WO2022189475A1 - Device and method for shaping free bar end portions of a conductor stack - Google Patents
Device and method for shaping free bar end portions of a conductor stack Download PDFInfo
- Publication number
- WO2022189475A1 WO2022189475A1 PCT/EP2022/055966 EP2022055966W WO2022189475A1 WO 2022189475 A1 WO2022189475 A1 WO 2022189475A1 EP 2022055966 W EP2022055966 W EP 2022055966W WO 2022189475 A1 WO2022189475 A1 WO 2022189475A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- tool
- deformation tool
- control
- deformation
- rod end
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 45
- 239000004020 conductor Substances 0.000 title claims abstract description 13
- 238000007493 shaping process Methods 0.000 title abstract description 15
- 230000003993 interaction Effects 0.000 claims abstract description 9
- 230000003213 activating effect Effects 0.000 claims description 3
- 230000015572 biosynthetic process Effects 0.000 description 21
- 238000005755 formation reaction Methods 0.000 description 21
- 238000007373 indentation Methods 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 229910000639 Spring steel Inorganic materials 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
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
- H02K15/0056—Manufacturing winding connections
- H02K15/0068—Connecting winding sections; Forming leads; Connecting leads to terminals
- H02K15/0081—Connecting winding sections; Forming leads; Connecting leads to terminals for form-wound windings
-
- 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
- H02K15/0037—Shaping or compacting winding heads
-
- 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
- H02K15/0056—Manufacturing winding connections
- H02K15/0068—Connecting winding sections; Forming leads; Connecting leads to terminals
- H02K15/0081—Connecting winding sections; Forming leads; Connecting leads to terminals for form-wound windings
- H02K15/0087—Connecting winding sections; Forming leads; Connecting leads to terminals for form-wound windings characterised by the method or apparatus for simultaneously twisting a plurality of hairpins open ends after insertion into the machine
Definitions
- the invention relates to a method and a device for deforming free rod end sections of a conductor stack of a stator and/or rotor of an electric motor, the free rod end sections protruding from the stator and/or rotor of the electric motor, with a movable deformation tool that at least partially forms a free rod end section sleeve-like encloses to deform it below.
- WO2020206480A1 by means of several gripping elements, in particular a positioning finger and a selection finger, to pick up and clamp the rod end section between the fingers and subsequently deform it.
- the new device and the new method make it possible to deform the bar end sections in a particularly space-saving manner.
- the new control tool and the new deformation tool make new, more efficient process steps possible.
- the new device and the new method make it possible to deform the rod end sections without a previously necessary preliminary process in which the rod end sections were radially expanded. Due to the new device and the new method, it is possible according to a special embodiment to realize a variable effective diameter, so that the rod end sections are variably clamped and deformed by the deformation tool. This avoids the disadvantage of a crown known from the prior art for deforming a bar crown, the crown having a predetermined, non-variably adjustable position. In addition, each rod end section can be actively clamped with the new deformation tool.
- a device for deforming free rod end sections of a conductor assembly of a stator and/or rotor of an electric motor, the free rod end sections protruding from the stator and/or rotor of the electric motor, with a deforming tool that can be moved via a drive, which at least partially encloses a free rod end section in the form of a sleeve in order to subsequently deform it.
- the embodiment is characterized in that the deformation tool is designed in at least two parts and a control tool that interacts with the deformation tool is provided, with a holding configuration or holding position and a release configuration or release position being able to be activated on the deformation tool by preferably mechanical interaction of the control tool with the deformation tool and the free rod end section can be clamped between the two parts of the deformation tool in the holding position of the deformation tool.
- the deformation tool can be equipped with an optical and/or electromagnetic sensor and the control tool can act as a suitable actuator.
- a control tool has, for example, a suitable light/laser source for activating the sensor.
- a magnetic sensor and a corresponding magnet are used on the control tool, for example.
- the deformation tool can easily be switched to different operating states or different operating states can be activated on the deformation tool. This allows greater functionality and more efficient operation of the forming tool or the forming process
- a positioning element is provided as the first part of the deformation tool and a clamping element that is movable relative to the positioning element and is preferably movably attached to the positioning element is provided as the second part of the deformation tool, the clamping of the free rod end section in the deformation tool being achieved by clamping between the Positioning element and the clamping element of the deformation tool can be produced.
