WO2019081516A1 - Procédé de fabrication d'une bobine électrique et dispositif d'enroulement - Google Patents

Procédé de fabrication d'une bobine électrique et dispositif d'enroulement

Info

Publication number
WO2019081516A1
WO2019081516A1 PCT/EP2018/079048 EP2018079048W WO2019081516A1 WO 2019081516 A1 WO2019081516 A1 WO 2019081516A1 EP 2018079048 W EP2018079048 W EP 2018079048W WO 2019081516 A1 WO2019081516 A1 WO 2019081516A1
Authority
WO
WIPO (PCT)
Prior art keywords
conductor
cross
sectional
deformation
forming
Prior art date
Application number
PCT/EP2018/079048
Other languages
German (de)
English (en)
Inventor
Lukas Eisenmann
Original Assignee
AMK Arnold Müller GmbH & Co. KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by AMK Arnold Müller GmbH & Co. KG filed Critical AMK Arnold Müller GmbH & Co. KG
Publication of WO2019081516A1 publication Critical patent/WO2019081516A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0025—Shaping or compacting conductors or winding heads after the installation of the winding in the core or machine ; Applying fastening means on winding heads
    • H02K15/0031—Shaping or compacting conductors in slots or around salient poles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/077—Deforming the cross section or shape of the winding material while winding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/082—Devices for guiding or positioning the winding material on the former
    • H01F41/086—Devices for guiding or positioning the winding material on the former in a special configuration on the former, e.g. orthocyclic coils or open mesh coils
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/08—Forming windings by laying conductors into or around core parts
    • H02K15/095—Forming windings by laying conductors into or around core parts by laying conductors around salient poles

Definitions

  • the present invention relates to a method of manufacturing an electrical coil, in which an electrical conductor is wound onto a carrier.
  • the invention further relates to a winding device.
  • a major component of electric motors are electric coils.
  • the fill factor quantitatively indicates how well the available winding space of a coil is filled with electrical conductors. If the fill factor can be increased, so also amplifies the electric field generated by the coil, whereby at the same space, the torque and thus the achievable power of an electric motor can be increased.
  • the electrical coil is produced by winding one or more electrical conductors onto a carrier, the carrier being, for example, a winding mandrel which is removed from the coil after winding or is designed as a coil former which remains in the coil.
  • the winding is carried out by a relative movement between the carrier and a feed device, which leads the wound electrical conductor from a supply roll or the like to the carrier.
  • the specific embodiment of this relative movement is referred to as a winding method, wherein generally different types of winding methods are known.
  • the linear winding method is mentioned, in which the carrier to be wound is rotated about its longitudinal axis and the supply of the electrical conductor via a wire guide tube (also referred to as Drahtriose), which can be moved relative to the rotating carrier in one or more directions
  • a wire guide tube also referred to as Drahtriose
  • Another exemplary winding method is the needle winding method, with the aid of which, for example, closely spaced pole pieces of an electronically commutated multi-pole three-phase motor can be directly wound. Since in this case the electrical conductor is pulled at an angle of 90 ° from the wire guide nozzle, a targeted placement of the conductor is only possible to a limited extent.
  • Another known winding method is the
  • an optimum fill factor can be generated, in particular for conductors with a round cross section.
  • the aim is to deposit the turns of an upper winding in the valleys of an under winding, so that the centers of each three directly adjacent conductors define an isosceles triangle. This can be accomplished by having a majority of the conductors of the coil perpendicular to the longitudinal axis of the coil, ie lying in planes perpendicular to the longitudinal axis of the coil.
  • the aim is to wind the largest possible peripheral portion of a respective turn within these orthogonal planes.
  • Windungssprung which is also referred to as a series jump or Windungs suits, depending on the conductor diameter and coil diameter and especially the winding width z.
  • carriers are used which have on their winding base, ie on its peripheral side, embossed grooves or depressions which correspond to the desired winding course of the first winding layer.
  • the winding transition region In the case of orthocyclically wound coils, it is desirable for the winding transition region to always be more or less at the same angular position for different layers. Since due to the reversal of the winding direction, the conductors in the winding transition region of two adjacent layers intersect, this leads to an increase in the winding height, ie in a round coil to a buckeiförmigen formation. In the design of electric motors is intended that these areas of greater winding height are in positions where sufficient space is available, so that the performance and / or efficiency of the electric motor is not or only slightly affected.
  • a machine for winding orthocyclic coils is described for example in US 1 504 005 A.
  • the wire guide is here not moved continuously but cyclically in the axial direction to realize the winding jump.
