Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/04—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
  • H02K15/043—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines winding flat conductive wires or sheets
  • H02K15/0432—Distributed windings
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
  • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
  • B21J5/002—Hybrid process, e.g. forging following casting
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22C—FOUNDRY MOULDING
  • B22C9/00—Moulds or cores; Moulding processes
  • B22C9/22—Moulds for peculiarly-shaped castings
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D13/00—Centrifugal casting; Casting by using centrifugal force
  • B22D13/08—Centrifugal casting; Casting by using centrifugal force in which a stationary mould is fed from a rotating mass of liquid metal
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D25/00—Special casting characterised by the nature of the product
  • B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
• • 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
• • 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
  • H01F41/041—Printed circuit coils
• • 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

Definitions

• Coiled coils are used in electrical machines.
• the coils produced in this way only partially fill the available space. This results in a lower power or torque density of the electrical machines in relation to the weight or the installation space.
• Cast Al and Cu coils can compensate for this disadvantage, but so far no series-suitable processes for the production of cast Al and Cu coils or cast coils made of Al and Cu alloys with a long service life are known.
• Cast AI and Cu coils or cast coils made of AI and Cu alloys are known per se, but have not so far been produced in permanent forms, but in lost form, e.g. in investment casting or in a lost foam process or by using salt cores, which define the contour and prevent direct contact of the melt with the tool.
• a contour-giving shape is used for the production of various geometries.
• cores are inserted or slides are used in addition to the shape, which has one or more divisions for easy casting removal.
• the invention has for its object to overcome the difficulties and disadvantages described and to propose a method suitable for series production, with the coils desired geometry, which should make the best possible use of space, can be produced with as little effort as possible.
• the invention is also based on the object to offer a coil which can be produced easily and with little effort and which requires comparatively little installation space, and to propose a suitable tool for producing such a coil or for carrying out a corresponding manufacturing process.
• a semifinished product in the form of an elongate conductor is first formed by casting in a cavity of a casting tool, and the coil is then formed after a
• the cavity of the casting tool is shaped such that the shape of the semi-finished product can be derived from a shape of the finished coil by stretching along a longitudinal axis of the coil and / or by bending this longitudinal axis.
• the semifinished product is accordingly bent and compressed in such a way that turns of the coil already present in the semifinished product, at least in some areas, during the forming process are brought closer to one another and brought into an arrangement along the longitudinal axis of the finished coil, the conductor being rotated or bent by no more than a right angle during the forming process in a course of each of the turns.
• the semi-finished product can be formed in the form of a rosette, so that the windings are fanned out around a center prior to forming.
• the mold cavity corresponding to the shape of the semifinished product can be filled from the center when the semifinished product is being cast, so that one or more sprue is formed in the center of the rosette. This advantageously results in short flow paths for the material forming the semi-finished product or the conductor of the coil.
• the cavity of the casting tool can be filled centrally from below when forming the semi-finished product.
• the cavity can be formed by only two tool halves of the casting tool.
• the semifinished product can be removed from the mold by separating the mold halves in a direction in which the semifinished product is free of undercuts, preferably in the direction of an axis of the rosette. No additional mold cores, slides or lost molded parts are typically required.
• the casting tool can be a permanent mold that can be used repeatedly, which is why the method can be implemented economically and is suitable for series production.
• the material used to cast the semi-finished product and form the conductor will typically be a metal with good conductivity.
• the semifinished product can be formed from aluminum or copper or an alloy containing aluminum or copper.
• the semifinished product is typically plastically formed, preferably without melting the material forming the semifinished product.