- the clamping element is attached to the positioning element.
- the control tool has a control element and the deformation tool has a release mechanism for activating the release configuration or release position or for switching between the release configuration and the holding configuration of the deformation tool.
- the release configuration and/or holding configuration of the deformation tool corresponds to a release state in which, for example, a rod end section clamped in a previous method step can be released or a rod end section can be accommodated in the deformation tool.
- the holding configuration of the deformation tool corresponds to a holding state in which, for example, an inserted rod end section can be clamped or fixed, so that it can be deformed, for example, in a subsequent deformation step.
- control tool has a geometric shape as a control element or control mechanism, for example a nose-shaped shape
- release mechanism of the deformation tool has a shape adapted to the geometric shape of the control element, in particular an access opening, with the geometric shape of the control element being connected to the geometric shape of the release mechanism interacts mechanically, in particular the nose-shaped shape engages in the engagement opening, whereby the clamping element can be lifted at least partially from the positioning element.
- control tool or the deformation tool has a control surface, for example a ramp, whereby the clamping element can be at least partially lifted off the positioning element by sliding the shape of either the control tool or the deformation tool or a part thereof on the control surface.
- the control tool has a device for geometrically pre-positioning the free rod end sections.
- the device for pre-positioning the free rod end sections has a pocket-like recess, whereby the free rod end sections can be aligned and/or pre-positioned individually and/or as a package, tangentially and/or radially.
- the device for pre-positioning has a pocket-like recess, as a result of which the free rod end sections are tangentially aligned and can be pre-positioned.
- the rod end sections are radially aligned, preferably in addition to the tangential alignment. This creates a predefined pin position. This radial and tangential positioning makes it possible to separate the respective outermost pin/rod end section from the pin package/rod end section package and subsequently to distance it radially from the remaining pins/rod end cross sections and then to deform or twist it.
- the deformation tool has a second engagement opening, so that in a predetermined position/configuration of the control tool, both the nose-shaped formation of the control tool and the pocket-like recess of the control tool can engage in one of the two engagement openings of the deformation tool.
- a novel method for deforming free bar end sections of a conductor stack of a stator and/or rotor of an electric motor, with the free bar end sections protruding from the stator and/or rotor of the electric motor, using a movable deformation tool that has at least one free bar end section partially sleeve-like in order to subsequently deform it, characterized in that the deformation tool is designed in two parts and a control tool is provided, and wherein the interaction of the control tool with the deformation tool on the deformation tool creates a holding configuration or holding position and a release configuration or release position for the free rod end section is activated.
- the release configuration or position and/or the holding configuration or position is/are activated by a mechanical actuation and/or by an actuation controlled by a sensor actuator. It is provided, for example, that the deformation tool changes between the release and the holding configuration by a mechanical and/or pneumatic and/or hydraulic drive.
- the control tool has a device for pre-positioning with a pocket-like recess and in one method step the free rod end sections are tangentially aligned and pre-positioned through the pocket-like recess.
- the control tool has an engagement element and the deformation tool has a release mechanism, and in a second method step, the control tool actuates the release mechanism through the engagement element, activates the release configuration or position of the deformation tool and thereby releases a movable clamping element of the deformation tool from a rigid positioning element of the Deformation tool at least partially lifts off to subsequently accommodate the free pre-positioned rod end section between the clamping element and the positioning element of the deformation tool.
- the control tool is moved away from the deformation tool, the holding configuration or holding position of the deformation tool is activated and the free rod end section is clamped between the clamping element and the positioning element of the deformation tool.
- the free rod end section is deformed by the deformation tool in a fourth method step.
- the moving parts of the device have suitable drives that are familiar to a person skilled in the art from the prior art.
- FIG. 1 shows a schematic view of a stator of an electric motor
- FIG. 2 shows a preferred embodiment of an exemplary device according to the invention in a first method position
- FIG. 3 shows a preferred embodiment of an exemplary device according to the invention in a second method position
- FIG. 4 shows a preferred embodiment of an exemplary device according to the invention in a third method position
- FIG. 5 shows a preferred embodiment of an exemplary device according to the invention in a fourth method position
- FIG. 6 shows a preferred embodiment of an exemplary device according to the invention in a fifth method position 7 shows a preferred embodiment of an exemplary device according to the invention in a sixth method position
- FIG. 8 shows a second embodiment in a schematic representation in a first method step
- FIG. 11 shows a second embodiment in a schematic representation in a fourth method step
- a stator 2 of an electric motor 1 is shown schematically in a plan view - in the upper part of Fig. 1 - and a side view - in the lower part of Fig.1.