  • WO 201 1/045016 A2 describes a winding method and a corresponding device, in which the incoming wire is pre-bent in the radial direction with respect to the longitudinal axis of the coil, ie transversely to a direction of deposition of the wire. This avoids that when winding a non-circular support body, such as a coil with a rectangular cross-section, the wire does not fully applied to the surface to be wound of the carrier body. Such an upset results from the fact that in the region of the corners of the carrier body, the wire must be wound with a very narrow radius, whereby alone by the wire feeder, no sufficient plastic deformation can be achieved.
  • JP 2000-217315A describes a winding device in which a wire can be longitudinally axially deformed by means of a forming device called a "press apparatus" for plastically impressing a winding jump two rollers, which are arranged at a fixed distance from each other on a roller carrier, wherein the deformation of the wire is effected by pivoting the roller carrier.
  • the conductor be plastically deformed prior to emergence on the support in the direction of a longitudinal axis of the coil and / or in its cross-sectional contour such that a resulting deformation of the conductor corresponds to a desired winding jump and a desired cross-sectional shape when running onto the support.
  • the electrical conductor or wire so the Windungssprung is already before winding on the carrier by the plastic Deformation permanently impressed, so that a precise, well controllable winding structure can be achieved.
  • the wire guide and the laying of the wire on the carrier or the already wound coil is done alone by the feeder, which deforms the incoming wire usually only elastically, in particular slipping of the wire and thus a Forming a wild winding avoided.
  • the desired winding jump can also amount to a multiple of the conductor diameter.
  • coils are made, which are not rectangular for better utilization of an existing installation space in longitudinal section, but run to one end conical or trapezoidal.
  • the conductor can also be plastically deformed transversely to the longitudinal axis such that the resulting deformation of the conductor corresponds to a desired positional jump.
  • the carrier may be formed as a winding mandrel, which may be removed after winding the coil or be formed by a bobbin, which remains in the coil and in particular at its end faces flanges for limiting and fixing the coil in the axial direction.
  • a plastic deformation in the cross-sectional contour can solve the problem that when the conductor is wound onto a bending section of the carrier due to the resulting bending radius, the cross-sectional contour of the conductor is plastically deformed, the resulting plastic deformation having a reduced winding density and thus reduced magnetic properties causes.
  • the undesirable cross-sectional deformation is caused by compression or extension of the radially inner or outer region of the conductor cross section in the bending deformation.
  • the aim of the plastic cross-sectional deformation carried out before the bending process is to form the cross-sectional shape of the conductor before winding on the support so plastically before, so that after completion of the winding process sets a desired cross-sectional shape, the plastic deformation carried out usually complementary to the form self-adjusting undesirable plastic deformation.
  • the fill factor can be increased.
  • the coil is constructed as an orthocyclic winding.
  • the method according to the invention has proved to be particularly advantageous since, in the case of orthocyclically wound coils, a precise shaping of the winding jump further optimizes the achievable fill factor.
  • the carrier has a groove-free lateral surface.
  • Such groove-free carriers which have no depressions or elevations which guide the wound wire, can be universally, d. H. be used for different conductor diameters. When changing the conductor diameter, therefore, no new winding mandrel or bobbin must be designed and manufactured.
  • the longitudinal axial deformation is performed such that the two conductor sections, which are located immediately before and behind the deformation, parallel to each other and in the direction of the longitudinal axis of the coil. The conductor is thus deformed approximately S-shaped. Thus, the course of the conductor before winding the unwinding of the wound coil corresponds.
  • a straight transition portion is formed, which is inclined by a transition angle to the two mutually parallel offset conductor portions.
  • a straight transition section has proved to be particularly advantageous for the formation of an orthocyclic winding.
  • the extent of the winding jump is essentially determined by the transition angle and the length of the transition section, but also the bending radii between the transition section and the two parallel mutually offset conductor sections exert a certain influence.
  • the transition angle may for example be between 5 ° and 60 °, in particular between 10 ° and 40 °.
  • the length of the longitudinal-axial transition section and / or the transition angle are variable. This allows the design of the winding jump to the already achieved winding height or number of layers be adjusted.
  • the electrical conductor is a wire.
  • Such conductor wire is particularly suitable for the intended plastic deformation.
  • a plastic pre-deformation of the cross-sectional contour of the conductor to a desired cross-sectional shape can be chosen so that an otherwise resulting plastic deformation of the conductor is compensated when running on a bending region of the carrier, so that the cross-sectional shape of the conductor after running on the Carrier substantially corresponds to the original cross-sectional contour.
