WO2023061687A1 - Method for installing hairpins of a plug-in winding into corresponding stator core slots, corresponding computer program, and corresponding installation system - Google Patents

Method for installing hairpins of a plug-in winding into corresponding stator core slots, corresponding computer program, and corresponding installation system Download PDF

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Publication number
WO2023061687A1
WO2023061687A1 PCT/EP2022/075502 EP2022075502W WO2023061687A1 WO 2023061687 A1 WO2023061687 A1 WO 2023061687A1 EP 2022075502 W EP2022075502 W EP 2022075502W WO 2023061687 A1 WO2023061687 A1 WO 2023061687A1
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WO
WIPO (PCT)
Prior art keywords
hairpin
braid
legs
conductor elements
laminated core
Prior art date
Application number
PCT/EP2022/075502
Other languages
German (de)
French (fr)
Inventor
Daniel Walz
Original Assignee
Robert Bosch Gmbh
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 Robert Bosch Gmbh filed Critical Robert Bosch Gmbh
Publication of WO2023061687A1 publication Critical patent/WO2023061687A1/en

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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
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H02K15/0414—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils
    • H02K15/0421—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils consisting of single conductors, e.g. hairpins
    • H02K15/0428—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils consisting of single conductors, e.g. hairpins characterised by the method or apparatus for simultaneously twisting a plurality of hairpins

Definitions

  • the present invention relates to an assembly method for inserting a hairpin braid of a plug-in winding into slots in a laminated core of a stator of an electrical machine.
  • the invention also relates to a computer program comprising instructions which, when the program is executed by a computer, cause the latter to carry out the steps of the assembly method.
  • the invention also relates to an assembly system for inserting the hairpin braid into the slots of the laminated core of the stator, comprising at least one gripping device and a pretensioning device.
  • Electrical machines can have what is known as a plug-in winding as the electrical winding.
  • the conductor elements In plug-in windings, the conductor elements have a comparatively large conductor cross-section compared to conventional wire windings, which increases the space factor in the stator slots.
  • the fill factor is the ratio of the effective cross-sectional area of the copper conductor to the theoretically maximum cross-sectional area of the available winding window. Due to the higher fill factor, among other things, material is generally saved, in particular relatively expensive copper. Electrical machines with a plug-in winding also have higher efficiency or power and lower noise development with the same installation space.
  • the typically three electrical phases of a plug-in winding preferably each comprise a large number of U-shaped conductor elements which are intertwined at the free ends.
  • the intertwined ends of an electrical phase are electrically related to each other connected that a series connection of the U-shaped conductor elements of the electrical phase results, the connection being made, for example, by laser welding.
  • a first part of the series-connected conductor elements of a phase thus typically forms a first waveform and a second part of the series-connected conductor elements thus typically forms a second waveform running in the opposite direction thereto.
  • first and second parts of the conductor elements connected in series are usually arranged one behind the other in the radial direction or overlapping one another in the radial direction and are electrically connected to one another by means of a reversing or layered connector.
  • the first and second parts are therefore set up to form electrical loops of an electrical phase as a result of their opposing waveforms.
  • the first and second parts of the series-connected conductor elements of the respective electrical phase of the plug-in winding are set up when excited with alternating current to generate an electromagnetic stator field for exciting the rotor of the electrical machine.
  • the rotor can, for example, have permanent magnets arranged in alternation or a so-called squirrel-cage rotor.
  • magnetic poles that rotate or revolve in the circumferential direction are generated by typically driving three electrical phases, each with a phase-shifted alternating current, which result in a rotation of the rotor of the electrical machine.
  • Document DE 10 2019 122 550 A1 discloses an electrical machine with a hairpin-shaped winding or a plug-in winding.
  • the electric machine includes a stator core defining slots and hairpins disposed in the slots and selectively connected at junctions to form windings.
  • a U-shaped bridge has spaced legs connected by a U-section.