- Rod-shaped conductors can be seen at both ends of the stator 2 on the electric motor 1 .
- the free bar end sections protrude from the stator and/or rotor of the electric motor. Depending on the design of the stator, these can be designed differently.
- the conductors are arranged in the rotor of the electric motor.
- the individual conductors are designed using hairpin technology.
- the characteristically curved center parts 3 of the individual hairpins therefore protrude from the stator on the first side of the stator 2 , while the individual bar end sections 4 protrude from the stator on the second side of the stator 2 .
- These bar end sections 4 are subsequently deformed—also referred to as “twists”—and then welded.
- the present further development starts with the deformation.
- FIG. 1 also shows the axial axis 5 of the stator and the top view shows the radially arranged individual rod end sections 4—sometimes also called pins in the art, as an example—only three pins are shown.
- the pins 4 are arranged radially in relation to a central axis 5 in one or more radial rows and are offset tangentially to one another.
- An exemplary tangential plane can be seen as straight line 6 in the plan view.
- a radial plane 7 - also visible as a straight line in the top view - shows in which direction the rod-shaped conductors run through the stator 2 parallel to the central axis 5 .
- the corresponding radial and tangential planes shown schematically and by way of example are provided for a better understanding of the radial and tangential directions as used in the disclosure of the application and correspond to non-limiting embodiments of the invention.
- a two-part deformation tool 8 with a clamping element 9 and a positioning element 10 can be seen.
- the design is shown in a schematic manner in plan and various detailed views, partially with the help of sections.
- the clamping element 9 is, for example, a spring plate that is fastened to the positioning element 10 in the lower area 11 .
- the deformation tool 8 is arranged opposite the pins 4 . 2 shows three end sections of three pins, with a first pin 12 and a second pin 13, as an example.
- the rod end sections are surrounded by insulation, with the insulation being stripped at their end, shown as an example at the end 14 of the first pin, mostly for the following method steps.
- a counter-holder 13A is provided on one side of the pins. This counter-holder 13A can be placed on the pins so that they are fixed, in particular in the radial direction.
- a control tool 15 is also shown in FIG. 2 .
- the control tool 15 has a base body with a control element, which in turn has two nose-shaped formations in the embodiment shown.
- a first nose-shaped formation 16 is made larger than a second nose-shaped formation 17. Both formations have recesses.
- the nose-shaped formation 16 has a recess 18 .
- the nose-shaped formation 17 has a recess 19 .
- recesses 18 and 19 are like pockets, which in the case of the first formation 16 are suitable for receiving the pins and in the case of the second formation 17 for receiving the tapered cross section of the shaping tool 8 .
- the recess 18 of the nose-shaped formation 16 serves to accommodate a rod end section, it being possible for the rod end section to be pre-aligned, in particular tangentially, through the recess.
- the recess 19 of the nose-shaped formation 17 is used to engage in a corresponding taper 20 on the cross section on the positioning element 10 of the deformation tool 8.
- the deformation tool 8 is sleeve-shaped, so that the pins are similar to a sleeve in the opening 22 at least partially encloses.
- the second nose-shaped formation 17 presses on the clamping element 9. Since the clamping element 9 is made of a flexible material, for example a spring steel sheet, and preferably only in the lower area 11 is attached to the positioning element 10, the clamping element lifts off the positioning element 10 in the upper region of the deformation tool 8. As a result, the deformation tool 8 is switched to a release position or release configuration or activated.
- the pin 12 pre-positioned through the recess 18 in the first nose-shaped formation 16 can now be inserted into the opening 22 of the deformation part.
- the counterholder 13A supports or fixes it together with the control tool in the radial direction. In addition, the pins are also tangentially supported or fixed in the recess 18 by the control tool 15 .
- FIG. 5 This insertion of the pin 12 into the opening 22 of the deformation part 10 is shown in FIG.