  • the cross-sectional contour in a round or rectangular shape of the conductor can be provided in this advantageous embodiment.
  • the conductor can be preformed to the various desired cross-sectional shape, whereby a compression or extension influence produced when running onto the bending region of the carrier can substantially compensate or completely eliminate an undesired change in the cross-sectional contour.
  • the highest possible filling factor can be achieved and a torque generated by an electric motor and its efficiency can be increased.
  • the conductor can be deformed at predetermined longitudinal positions and / or predetermined cross-sectional positions and / or with a desired cross-sectional shape, wherein the longitudinal positions are predetermined as a function of an already wound number of turns and in particular are equidistant at least for a predetermined number of turns, and / or the cross-sectional positions and / or the desired cross-sectional shape depending on a cross-sectional dimension and a bending radius of the bending region of the carrier are predetermined.
  • the distance of the longitudinal positions for all turns of a respective layer can be kept constant and for a subsequent position according to the by the Layer jump conditional increase in circumference of the coil can be adjusted.
  • the cross-sectional shape complementary to a cross-sectional deformation resulting from running on the carrier can be previously impressed in the conductor, whereby a new cross-sectional contour is generated after bending of the cross section of the conductor onto the bending section of the carrier
  • the resulting cross-sectional contour is the same as an original cross-sectional contour of the conductor.
  • the distance of the longitudinal positions depending on the number of already wound turns and / or layers may be variable, and / or the cross-sectional positions and / or the desired cross-sectional shape depending on a cross-sectional dimension of the conductor and a bending radius of the bending region of the carrier to be changeable.
  • the cross-sectional positions for all windings may be provided prior to winding on the carrier to a respective suitable cross-sectional deformation. In other words, therefore, the cross-sectional contours and cross-sectional positions can be adjusted.
  • the invention further relates to a winding device for producing an electrical coil, wherein the winding device is adapted to wind an electrical conductor on a support, in particular for carrying out the method according to one of the embodiments described above.
  • the winding device comprises a forming device, which is designed to plastically deform the conductor prior to emergence on the carrier in the direction of a longitudinal axis of the coil and / or in its cross-sectional contour such that a resulting deformation of the conductor a desired winding jump and a desired cross-sectional shape Accumulation on the carrier corresponds.
  • the forming device comprises at least one cooperating with the conductor, transversely displaceable transversely to a longitudinal extent of the conductor in the direction of a longitudinal axis of the coil first forming element.
  • the or pairwise Umformelmente can be displaceable transversely to a feed direction of the conductor linear or rotary.
  • the first forming element necessary for deforming the conductor transverse forces are applied.
  • two first forming elements are provided, which are designed such that they can deform the conductor in mutually opposite directions.
  • At least one jaw region of the at least first deformation element can be preformed in the radial direction of the cross-sectional contour of the conductor before emergence onto the carrier to a desired cross-sectional shape, so that a resulting upon emergence of the conductor on a bending portion of the carrier plastic cross-sectional deformation of the conductor is compensated by the previous cross-sectional deformation of the conductor to a desired cross-sectional shape through the jaw portion of the first Umformelements in the radial direction, wherein preferably the shape of the jaw portion of the first Umformelements is adjustable, and / or the jaw portion of the first Umformelements exchangeable and / or is changeable.
  • the undesirable plastic cross-sectional deformation of the conductor which is formed when the conductor strikes the bending section of the carrier, is usually complementary in cross-sectional shape, depending on the cross-sectional dimension of the conductor and / or bending radius the bending portion of the carrier can be adjusted.
  • the shape of the jaw region of the first deformation element can be adjustable such that, for example, in the case of molding as a wedge element for rectangular conductor cross sections, a predetermined angle can be selected depending on the bending radius or conductor diameter. This adjustment, for example, the angle of a wedge portion of the jaw portion can be changed by adjusting elements such as screws or by changing various wedge-shaped Baking areas be changeable.
  • both the cross-sectional deformation of the conductor in the radial direction of the cross-sectional contour of the conductor and the longitudinal axial deformation of the conductor in the direction of the longitudinal axis of the coil can be performed by a one-piece jaw region of the first reshaping element.
  • the first forming element with the one-piece jaw region is arranged at right angles to a longitudinal extent of the conductor in the longitudinal axial direction of the conductor, wherein the first deformation element is displaceable.
  • the one-piece jaw region is set up to carry out a cross-sectional deformation of the conductor at the same time during the preceding longitudinal axial deformation of the conductor.