  • the U-shaped conductor elements of the plug-in winding are typically inserted or plugged into the slots of the laminated core of the stator with the two parallel, straight legs or hairpins parallel to the axis of rotation of the stator or rotor, with preferably all curved areas of the conductor elements on a predetermined side or Plug-in side of the stator are arranged. Then the free ends of the legs are intertwined on the side of the stator opposite the predetermined side or the plug-in side and welded to one another to form the waveform or the opposite waveform electrically connected or connected in series.
  • a first hairpin braid is preferably formed in this way, which encompasses the respective first part of all series-connected conductor elements of three electrical phases.
  • a second hairpin braid is preferably formed analogously, which includes the respective second part of all series-connected conductor elements of three electrical phases.
  • a so-called hairpin basket or winding head comprises at least the first and the second hairpin braid. It can be provided that the hairpin basket comprises more than two hairpin braids. Then, according to the known prior art, the first and the second hairpin braid or the hairpin basket as a whole is inserted into the slots of the stator. Then, after the arrangement of the hairpin basket in the stator, the free ends of the straight legs are intertwined and electrically connected, and the respective electrical windings of the same electrical phase of the different hairpin braids are electrically connected to one another by means of a layer or reversing connector.
  • the assembly of the plug-in winding is technically and economically demanding, since a large number of process steps result, for example by arranging the large number of conductor elements with the interlocking of the curved areas to form the hairpin braid or hairpin basket.
  • the document DE 10 2018 121 745 A1 discloses a method for producing an arrangement of coil elements for a plug-in coil of an electrical machine, wherein an at least single-layer arrangement of rod-shaped coil elements for a plug-in coil of an electrical machine is produced on a workpiece carrier and the at least single-layer arrangement of the coil elements is held on the workpiece carrier by means of a gripping device after the coil elements have been taken over.
  • Document DE 10 2019 120 261 A1 discloses a rim arrangement and joining device for forming and inserting a rim arrangement from at least one rim or a plurality of concentrically arranged rims of preferably U-shaped electrical conductors in a component of an electrical machine.
  • Document DE 10 2018 114 875 A1 discloses a device for producing a machine element provided with windings for an electrical machine, comprising: at least one auxiliary device for providing pre-inserted hairpins which are aligned with one another as in the machine element to be produced; and a joining device for removing the mutually aligned hairpins from the auxiliary device and for introducing them into a machine element.
  • the document DE 10 2019 124488 A1 discloses a device for equipping a stator core with conductor pieces which are designed in particular with a rectangular conductor cross section.
  • the device includes a receptacle for receiving the conductor sections with play.
  • the conductor pieces are arranged in the receptacle in a configuration which corresponds to a configuration of the conductor pieces intended for insertion into a stator core.
  • the device has a gripping device, which is used to remove the conductor pieces held with play in the receptacle from the receptacle and to insert them into the stator core in the intended final arrangement. It is provided that the gripping device comprises an alignment device.
  • the aligning device is designed to align, in a gripping process, a plurality of rows of conductor pieces which are held with play in the receptacle and which are arranged in a radially extending manner in their intended row arrangement so that they rest against one another in a radially extending manner.
  • the respective row of conductor pieces bears against a radial stop in the radial direction and the individual conductor pieces of the row of conductor pieces are contacted circumferentially on both sides by the alignment device.
  • a separately formed abutment means is formed and arranged to form a radial stop on a second radial side (located opposite the first radial side) in the gripping operation of the gripping device.
  • the gripping device is designed to fix the conductor sections of the respective row arrangement or conductor section row in a clamping manner between the radial stop of the alignment device and the radial stop of the counter-bearing device.
  • the device disclosed in DE 10 2019 124488 A1 allows all the shark pins to be gripped in one gripping process.
