shift

11 first longitudinal end

12 first longitudinal end

13 second longitudinal end

14 second longitudinal end

15 first line projection

16 first line projection

17 second line supernatant

18 second line supernatant

19 insulation layer

20 insulation element

21 length

22 axial length

23 first winding head

24 second winding head

, 25 'first bending tool

, 26 'second bending tool

27 first direction of rotation

28 second direction of rotation

29 VAT system

Claims

Patent claims

1. A method for the automated production of a component of a stator (1) or the rotor of an electrical machine, the method comprising the following method steps,

- Providing a substantially hollow cylindrical or cylindrical laminated core (2) having a plurality of stacked, a major axis (6) defining laminations (2 '), which laminations (2) arranged a plurality of distributed in the circumferential direction, between a first and second axial end face (7, 8) of the laminated core (2) has receiving grooves (5) for line sections of an electrical winding;

- Providing a plurality of rod-shaped conductor elements (3, 4) having a first and a second longitudinal end (11, 12; 13, 14), which rod-shaped conductor elements (3, 4) are provided for forming the electrical winding, wherein a length (21) the rod-shaped conductor elements (3, 4) is greater than an axial length (22) of the laminated core (2);

- Introducing at least one of the rod-shaped conductor elements (3, 4) in a plurality or in all of the receiving grooves (5) of the laminated core (2), wherein the rod-shaped Leiterele- elements (3,4) starting from the first and / or second axial Front end (7, 8) of the laminated core (2) are introduced into the receiving grooves (5);

- Positioning the rod-shaped conductor elements (3, 4) such that their first and second longitudinal ends (11, 12, 13, 14) relative to the first and second front end (7, 8) of the Blechpa- kets (2) respectively protrude and each first and second line projections (15, 16; 17, 18) opposite the laminated core (2), the method being further characterized in that it comprises the following steps:

- attaching at least one first bending tool (25, 25 ') to the first longitudinal ends (11, 12) of the conductor elements (3, 4); - attaching at least one second bending tool (26, 26 ') to the second longitudinal ends (13, 14) of the conductor elements (3, 4);

- initiating a bending operation to bend the first and second overhangs (15, 16, 16, 17) and / or the first and second longitudinal ends (11, 12, 13, 14) by simultaneously

Performing a first rotational movement of the at least one first bending tool (25, 25 ') in a first rotational direction (27) about the main axis (6), and a second rotational movement of the at least one second bending tool (26, 26') in the first Direction of rotation (27) opposite, second direction of rotation (28).

2. The method according to claim 1, characterized by a simultaneous or approximately simultaneous starting of the first and second rotational movement and by terminating the first and second rotational movement at the same or approximately the same time, so that the forces or torques relative to the laminated core (2) compensated or at least partially compensated.

3. The method according to claim 1 or 2, characterized by covering a magnitude same angle of rotation (33, 34) of the at least one first and the at least one second bending tool (25, 25 ', 26, 26').

4. The method according to any one of the preceding claims, characterized by at least a first and at least a second movement drive (30, 31) for the first and for the second bending tool (25, 25 ', 26, 26'), wherein the first and the second Movement drive (30, 31) are controlled such that the same or approximately the same drive torques are present at the same time, which act in opposite directions.

5. The method according to any one of the preceding claims, characterized by bringing the main axis (6) of the laminated core (2) in a horizontal orientation respectively by maintaining a horizontal orientation of the main axis (6) of the laminated core (2) before the bending operation respectively during the bending process the first and second longitudinal ends (11, 12, 13, 14) and / or the first and second conductor projections (15, 16, 17, 18) of the conductor elements (3, 4) is performed.