  • the first deformation element be equipped so that a starting portion of the first Umformelements a lijnsaxialen and cross-section deformed portion of the conductor, an end portion of the first Umformelement one end of the cross-sectionally deformed portion of the conductor and an angled extending portion of the first Umformelements a cross-section deformed angled portion of the longitudinal extension of the conductor deform to perform the longitudinal axial deformation of the conductor.
  • At least one jaw region of the first deformation element can consist of at least two partial jaw elements which are parallel in the cross-sectional plane of the conductor and which can each be controlled differently and independently of one another.
  • each partial jaw element can be controlled separately, so that each individual partial jaw element can preferably move in the radial direction in the cross-sectional plane of the conductor.
  • the individually controlled part jaw element deforms only a portion of the cross-sectional contour of the conductor in the radial direction of the cross section of the conductor, whereby the entire cross-sectional contour of the conductor can be preformed preformed.
  • the forming device further comprises at least one cooperating with the conductor second forming element, which is spaced in the direction of the longitudinal extent of the conductor of the first forming element.
  • the second forming element or elements are preferably not displaceable, ie they are only passively involved in the deformation process. They fix the conductor at one end of the transition gate while the first forming elements actively effect the deformation.
  • the second forming element or elements can be adjustable in their position.
  • the forming device comprises at least two transverse to the longitudinal extent of the conductor spaced apart first forming elements as first set forming elements and at least two transversely to the longitudinal extent of the conductor spaced apart second forming elements as the second set forming elements, in particular the distance of the first forming elements to each other and / or the distance of the second forming elements to each other and / or the distance between the first forming elements and the second forming elements is variable.
  • the respective gap between the first and the second forming elements, through which the tapered conductor is passed be adapted to the cross section of the conductor, so that a precise Guiding the conductor during forming is guaranteed.
  • the length of the transition section can be influenced, wherein this change can be made in particular depending on the already wound layer number.
  • At least one jaw region of the set of first reshaping elements and / or the set of second reshaping elements for cross-section deformation of the conductor in the radial direction of the cross-sectional contour of the conductor can be preformed to a desired cross-sectional shape before emergence onto the carrier, so that a Appearance of the conductor on a bending portion of the carrier resulting plastic cross-sectional deformation of the conductor is compensated by the previous cross-sectional deformation of the conductor through the jaw portion of the forming, preferably the jaw portion of the set of the first forming elements and / or the set of second forming elements are adjustable, and / or the jaw region of the forming elements is exchangeable and / or changeable.
  • the set of first deformation elements can interact with at least one jaw region and the set of second deformation elements can interact with at least one jaw region.
  • the jaw region of the set of first and / or of the set of second deformation elements can be parallel to at least two in the cross-sectional plane of the conductor Part baking elements exist, each of which can be controlled differently.
  • each partial jaw element can be controlled as a function of a cross-sectional dimension and / or a bending radius of a bending region of the carrier, so that a precise cross-sectional deformation of the conductor is made possible.
  • both the longitudinal axial deformation of the conductor is also separately adjustable by the individual controllable partial jaw element, so that the highest possible flexibility can be achieved.
  • At least three sets of longitudinally axially spaced forming elements may be included with respective jaw regions, wherein at least one jaw region of the set of first deformation elements at the beginning of a longitudinal axial deformation section of the conductor, at least one jaw region of the set of second deformation elements at the end of the longitudinal axial deformation section of the Conductor and at least one jaw portion of the set of third deformation elements can be formed for an angled course region of the longitudinal axial deformation portion of the conductor, and cause a plastic cross-sectional deformation of the deformation portion.
  • the set of first forming elements with the baking area and the set of the second forming elements with the baking area are respectively arranged perpendicular to the longitudinal axial deformation section, while the set of the third forming elements with the baking area parallel to the angled course area of longitudinal axial deformation portion of the conductor is arranged.
  • a cross-sectional deformation for the longitudinal axial beginning and end region and for the angled longitudinal course is possible, for which purpose three separately adjustable forming elements or pairs of forming elements can be used.
  • different cross-sectional profiles in the course of the longitudinal axial winding jump can be impressed in order to achieve an optimized packing density of adjacent conductors in the bending region of the bobbin.
  • the winding device has a feed device for the conductor, wherein the forming device is adapted to offset the forming element in dependence on a relative angular position between the feed device and the coil. This can be ensured, for example, that the deformation always comes to rest at a desired, in particular always the same angular position of the coil.