  • the alignment device has a plurality of fork-shaped pickups, each of which is designed and arranged to grasp the conductor sections of a row arrangement, with the gripping device being designed in particular in such a way that the respective fork-shaped pickups each open in the radial direction during the gripping process the conductor pieces of a respective row arrangement are pushed on.
  • the conductor sections of a row arrangement are aligned with one another by the alignment device and the individual row arrangements are fixed in their angular position in the circumferential direction.
  • the object of the present invention is to improve an assembly method for inserting a provided hairpin braid with U-shaped conductor elements into the slots of a stator.
  • the present invention relates to an assembly method for inserting or for positioning a hairpin braid of a plug-in winding in the slots of a laminated core of a stator.
  • the assembly method includes providing the hairpin braid of an electrical winding for an electrical machine.
  • the hairpin braid was advantageously produced in a pre-assembly process that is not described in detail in this application.
  • the hairpin braid preferably has a large number of separate U-shaped conductor elements arranged next to one another in a circle, each with two straight legs or hairpin feet or hairpins, with at least two adjacent U-shaped conductor elements preferably being arranged one behind the other in the radial direction and their curved areas interlocking.
  • the hairpin braid is gripped, the hairpin braid being gripped in particular in the curved region of the conductor elements.
  • the conductor elements bent in a U-shape are preferably gripped at at least one respective support point in the bent region of the conductor elements and thus positioned or fixed in the z-direction and in the radial direction.
  • the U-shaped conductor elements are pivoted around the tangential axis.
  • the position of the legs and the position of the free ends of the legs of the conductor elements of the hairpin braid are advantageously essentially defined by the weight and the contact points on the gripping device, which is why the position of the legs and the position of the free ends of the legs of the conductor elements are advantageously defined of the hairpin braid initially have a high position and angle tolerance. Subsequently, the legs of the conductor elements of the gripped hairpin braid are introduced into a pretensioning device arranged coaxially to the axis of the hairpin braid.
  • the biasing device is in particular ring-shaped, that is, the legs of the conductor elements of the gripped hairpin braid are preferably coaxial with the Axis of the hairpin braid arranged biasing device introduced so that the biasing device is advantageously arranged around the legs of the conductor elements.
  • the prestressing device is preferably arranged perpendicularly or coaxially to the axis of the hairpin braid. A large number of alignment elements of the prestressing device are then extended, with one alignment element aligning at least one leg of the conductor elements in the tangential direction. For example, an alignment element is arranged in each case between two legs, so that the legs of the conductor elements are advantageously positioned or aligned in the tangential direction.
  • the free ends of the legs of the conductor elements of the hairpin braid are shifted inwards or outwards in the radial direction, in particular by means of a mechanical stop of the alignment elements, so that a lateral surface of a truncated cone is formed as the outer envelope surface around the legs of the hairpin braid becomes.
  • the displacement of the free ends of the legs of the conductor elements of the hairpin braid takes place in particular in the radial direction inwards.
  • a laminated core of a stator of an electrical machine is then provided, the laminated core having a multiplicity of straight grooves for receiving the legs of the conductor elements of the hairpin braid.
  • the grooves each comprise an insulating paper which is preferably arranged on the outer circumference of the respective groove.
  • the laminated core of the stator and the hairpin braid are advantageously arranged or aligned coaxially to one another with the axis of rotation.
  • the free ends of the legs of the conductor elements are inserted or introduced into the slots of the stator or positioned in the slots, preferably by moving the hairpin braid in the z-direction from top to bottom.
  • the method has the advantage over known methods that the individual hairpin braids are inserted directly into the laminated core of the stator at increased speed.
  • the truncated cone-shaped lateral surface of the outer enveloping surface of the hairpin plait facilitates the successive insertion of several hairpin plaits, since the curved areas of the plurality of conductor elements of a hairpin plait do not prevent the insertion of a subsequent hairpin plait.