- the deformation tool slides along the control tool 15, with the second nose-shaped formation 17 in turn sliding along the taper 20 on the cross section of the deformation tool, in particular the positioning element 10, and pushing the clamping element 9 further away from the positioning element 10 via the second nose-like formation 17.
- the control tool 15 is removed from the deformation tool 8 laterally to the right.
- Deformation tool 8 and control tool 15 have suitable drives known from the prior art (not shown separately).
- the pin 12 in FIG. 5 is fixed in the holding configuration or position of the deformation tool 8 and the deformation of the pin 12 can begin.
- the deformation tool 8 is correspondingly moved via a suitable drive in order to achieve, for example, a deformation of the pin 12 as shown in FIG.
- the control tool 15 is again moved up to the deformation tool 8 .
- the first nose-shaped formation engages in an engagement opening in the deformation tool 8 which is formed by the first taper 20 in the cross section of the deformation tool 8 .
- the clamping element 9 is lifted off the positioning element by the first nose-shaped formation 16 of the control tool 15 and switched to a release configuration or release position or this release configuration or position is activated.
- the pin can be moved out of the deformation tool 8 by vertically lowering the deformation tool 8 .
- FIG. 8 a second possible embodiment of the invention is shown in schematic figures.
- the embodiment is shown as an elevation, with parts of the drawing enlarged as details and parts in a sectional view are shown. Larger elements are partially shown in a broken view with a break line.
- a deformation tool 23 and a control tool 24 are shown in FIG. 8 .
- the deformation tool 23 has a positioning element 25 and a clamping element 26 .
- a number of pins for example rod end sections 27 for example of a hairpin winding of a stator of an electric machine, are again shown schematically.
- the rod end sections 27 are arranged radially and are supported or fixed laterally by a counter-holder 28 .
- the counter-holder 28 provides radial support.
- a tangential support, in particular an additional one, can also be realized by redesigning the counter-holder.
- the pins are supported or fixed on the side opposite counter-holder 28 by a nose-shaped formation 29 of control tool 24 .
- the pins are at least partially radially and tangentially supported or fixed by the recess 30 in the nose-shaped formation 29 of the control tool 24 .
- the positioning element 25 has a tapering shape and/or tip 31 at one end and is accommodated with this end in the sleeve-like shape of the clamping element 26 .
- Positioning element 25 and clamping element 26 are connected via a spring element 32, for example a spring plate.
- spring element 32 is secured at a first end section by fastening means 35 (only one of the four screws shown is referenced in Fig. 8), in particular screws, at clamping element 26 and at the other end of spring element 32 attached to the positioning member 25.
- a resilient behavior of the clamping element in relation to the positioning element can be realized by cleverly arranging the fastening means.
- the control tool shown has a special control element, which has an actuating element 33, for example in the form of an actuating finger shown schematically.
- This actuating element 33 slides on a control surface 34, for example a ramp of the deformation tool 23.
- This control surface 34 is designed to interact with the actuating element 33 and is designed, for example, as a recess with a ramp, whereupon the actuating element can slide off.
- the deformation tool 23 is raised so that a rod end section of a pin can be accommodated in the opening between the positioning element 25 and the clamping element 26.
- the actuating element 33 slides down the ramp 34 and thereby exerts a force on the clamping element 26 .
- the spring element 32 is elastically deformed so that the distance of the positioning element 25 from the clamping element 26 in the area of the rod end section, receiving opening 36 and in that for which Recording of the rod end section provided, recording space under the opening 36 is increased.
- the threading of the rod end cross-section into the opening 36 is thus easy and technically reliable.
- the rod end cross sections or pins are supported or held in a radial and/or tangential position by the control tool 24 and the counterholder 29, as already described.
- the pins or rod end sections are also suitably fixed in the axial direction.
- the control tool 24 is removed from the deformation tool 23 after the rod end section has been successfully threaded into the deformation tool.
- the spring element 32 springs back at least partially after removal of the actuating element 33 and the elimination of the corresponding compressive force, with the result that the rod end section is clamped in the receiving space below the opening 36 between the positioning element 25 and the clamping element 26 .
- the rod end section or the pin is deformed by a suitable movement of the deformation tool 23, the so-called expanding and/or twisting, as shown in FIG. For the sake of clarity, only the deformed rod end section or pin is shown. Also shown in FIG. 10 is the control tool 24 at which the deformation tool 23 is located.