6. The method according to any one of the preceding claims, characterized in that at least in some of the receiving grooves (5) two or more in the radial direction to the main axis (6) juxtaposed conductor elements (3, 4) for forming two or more concentric layers (9 , 10) of conductor elements (3, 4) are arranged, wherein the longitudinal ends (11, 13) of all the conductor elements (3) within a radially inner layer (9) by means of the respective associated bending tools (25 ', 26') simultaneously or at least in phases be simultaneously bent by a defined angle of rotation in opposite directions, and that at the same time or at least at the same time also the longitudinal ends (12, 14) of all conductor elements (4) of an immediately adjacent, radially outer layer (10) by means of further, respectively associated bending tools ( 25, 26) at the same time or at least in phases at the same ge by a defined angle of rotation in opposite set turning directions to be bent.

7. The method according to any one of the preceding claims, characterized in that the at least one first and the at least one second bending tool (25, 25 '; 26, 26') corresponding to a desired offset angle of the conductor elements (3, 4) plus a return twisting compensation angle are twisted.

8. The method according to any one of the preceding claims, characterized in that in the course of attaching the at least one first bending tool (25, 25 ') and / or of the at least one second bending tool (26, 26') at the respectively associated longitudinal ends ( 11, 12, 13, 14) or line projections (15, 16, 17, 18), the conductor elements (3, 4) in the axial direction of the laminated core (2) in the receiving grooves (5) are moved and positioned.

9. A device for automated production of a component of a stator or

A rotor of an electric machine, comprising a support frame (35) for supporting at least one first bending tool (25, 25 '), which has at least one first bending tool (25, 25') for attachment to first longitudinal ends (11, 12) of electrical conductor elements (3, 4) which are inserted in a laminated core (2) of a stator or rotor to be produced, and which at least one first bending tool (25, 25 ') for bending the first line over Stands (15, 16) of the electrical conductor elements (3, 4) opposite the laminated core (2) is arranged, at least a first movement drive (30), which for the controlled generation of rotational movements of the at least one first bending tool (25, 25 ') is formed , and at least one electronic control device (29) for the controlled activation of the at least one first movement drive (30), characterized in that on the support frame (35) for the at least one first bending tool (25, 25 ') or on an additional Support frame (36) at least a second bending tool (26, 26 ') is mounted, which at least one second bending tool (26, 26') for attachment to the opposite second longitudinal ends (13, 14) of the i n the laminated core (2) of the stator to be produced o- the rotor inserted electrical conductor elements (3, 4) is provided, and which at least one second bending tool (26, 26 ') for bending the second line projections

(17, 18) of the electrical conductor elements (3, 4) relative to the laminated core (2) is set, and that the electronic control device (29) is further adapted to a bending operation for simultaneous or predominantly simultaneous bending of the first and the second line projections (15, 16, 17, 18) of the conductor elements (3, 4), said bending process also being performed by performing a first rotational movement of at least one of the first bending tools (25, 25 ') in a first rotational direction (27), and an execution of a second rotary movement of at least one of the second bending tools (26, 26 '), which runs simultaneously at least at times, is defined in the second direction of rotation (28) opposite to the first direction of rotation (27).

10. The device according to claim 9, characterized in that the at least one first bending tool (25, 25 ') has at least two bending tools with different diameters, and that the at least one second bending tool (26, 26') at least two to the diameters of the first Bending tools (25, 25 ') corresponding bending tools (26, 26'), and in that opposite bending tools (25, 26; 25 ', 26') each having a corresponding diameter of the control device (29) simultaneously activated or approximately be operated simultaneously.

11. The device according to claim 9 or 10, characterized in that the at least one first bending tool (25, 25 ') and / or the at least one second bending tool

(26, 26 ') with respect to their distance (37) are adjustable relative to each other.

12. Device according to one of claims 9 to 11, characterized in that the at least one first bending tool (25, 25 ') and / or the at least one second bending tool (26, 26') along their mutually aligned rotational or rotational axes in their distance (37) are adjustable relative to each other.

13. Device according to one of claims 9 to 12, characterized in that the control device (29) for implementing the method measures according to one or more of claims 2 to 8 is formed.