  • the lower positional tolerance of the legs of the conductor elements which is based on the generated frustoconical lateral surface of the outer envelope surface of the hairpin braid, results in a more precise insertion position or in a lower tolerance of the insertion position of the straight legs of the conductor elements in the grooves, whereby the insertion or insertion of the legs into the grooves, which preferably a Have insulation paper is facilitated.
  • the assembly method results in a cost advantage, since no auxiliary device is required in which all hairpin braids are combined to form a hairpin basket.
  • the present invention has the advantage that the required insertion force of an individual hairpin braid into the stator or the laminated core of the stator is reduced compared to a classic insertion of the entire hairpin basket, which also advantageously makes it easier or more error-free to insert the legs into the stator slots with insulating paper , since the insulation paper is less damaged.
  • the assembly method of the present invention also has the advantage of great flexibility in terms of the size of the hairpins, the interlacing of the bent portions of the U-shaped conductor members, and the number of hairpins.
  • the pretensioning device when inserting the hairpin braid into the pretensioning device, is arranged in the area between the middle of the straight legs of the ladder elements and the free ends of the legs of the ladder elements.
  • the truncated cone-shaped lateral surface of the outer envelope surface of the hairpin braid is produced with a higher dimensional tolerance, which means that the insertion of the legs into the stator slots or the overall process becomes more error-free or the process reliability of the method is increased. In addition, less force is required to move the free ends of the legs in the radial direction.
  • the free ends of the legs of the conductor elements of the hairpin braid are introduced into a positioning aid.
  • the positioning aid is arranged coaxially to the stator in the z-direction, with the positioning aid being set up by means of a large number of positioning aids to align the legs of the conductor elements above the slots of the stator.
  • the positioning aid elements each have at least one guide surface angled toward the z-direction on the upper side toward the prestressing device.
  • This design increases the positioning accuracy of the insertion or the introduction of the free ends of the legs of the conductor elements into the slots of the laminated core of the stator and thus, for example, damage to insulating paper in the slots of the laminated core is reliably avoided.
  • the legs of the conductor elements of the hairpin braid are pressed radially outwards or inwards. The previous insertion or insertion of the legs of the conductor elements into the grooves takes place in particular only for a short distance, i.e.
  • the free ends of the legs are only inserted for a distance less than or equal to five centimeters and then pressed on, in particular the free ends are inserted
  • the legs end in the grooves for a distance of less than or equal to three centimeters, and more preferably for a distance of less than or equal to one centimeter.
  • the pressing takes place in each case between two positioning aids and against the stator or against a hairpin braid that has already been pushed through or completely inserted into the slots of the stator.
  • the pressing action advantageously changes or converts the outer envelope surface of the hairpin braid from the frustoconical to a cylindrical surface.
  • the legs of the conductor elements are then pushed through the slots of the stator or guided completely through the slots of the stator, in particular until the free ends of the legs leave the slots on a side of the stator opposite the insertion side.
  • at least part of the legs or each leg of the conductor elements of the hairpin braid are pressed on in the radial direction from the inside to the outside between two positioning aids, in particular by means of a clamping device.
  • the alignment elements are at least partially retracted or removed at least in the radial direction.
  • the contact pressure advantageously converts or changes the outer envelope surface of the hairpin braid from the frustoconical lateral surface to an approximately cylindrical lateral surface, so that the straight legs of the conductor elements can be guided or inserted completely through the slots of the stator.
  • the pressing in particular by means of the tensioning device, is also advantageously set up to push and/or press a currently inserted hairpin braid onto the last inserted hairpin braid.
  • the filling factor can advantageously be further increased by the contact pressure, since an air gap can be minimized.
  • additional adhesion between the hairpin braids can be supported by a pressing force, with an additional Bonding between hairpin braids also minimizes vibrations of the electric machine during operation.
  • the method is preferably repeated until at least two hairpin braids are positioned in the slots of the laminated core of the stator.
  • the invention also relates to a computer program comprising instructions which, when the program is executed by a computer, cause the latter to carry out the steps of the method according to one of the preceding claims.