  • the forming elements can be arranged fixed relative to the carrier in the course of the feed direction of the conductor. In order to produce a precise forming, it is advisable to wind the conductor cyclically in the feed direction on the carrier. In order to achieve a high winding speed while at the same time precise forming, it is expedient in a preferred embodiment to make the forming device, in particular at least one of the forming elements movable in the feed direction of the conductor, so that during the forming process the forming element (s) moves relative to the conductor.
  • the forming device, or the forming process taking place forming elements can be carried in the feed direction of the conductor, so that a reduced relative speed to the feed rate of the conductor, ideally a relative standstill between supplied conductor and forming element is reached.
  • the or the forming elements can make an axial longitudinal deformation and / or a plastic cross-sectional deformation in the running movement of the conductor, hereafter detach from this and move back to an initial position to make a further forming operation - preferably at a distance of the bending areas.
  • the forming device at least the forming elements oscillates in an amplitude that can depend on the length of the bending region and move approximately or at the same speed as the supplied conductor.
  • the return movement to the initial position at a higher speed than the feed rate of the conductor is at a higher speed than the feed rate of the conductor.
  • parts of the forming device in particular forming elements, which cause a longitudinal axial deformation of the conductor and / or a cross-sectional deformation of the conductor arranged sequentially in the feed direction of the conductor, wherein preferably the individual parts of the longitudinal axial deformation and the cross-sectional deformation are moved separately ,
  • individual forming elements, which cause a plastic cross-sectional deformation in the feed direction of the conductor can be arranged before emergence on the support before forming elements that make a longitudinal axial deformation.
  • two or more forming elements which make a longitudinal axial deformation, be arranged one behind the other to form complex or variable winding jumps.
  • individual forming elements or parts of the forming device which are designed for a plastic cross-sectional deformation, and parts which are formed for a longitudinal axial deformation, with the conductor to be arranged separately movable behind each other, and oscillate at the same or different operating speeds. It is also conceivable that individual forming elements of a plurality of forming elements, which are used exclusively for the longitudinal axial forming or the plastic cross-sectional deformation, are independently movable.
  • an embodiment of the forming process and, for example, a conversion of the forming device at different conductor cross-sections and conductor shapes and different types of support very easy to implement and the individual forming steps can be independently realized and controlled independently.
  • Fig. 1 is a schematic and not to scale side view of an orthocyclic wound electric coil according to the prior
  • FIG. 2 and 3 are schematic and not to scale views of a
  • Winding device according to an embodiment
  • 5a to 5d are schematic and not to scale views of details of a forming device according to an embodiment
  • Fig. 6a is a schematic and not to scale top view of a
  • Fig. 7 is a schematic and not to scale top view of a
  • 8a and 8b are schematic and not to scale sectional views of details of a forming device according to an embodiment.
  • Fig. 1 shows a partially wound electric coil 10 having an orthocyclic winding structure.
  • the coil 10 comprises a carrier, which in the exemplary embodiment is designed as a bobbin 12, which has a lateral surface 14 which extends along a longitudinal axis L.
  • the bobbin 12 is frontally bounded by two flanges 16 which project beyond the lateral surface 14 in the radial direction on all sides.
  • the flanges 16 extend in planes that are perpendicular to the longitudinal axis L.
  • the bobbin 12 is constructed groove-free, ie, the lateral surface 14 is free of depressions or elevations, which are required in conventional manufacturing processes for orthocyclic wound coils.
  • a winding mandrel can be used as a carrier, from which the coil can be removed after completion of the winding and optionally a subsequent packaging of the turns as a self-supporting coil.
  • the mandrel is advantageously also formed groove-free.
  • an electrical conductor or wire 20 is wound in a plurality of turns 18.
  • the individual windings 18 lie, with the exception of a certain angle range, in planes which run parallel to the flanges 16 and thus perpendicular to the longitudinal axis L. In the areas where the windings 18 are not parallel to the flanges 16, the wire 20 goes from one turn to the next. This area is referred to as a winding step 22.
  • the wire can be brought to the bobbin 12 by means of a feed device (not shown in FIG. 1). After winding a complete turn 18, the feed device is offset by an amount corresponding to the wire diameter in a direction parallel to the longitudinal axis L extending Ablageichtung A.
  • An orthocyclic wound coil 10 may have a maximum mechanical fill factor of 91%, but only for the portion of the coil 10 in which the turns 18 are orthocyclically aligned. In a transition region in which the winding jump 22 is present, the filling factor is lower due to the intersecting conductors of adjacent winding layers.
  • Figs. 2 and 3 is an exemplary winding device 30 for producing a electric coil, in particular an orthocyclically wound coil 10 shown in FIG. 1, shown.
  • the winding device 30 can operate according to the linear winding method.