- the control tool 24 is fed back to the deformation tool 23.
- the actuating element 33 presses on a protruding area 36 of the clamping element 26, which in turn exerts a compressive force on this part of the deformation tool 23 and thus on the spring element 32. Compression of the spring element 32 releases the clamping of the rod end section between the positioning element and the clamping element, whereupon the deformed rod end section is released.
- the deformed rod end section can then be unthreaded from the deformation tool, in particular by moving the deformation tool in the vertical direction, and the deformation of a further rod end section can be started in a next method step.
- the task of aligning the joined pins and creating a defined initial situation for deformation is realized in a particularly efficient manner.
- a particularly simple expansion and twisting of the pins can be implemented in a simplified and improved method.
- the present device several processes are realized in a single tool.
- the process of expanding and/or twisting is preferably done in layers.
- the available degrees of freedom of the twisting tool in the radial and axial direction are used.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Power Engineering (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE112022001441.5T DE112022001441A5 (en) | 2021-03-11 | 2022-03-09 | DEVICE AND METHOD FOR DEFORMING FREE BAR SECTIONS OF A CONDUCTOR PACKAGE |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP21161958 | 2021-03-11 | ||
EP21161958.0 | 2021-03-11 |
Publications (1)
Publication Number | Publication Date |
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WO2022189475A1 true WO2022189475A1 (en) | 2022-09-15 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/EP2022/055966 WO2022189475A1 (en) | 2021-03-11 | 2022-03-09 | Device and method for shaping free bar end portions of a conductor stack |
Country Status (2)
Country | Link |
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DE (1) | DE112022001441A5 (en) |
WO (1) | WO2022189475A1 (en) |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102006054833A1 (en) * | 2006-05-24 | 2007-11-29 | Mitsubishi Electric Corp. | Electric winding end part forming device for e.g. vehicle generator, has bent centered around part of conductor end part, and comprising radius, which is equal to pre-determined distance |
US10284057B2 (en) * | 2012-06-22 | 2019-05-07 | Honda Motor Co., Ltd. | Stator manufacturing device and stator manufacturing method |
EP3493377A1 (en) * | 2017-12-01 | 2019-06-05 | Toyota Jidosha Kabushiki Kaisha | Coil forming device |
US10587171B2 (en) * | 2013-08-29 | 2020-03-10 | Honda Motor Co., Ltd. | Manufacturing method for rotating electric machine |
EP3706296A1 (en) * | 2018-01-31 | 2020-09-09 | Aisin Aw Co., Ltd. | Method for manufacturing armature, and device for manufacturing armature |
WO2020206480A1 (en) | 2019-04-11 | 2020-10-15 | Miba Automation Systems Ges.M.B.H. | Method and forming unit for forming free rod end portions of a lamination stack |
-
2022
- 2022-03-09 WO PCT/EP2022/055966 patent/WO2022189475A1/en active Application Filing
- 2022-03-09 DE DE112022001441.5T patent/DE112022001441A5/en active Pending
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102006054833A1 (en) * | 2006-05-24 | 2007-11-29 | Mitsubishi Electric Corp. | Electric winding end part forming device for e.g. vehicle generator, has bent centered around part of conductor end part, and comprising radius, which is equal to pre-determined distance |
US10284057B2 (en) * | 2012-06-22 | 2019-05-07 | Honda Motor Co., Ltd. | Stator manufacturing device and stator manufacturing method |
US10587171B2 (en) * | 2013-08-29 | 2020-03-10 | Honda Motor Co., Ltd. | Manufacturing method for rotating electric machine |
EP3493377A1 (en) * | 2017-12-01 | 2019-06-05 | Toyota Jidosha Kabushiki Kaisha | Coil forming device |
EP3706296A1 (en) * | 2018-01-31 | 2020-09-09 | Aisin Aw Co., Ltd. | Method for manufacturing armature, and device for manufacturing armature |
WO2020206480A1 (en) | 2019-04-11 | 2020-10-15 | Miba Automation Systems Ges.M.B.H. | Method and forming unit for forming free rod end portions of a lamination stack |
Also Published As
Publication number | Publication date |
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DE112022001441A5 (en) | 2024-01-25 |
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