  • the invention also relates to an assembly system for inserting or for positioning a hairpin braid in the slots of a laminated core of a stator.
  • the assembly system has at least one gripping device which is set up to grip a provided hairpin braid.
  • the hairpin braid provided preferably has the multiplicity of separate U-shaped conductor elements arranged next to one another in a circle, each with two straight legs or hairpin feet.
  • the gripping device is also set up in particular to grip or position the conductor elements bent in a U-shape in the bent area at at least one support point in the z-direction and in the radial direction.
  • the gripping device is set up to mount the conductor elements of the hairpin braid, which are bent in a U-shape, so that they can rotate about the tangential axis.
  • the assembly system also includes at least one pretensioning device, which has a large number of alignment elements.
  • the alignment elements are each set up to align at least one leg of the conductor elements in the tangential direction.
  • the plurality of aligning elements are set up to be extended in the radial direction inwards or outwards between each two legs of the conductor elements of the hairpin braid, the legs being positioned or aligned in the tangential direction.
  • the prestressing device is in particular ring-shaped. According to the invention, at least some of the alignment elements have at least one mechanical stop.
  • the prestressing device is set up by means of the mechanical stops of the alignment elements to move the free ends of the legs inwards or outwards in the radial direction, so that the outer envelope surface around the legs of the U-shaped conductor elements of the hairpin braid is a truncated cone-shaped lateral surface results.
  • the gripping device is also set up to be moved at least in the z-direction in order to insert the free ends of the legs of the U-shaped conductor elements of the gripped hairpin braid in the z-direction from top to bottom into the slots of a provided stator of an electrical machine plug in
  • the assembly system according to the invention achieves high positional accuracy of the free ends of the legs of the conductor elements when inserting U-shaped conductor elements of a plug-in winding into slots in a stator that have insulating paper, which increases process reliability and reduces the error rate of the plug-in process, for example due to damage to the insulating paper. a plug-in winding is reduced. Furthermore, the advantages of the method according to the invention described above result.
  • the assembly system according to the invention allows greater parallelization of the process steps in the production of the electrical machine or the stator, since different hairpin braids can be inserted one after the other and thus a higher cycle speed of the overall process can be achieved, thereby reducing production costs.
  • the assembly system also has a positioning aid.
  • the positioning aid is set up to be arranged in the z-direction below the prestressing device and above the provided laminated core of the stator or between the prestressing device and the laminated core coaxially to the laminated core of the stator and coaxially to the pretensioning device.
  • the positioning aid is designed in particular to be arranged directly above the stator.
  • the positioning aid is in particular ring-shaped.
  • the positioning aid has a large number of positioning aids.
  • Each positioning aid element is arranged above a web of the stator and has at least one guide surface angled toward the z-direction, in particular on the upper side toward the prestressing device.
  • the positioning aids are set up to align the free ends of the legs of the conductor elements with the slots in the laminated core.
  • the arrangement of the positioning aid results in high dimensional accuracy with regard to the positioning of the free ends of the legs of the conductor elements during insertion into the slots of the stator, so that buckling or damage to insulating paper in the slots of the stator is very reliably avoided.
  • the assembly system preferably also includes a clamping device which is arranged coaxially to the stator and inside or outside the hairpin braid and is set up to move the inserted legs of the U-shaped conductor elements of the hairpin braid in the radial direction outwards or inwards by means of a large number of slides or to press against a surface, in particular this pressing takes place between the positioning aids and against the respective bottom surfaces of the grooves of the laminated core of the stator or against the outer surface of another hairpin braid already inserted and arranged in the laminated core.
  • the tensioning device is preferably set up to be arranged within the hairpin braid and advantageously directly above or in the upper region of the laminated core on the insertion side and advantageously at least partially within the stator.
  • the tensioning device is preferably set up to press the inserted legs of the U-shaped conductor elements of the hairpin braid from the inside outwards in the radial direction by means of a large number of slides.