  • the bobbin 12 can be rotated about its longitudinal axis L, wherein a feed device (not shown) can move the wire 20 continuously or in discrete steps according to the winding progress in the direction of the respective direction of deposition A.
  • the winding device 30 comprises a forming device 32, in which the wire coming from a supply reel (not shown) enters in a feed direction Z and leaves the forming device 32 in the direction of the reel 10.
  • the forming device 32 has a pair of second displaceable forming elements 34A, 34B and a counter to the feed direction Z spaced apart pair of first fixed forming elements 36A, 36B.
  • the wire 20 passes between the forming elements 34A, 34B and 36A, 36B, respectively.
  • the distance between the fixed forming elements 34A, 34B and between the displaceable forming elements 36A, 36B may be adjustable to ensure adaptation to different wire thicknesses.
  • the displaceable forming elements 36A, 36B are in their neutral position in FIG. 2, in which the gap between the forming elements 36A, 36B is aligned with the gap between the fixed forming elements 34A, 34B.
  • the displaceable forming elements 36A, 36B may be displaced by means of suitable drive means, for example pneumatic cylinders, in a displacement direction V which is parallel to the longitudinal axis L of the spool and transverse, in particular perpendicular to the feed direction Z of the wire 20.
  • the displacement can take place in positions on both sides of the neutral position shown in Fig. 2, wherein in Fig. 3, only the displacement is shown in the left position.
  • the displacement of the displaceable deformation elements 36A, 36B takes place in the same direction, wherein the distance or gap between the displaceable deformation elements 36A, 36B is substantially retained. However, it can also be a minor one Distance reduction may be provided to clamp the wire 20 during the forming process.
  • the wire 20 is deformed such that the deformation has a straight transition section 40, which extends inclined to the two mutually parallel, adjacent conductor sections.
  • the bending radii between the transition section 40 and the mutually offset parallel conductor sections are preferably chosen as narrow as the wire material used to achieve a compact possible winding in which the winding jump 22 only over the smallest possible angular range of a respective turn 18th extends.
  • an approximately S-shaped longitudinal axial deformation 38 is generated in the incoming wire 20, which corresponds to the desired winding step 22 of the coil 10.
  • the wire 20 is not only plastically deformed by the forming members 34A, 34B, 36A, 36B, but also elastically, so that the amount of displacement of the longitudinal axial deformation 38 after being released by the forming members 34A, 34B, 36A, 36B and after leaving the forming device 32 is due to the elastic restoring forces again slightly smaller than it would correspond to the adjustment of the displaceable forming elements 36A, 36B.
  • the adjustment path of the displaceable forming elements 36A, 36B can be increased by the amount of the desired winding step 22.
  • a further re-deformation of the wire 20 may be taken into account, which is caused by a wire brake (not shown), which may be provided above the forming device 32 to exert a suitable winding tension on the incoming wire 20.
  • the deformation or deformation of the wire 20 can take place at certain longitudinal distances of the wire 20, these distances resulting from the circumference of the respective turns 18.
  • the forming device 32 is each actuated when the wire 20 has reached a corresponding longitudinal position, said longitudinal position can be determined directly by measuring the continuous wire length or indirectly in dependence on a respective angular position of the rotating coil 10.
  • the reversal direction A is reversed.
  • the offset direction V is also changed so that the longitudinal axial deformation 38 has a mirror-image course.
  • the direction of departure A of the wire 20 on the spool 10 and the displacement direction of the displaceable deformation elements 36A, 36B extend in the opposite direction.
  • a separate feed device for the wire 20 is not shown.
  • the function of a feeder can also be met by a linear displacement of the forming device 32 in the direction of the direction A, wherein this displacement continuously or stepwise, z. B. synchronous with the emergence of the deformation on the bobbin 12, can take place.
  • an adjusting device may be provided to displace the forming device 32.
  • the winding device 10 By means of the winding device 10 according to the invention and by the method for producing an electrical coil 10, it is possible to produce in particular orthocyclically wound coils which have a defined winding step 22 impressed into the conductor 20 by the plastic longitudinal axial deformation 38. Due to the pre-embossment of the winding jump 22, a slippage of individual windings and thus an undesirable generation of wild windings is avoided, which significantly reduce the fill factor. Thus, a precise winding of the coil 10 with maximum filling factor is made possible.
  • Figs. 4a to 4d show a partially to be preformed conductor 20 with a pair of first forming elements 34A, 34B, wherein a conductor 20 with a rectangular Cross-sectional shape in a feed direction Z enters.