• the turns can be pushed over a guide rod or mandrel to form the semi-finished product, at the end of which a shoulder can be arranged, which can serve as a stop for a first turn. Behind the resulting coil, another tool part can be pushed onto the guide rod or mandrel, with the help of which the turns can be pressed together.
• the conductor is formed with a flat cross section, which has a smaller diameter in the direction of the longitudinal axis of the coil and a larger diameter in a direction perpendicular to the longitudinal axis of the coil. This enables a particularly space-saving construction of the coil to be achieved.
• a coil produced by a method described is advantageous.
• Such coils are suitable for use in electrical machines, in particular electric motors.
• the advantages of the coil produced in this way are particularly evident in applications in which space and weight-saving design is important, for example in electric motors in aircraft, where appropriately equipped electric motors e.g. can be used as a drive for rudders, flaps or undercarriage parts.
• a casting tool suitable for carrying out the described method and for producing a corresponding coil or a corresponding semifinished product can comprise two tool halves, one in one
• 1 is a frontal view of two mold halves of a casting tool
• FIG. 3 is a perspective view of a semi-finished product produced by casting in this casting tool
• Fig. 5 each in perspective illustration of two parts of a forming tool and a coil formed from the semi-finished product in three successive stages of a forming process, on the left in the picture in an expanded drawing individually and on the right in the picture with windings pushed onto a guide rod or mandrel of the semi-finished product or the resulting coil, and
• Fig. 6 is also a perspective view of a variant of the forming tool, in which the guide rod or mandrel is curved.
• a lower tool half 1 of a casting tool is shown. It can be seen a rosette-shaped cavity 2 of this casting tool, which can be closed by connecting the lower tool half 1 with an upper tool half 3.
• FIGS. 3 and 4 show a semifinished product 5 formed by casting in this casting tool, which can be formed from aluminum, copper or an alloy containing aluminum or copper.
• the semifinished product 5 is an elongated conductor which already forms turns of a coil formed thereafter.
• the semifinished product 5 is formed in the form of a rosette in accordance with the shape of the cavity 2, so that the windings are fanned out around the center.
• 3 and 4 has no undercut in the direction of an axis of the rosette and can therefore be removed from the mold by separating the mold halves 1 and 3 from one another after the casting and curing of the semifinished product 5 in the direction of this axis.
• This direction is illustrated in FIG. 2 by two arrows.
• the casting mold does not need a mold core or any slider or lost molded parts.
• the semifinished product 5 is plastically formed without melting the material forming the semifinished product or the conductor in order to form the coil 6 already mentioned.
• the semifinished product 5 is bent and compressed in such a way that the turns of the resulting coil 6 are moved towards one another during the shaping, that is to say are brought closer to one another, and are brought into an arrangement along a longitudinal axis of the finished coil 6.
• the conductor is rotated and bent by no more than about 20 ° in the course of each of the turns. This is possible because the cavity 2 of the casting mold is shaped such that the shape of the semifinished product 5 formed therein can be derived from the later shape of the finished coil 6 by stretching along the longitudinal axis of the coil 6 and by bending this longitudinal axis.
• the shaping of the semifinished product 5 for forming the coil 6 can take place by means of a shaping tool that has a guide rod or mandrel 7, at the end of which a shoulder 8 is arranged.
• the turns of the semifinished product 5 can be pushed about this Füh approximately rod or mandrel 7, which is threaded into the turns.
• the shoulder 8 serves for a first turn.
• a further tool part 9 can be pushed onto the guide rod or mandrel 7 in order to fertilize and compress the coil 6 to their final shape, in which it only fills a very small volume.
• the semifinished product 5 is already shown in a straight-curved form, in which the rosette is bent up and the windings are arranged along the longitudinal axis of the coil 6 and are aligned with one another.
• a modification of the forming tool with which the straight bending of the semifinished product 5 or the ro sette is simplified and completed when the windings are compressed is shown in FIG. 6.
• the guide rod or mandrel 7 is executed curved in this conversion.
• the first the semifinished product 5 and later the coil 6 conductor has a flat cross section which has a smaller diameter in the direction of the longitudinal axis of the coil 6 and a larger diameter in a direction perpendicular to the longitudinal axis.