  • the clamping device is preferably set up to convert or change the outer envelope surface of the hairpin braid from the frustoconical lateral surface to the cylindrical shape, so that the conductor elements can be pushed through or inserted completely through the slots of the stator.
  • FIG. 1 U-shaped conductor element of a hairpin braid
  • Figure 2 Side view of a stator with two hairpin braids of the end winding
  • FIG. 3 three-dimensional representation of the assembly plant in an oblique side view
  • Figure 4 Gripping device with a hairpin braid
  • FIG. 6 Detailed view of the prestressing device with legs of the conductor elements
  • FIG. 8 Sectional view of the positioning aid and clamping device
  • FIG. 9 Auxiliary positioning element of the auxiliary positioning device
  • Figure 10 Top view of the positioning aid above the laminated core of the stator
  • FIG. 11 Side view of the positioning aid above the laminated core
  • FIG. 14 outer enveloping surface forms the lateral surface of a truncated cone
  • FIG. 15a Cylindrical outer enveloping surface before the alignment elements are extended
  • FIG. 15b Formation of the outer enveloping surface as the lateral surface of a truncated cone
  • FIG. 16 Flow chart of the method as a block diagram
  • a U-shaped conductor element 10 of a hairpin braid is shown in a three-dimensional view in FIG.
  • the conductor element 10 has two straight legs 12 or hairpin feet parallel to one another, a curved region 11 and a free end 13 of the legs 12 on each of the legs 12 .
  • FIG. 2 shows a side view of a stator 20 of an electrical machine with two hairpin braids 100, 101, 102 arranged one behind the other or next to one another in the radial direction in the slots 23 of the stator 21.
  • the stator 20 comprises a laminated core 21 with a plurality of webs 22, wherein the laminated core 21 has a groove 23 between each of two webs 22 .
  • An insulating paper 25 is typically arranged in a groove 23 .
  • the outer hairpin braid 100, 101 has a larger diameter than the inner hairpin braid 100, 102.
  • Figure 2 also shows how the individual U-shaped areas 11 of the conductor elements 10 bent in a U-shape intermesh in a hairpin braid of adjacent conductor elements 10, so that the radial and axial expansion of the respective hairpin braid 100 outside of the laminated core 21 of the stator 20 is minimized.
  • the laminated core 21 of the stator 20 typically has an empty cylindrical inner area 24 which is set up to accommodate a rotor of the electric machine.
  • FIG. 3 shows a three-dimensional representation of components of an assembly system 200 in an oblique side view.
  • a gripping device 210 is set up to grip a hairpin braid 100, 101, 102 and to move it at least in the z-direction.
  • a pretensioning device 220 of the assembly system 200 is set up by means of a large number of alignment elements 221 to align the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102, so that the legs 12 are pre-positioned or aligned in the tangential direction of the hairpin braid 100, 101, 102 and the free ends 13 of the legs 12 are shifted inwards or outwards in the radial direction, so that a lateral surface of a truncated cone is formed as the outer envelope surface around the legs 12 of the hairpin braid 100, 101, 102, see also FIG.
  • the alignment elements 221 can be extended by a rotary mechanism by means of curved grooves in which a pin connected to a respective alignment element 221 is guided.
  • the assembly system 200 also includes a positioning aid 240.
  • the positioning aid 240 is set up to arrange positioning aids 241 above the webs 22 of the laminated core 21 of the stator 20; for example, these positioning aids 241 can also be extended by a rotary mechanism.
  • the positioning aid elements 241 are designed to guide the conductor elements 10 into the grooves 23 when the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102 are inserted.
  • the positioning aids 241 have guide surfaces 242 for this purpose.
  • the guide surfaces extend at an oblique angle to the axial direction z of the hairpin braid 100, 101, 102.
  • the assembly system includes a clamping device 230.