  • a former 32 may have only the pair of the first forming members 34A, 34B to impress a desired cross-sectional shape Y of the conductor 20 through a jaw portion 46. As shown in Fig.
  • a desired cross-sectional shape Y of the conductor can be impressed on the carrier 12 before emergence, which can compensate for the preceding resulting plastic cross-sectional deformation W, so that the cross-sectional shape of the conductor 20 after running on the carrier 12 in principle the original cross-sectional contour X corresponds, see Fig. 4d.
  • a wedge element with an angle ⁇ can be attached as a jaw region 46 with adjusting screws 52 on the forming element 34A, 34B, whereby the angle ⁇ is adjustable to produce various desired cross-sectional shapes Y.
  • 5a to 5d is a circular cross-section conductor 20 entering and to be preformed in a feed direction Z with a pair of first forming elements 34A, 34B, wherein a jaw region 46 has a radius R1 and a radius R2, wherein the radius R1 is greater than that Radius R2 is formed, as shown in Fig. 5c.
  • a conductor 20 is considered with an approximately circular cross-section example, which has an original circular cross-sectional contour X.
  • the jaw region 46 it is possible to compensate for a plastic cross-sectional deformation W (see FIG. 5 a), which is undesirably produced when the conductor 20 is wound onto a carrier 12, which is shown in the form of a compressed ellipse.
  • a forming device 32 shown in FIG. 6a comprises in the longitudinal direction of the conductor path three pairs of independently controllable forming elements 34A, 34B, 36A, 36B, 42A, 42B, each forming element 34A, 34B, 36A, 36B, 42A, 42B having a jaw region 46 ,
  • the pair of first deforming members 34A, 34B are disposed at the beginning of a longitudinal axial deforming portion 50 of a conductor 20
  • the pair of second deforming members 36A, 36B are disposed at the end of the longitudinal axial deforming portion 50 of the conductor 20
  • the pair of third deforming members 42A, 42B arranged parallel to a by a transition angle ß angled course region of the longitudinal axial deformation portion 50 of the conductor 20.
  • the conductor 20 enters in a feed direction Z.
  • a longitudinal axial deformation of the conductor 20 but advantageously also a cross-sectional deformation of the conductor in the radial direction of the cross section of the conductor 20 can be performed. It is possible to deform the cross section of the conductor in the beginning and end area with a shape other than the bending area, so that the filling factor in the bending area can be increased or higher bending radii can be made possible with acceptable filling factors.
  • FIGS. 6b to 6d are sectional views at different longitudinal positions of the forming device shown in FIG. 6a.
  • a wedge element with an angle ⁇ can be formed as a jaw region 46 of the first, second and third deformation element 34A, 34B, 36A, 36B, 42A, 42B, wherein the angle ⁇ of the individual jaw regions can also differ, or an angular course along the longitudinal extent of the conductor 20 is preferably continuously variable.
  • the jaw contour or the angle ⁇ can be changed so that different desired cross-sectional shapes Y are generated depending on the conductor cross-section or bending radius on the carrier 12 in order to counteract various resulting plastic cross-sectional deformations of the conductor 20.
  • a deformation portion 50 of a conductor 20 is shown, wherein a one-piece forming element as fourth forming element 44 A, 44 B of Forming device 32 is formed.
  • a cross-sectional deformation of the conductor 20 in the radial direction B of the cross-sectional contour X of the conductor 20 and a longitudinal axial deformation of the conductor 20 in the direction of the longitudinal axis L of the coil 10 shown in FIG. 2 of a one-piece baking region 46 of the fourth forming element 44A, 44B can be made, whereby the conductor 20 can be angled in its longitudinal extent by a transition angle ß.
  • the conductor 20 enters a feed direction Z.
  • the one-piece forming element 44A or 44B allows a plastic cross-sectional deformation with simultaneous longitudinal axial bending.
  • Figs. 8a and 8b show, in a cross-sectional view of a conductor 20, a pair of two first forming elements 34A, 34B, each comprising a jaw region 46.
  • Each jaw region 46 in turn comprises three partial jaw elements 48, which are arranged parallel to one another in a cross-sectional plane of a conductor 20.
  • Each partial jaw element 48 can move in the radial direction B of a cross-sectional contour X of the conductor 20, wherein each partial jaw element 48 can be controlled separately.
  • the conductor 20 can be preformed before emergence onto a carrier 12 in the radial direction B of the cross-sectional contour X of the conductor 20 to a desired cross-sectional shape Y.