• the coil 6 can be used in an electrical machine, for example an electric motor.
• an electric motor can be used in an aircraft, e.g. as a drive for an oar, a flap or a retractable landing gear.
• the position can also be carried out by centrifugal casting.
• Several cavities can be arranged one behind the other for multiple occupancy.
• the cavity can be filled centrally from below in low-pressure die-casting and the gate mechanically closed or brought to a quick solidification by means of a correspondingly thin-walled design and / or temperature control in the gate area in order to seal in the gate area to reach.
• a stamp can then be inserted into the still molten center from above and the contour can be made up under the pressure of the stamp.
• the laminar mold filling of the low pressure casting is combined with a pressure-supported make-up, i.e. a die casting.
• the casting plant can be designed in such a way that the center of the cavity consists of a tigle into which a metallic granulate is filled, which is melted inductively. After melting the crucible
• the shape and the Tigel are set in rotation, with the centrifugal force and appropriate Tigel design the melt is pressed over the Tigelrand into the cavity, or
• Pressing down the wall of the Tigel exposes the gates of the contour to be cast and the melt in the Tigel is pressed through the openings of the stamp corresponding to the cut into the cavity.
• the coil is plastically deformed again in order to maintain the geometrical installation state.
• the sprue is arranged in the middle of the geometry, which results in a symmetrical mold filling and the shortest possible flow paths.
• the geometry can be used in various casting processes, in particular gravity sand casting, low pressure sand casting, gravity die casting. Cast iron, low-pressure die casting and also die casting, when using a central cast iron.
• a model for the investment casting made of wax or plastic can be injection molded and foamed for the lost foam process.
• a stack casting can be realized, in which several coil tools can be stacked on top of one another and cast in one casting in all of the above-mentioned methods.
• the tool inserts can be made of conventional tool materials, or especially for the high temperature load when processing copper and the strong tool attack when using aluminum made of ceramic materials.
• the production of a coil described here is characterized by the simple tool geometry, the possible simple production of a semi-finished product for the coil and the simple subsequent rework.
• the sprue area can be used for the handling processes.
• the sprue stiffens the coil geometry and can be removed after the main subsequent processes.
• the gates are optimally positioned, e.g. in the middle of the turn or at the edge, the gate can be removed as the last step before forming and a possible remaining burr can be tolerated.
• the entire shape geometry can be designed so that possible burrs can be tolerated in order to simplify production.
• the casting tool can e.g. are designed so that the burrs that result from the demoulding of the finished coil each lie in hollows provided for this purpose on a surface of an adjacent turn.
• this geometry variant is the simple forming process after casting by inserting a guide rod into the core of the turn and directly forming the turns on each other. This is achieved by threading onto a mandrel with a shoulder, as shown in FIGS. 5 and 6. With this construction, the coil is deformed or brought back into the installed state.
• the forming process and calibration can be combined.
• the guide rod can be made thin at the beginning to simplify threading and then becomes thicker for the pressure-bearing surface - ie the shoulder 8 - and corresponds there to the end contour of the interior of the winding.
• the end contour of the interior has at least the same height as the overall coil to be achieved, see FIGS. 5 and 6.

Landscapes

• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Manufacture Of Motors, Generators (AREA)
• Molds, Cores, And Manufacturing Methods Thereof (AREA)
• Manufacturing Cores, Coils, And Magnets (AREA)
• Coils Or Transformers For Communication (AREA)

Priority Applications (5)

Applications Claiming Priority (2)

Publications (1)

Family

ID=68069733

Family Applications (1)

Country Status (7)

Families Citing this family (1)

Citations (5)

Family Cites Families (17)

• 2018
  • 2018-09-19 DE DE102018215972.6A patent/DE102018215972A1/de not_active Ceased
• 2019
  • 2019-09-19 CN CN201980061706.XA patent/CN112912188B/zh active Active
  • 2019-09-19 CA CA3112628A patent/CA3112628A1/en active Pending
  • 2019-09-19 EP EP19778443.2A patent/EP3852946B1/de active Active
  • 2019-09-19 JP JP2021515156A patent/JP7441215B2/ja active Active
  • 2019-09-19 WO PCT/EP2019/075165 patent/WO2020058400A1/de not_active Ceased
  • 2019-09-19 US US17/277,903 patent/US12362637B2/en active Active

Patent Citations (5)

Non-Patent Citations (1)

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