  • each partial jaw member flexible different cross-sectional deformations can be achieved, so that when using different conductor cross-sections or different curved support a simple adaptation without constructive change of the forming elements to achieve an optimized winding jump and an optimized filling factor in the bending region of the coil is made possible.
  • Such an embodiment is particularly suitable for the production of special windings in small quantities with the highest quality standards.
  • 34A, 34B first forming element, fixed forming element

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'invention concerne un procédé de fabrication d'une bobine électrique (10) dans lequel un conducteur électrique (20) est enroulé sur un support (12). Selon l'invention, le conducteur (20) est déformé plastiquement en direction d'un axe longitudinal (L) de la bobine (10) et/ou dans son contour en coupe transversale (X) avant de l'enrouler sur le support (12) de sorte qu'une déformation résultante (38) du conducteur (22) corresponde à un pas d'enroulement souhaité (22) et/ou à une forme en coupe transversale souhaitée (Y) lors de l'enroulement sur le support (12). L'invention concerne en outre un dispositif d'enroulement (30) destiné à produire une bobine électrique (10). Le dispositif d'enroulement (30) est adapté pour enrouler un conducteur électrique (20) sur un support (12), en particulier pour mettre en œuvre le procédé. Le dispositif d'enroulement (30) comprend un dispositif de formage (32) qui est conçu pour déformer plastiquement le conducteur (20) en direction d'un axe longitudinal (L) de la bobine (10) et/ou de son contour en coupe transversale (X) avant de l'enrouler sur le support (12) de sorte qu'une déformation résultante (38) du conducteur (20) corresponde à un pas d'enroulement souhaité et/ou une forme en coupe transversale souhaitée (Y) de l'enroulement sur le support (22).
PCT/EP2018/079048 2017-10-24 2018-10-23 Procédé de fabrication d'une bobine électrique et dispositif d'enroulement WO2019081516A1 (fr)

Applications Claiming Priority (2)

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DE102017124859.5 2017-10-24
DE102017124859.5A DE102017124859A1 (de) 2017-10-24 2017-10-24 Verfahren zum Herstellen einer elektrischen Spule und Wickelvorrichtung

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WO2019081516A1 true WO2019081516A1 (fr) 2019-05-02

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DE102021125495A1 (de) 2021-10-01 2023-04-06 Bayerische Motoren Werke Aktiengesellschaft Verfahren zum Herstellen einer ein- oder mehrfachen Lagenspule, Lagenspule, elektrische Maschine sowie Vorrichtung

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1504005A (en) 1922-06-01 1924-08-05 Gen Electric Coil-winding machine
GB565253A (en) * 1943-06-08 1944-11-02 Swift Levick & Sons Ltd Improvements in or relating to metal coils having a helical formation
DE1151321B (de) 1958-10-24 1963-07-11 Philips Nv Verfahren und Maschine zum Wickeln ortho-zyklischer Spulen zwischen Flanschen und auf eine Schablone oder einen Spulenkoerper
DE19905747A1 (de) * 1998-02-12 1999-09-30 Toyota Motor Co Ltd Verfahren und Vorrichtung zur Herstellung einer Spule mit rechteckigem Draht
JP2000217315A (ja) 1999-01-21 2000-08-04 Toyota Motor Corp 巻線装置
JP2008312345A (ja) * 2007-06-14 2008-12-25 Asmo Co Ltd 巻線装置及び回転電機の製造方法
WO2011045016A2 (fr) 2009-10-12 2011-04-21 Aumann Gmbh Procédé d'enroulement, notamment pour former des bobines électriques

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1504005A (en) 1922-06-01 1924-08-05 Gen Electric Coil-winding machine
GB565253A (en) * 1943-06-08 1944-11-02 Swift Levick & Sons Ltd Improvements in or relating to metal coils having a helical formation
DE1151321B (de) 1958-10-24 1963-07-11 Philips Nv Verfahren und Maschine zum Wickeln ortho-zyklischer Spulen zwischen Flanschen und auf eine Schablone oder einen Spulenkoerper
DE19905747A1 (de) * 1998-02-12 1999-09-30 Toyota Motor Co Ltd Verfahren und Vorrichtung zur Herstellung einer Spule mit rechteckigem Draht
JP2000217315A (ja) 1999-01-21 2000-08-04 Toyota Motor Corp 巻線装置
JP2008312345A (ja) * 2007-06-14 2008-12-25 Asmo Co Ltd 巻線装置及び回転電機の製造方法
WO2011045016A2 (fr) 2009-10-12 2011-04-21 Aumann Gmbh Procédé d'enroulement, notamment pour former des bobines électriques

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