  • the clamping device 230 is set up by means of a large number of slides 231, the legs 12 of the conductor elements 10 of an already inserted Hairpin braids 100, 101, 102 and hairpin braids 100, 101, 102 still to be pushed through the grooves in the radial direction from the inside to the outside or vice versa, with the conductor elements 10 against a stop of the positioning aid 240 or against a bottom surface of the grooves 23 of the stator or against an outer surface of one already in the grooves of Laminated core 21 of the stator 20 arranged hairpin plait 100, 101, 102 is pressed, whereby the outer envelope surface around the legs 12 of the hairpin plait 100, 101, 102 is converted into a cylindrical lateral surface.
  • the clamping device 230 is set up to align the legs 12 of the conductor elements 10 axially parallel to the z-direction, with this axially parallel alignment of the legs 12 taking place by displacing or pressing the legs 12 against an axially parallel stop, the axially parallel stop in particular being a Stop of the positioning aid 240, the bottom surface 26 of the grooves 23 of the laminated core 21 of the stator 20 or an outer surface of a hairpin braid already arranged in the grooves of the stator 20 100, 101, 102.
  • the assembly system also includes a receptacle 250 for a laminated core 21 of the stator 20.
  • FIG. 4 shows a three-dimensional side view of a gripping device 210 with a gripped hairpin braid 100, 101, 102.
  • the gripping device 210 comprises lamella slides or gripping elements 211 for gripping the conductor elements 10 of the hairpin braid 100, 101, 102.
  • the gripping device 210 shown in Figure 4 grips each U-shaped conductor element 10 in the respective curved area 11 with two lamella slides or gripping elements 211.
  • the hairpin braid comprises a multiplicity of conductor elements 10 bent in a U-shape, which are arranged next to one another in a circle.
  • the respective curved area 11 of each conductor element 10 is curved in such a way that the curved areas 11 of the individual conductor elements 10 can intermesh and the axis-parallel alignment of all legs 12 or hairpin feet is made possible.
  • a prestressing device 220 with alignment elements 221 is shown in FIG.
  • the pretensioning device has a first rotary element 223 with first guide grooves 224 .
  • the alignment elements 221 are each connected to a first pin 225 or first pin or first guide element, which engages in a respective first guide groove and is guided by this when the first rotary element 223 rotates. This guidance of the alignment elements 221 during the rotary movement of the first rotary element 223 allows all the alignment elements 221 to be moved in and out in parallel.
  • FIG. 6 shows an enlarged representation of a section of the prestressing device 220 according to FIG. 5, the legs 12 of the conductor elements 10 being inserted or arranged in the prestressing device 220 .
  • the Alignment elements 221 are in a middle position, since the first pins 225 or the guide elements are each positioned in a middle position of the guide groove 224 of the first rotary element 223 .
  • a mechanical stop 222 of a respective alignment element 221 is set up to move the legs 12 of the conductor elements 10 inwards in the radial direction when the alignment elements 221 are extended. This displacement of the legs 12 in the radial direction from the outside to the inside produces a frustoconical lateral surface as the outer envelope surface around the legs 12 of the conductor elements 10 .
  • FIG. 7 shows a three-dimensional view of a laminated core 21 of the stator 20 with slots 23 in the receiving device 250, with an insulating paper 25 being arranged in each slot 23 in particular.
  • a positioning aid 240 and a clamping device 230 are arranged above the laminated core 21 .
  • Auxiliary positioning device 240 has a second rotary element 244 with second guide grooves 245 for guiding second guide elements 246, the second guide elements 246 each being a second pin, for example, which is inserted or arranged in a receptacle of an auxiliary positioning element 241, for example, and is shaped and shaped with it / or is firmly bonded.
  • the positioning aid elements 241 are shown in FIG.
  • Clamping device 230 has a third rotary element 232 with third guide grooves 233 for guiding third guide elements 234, with the third guide elements 233 each being a third pin, for example, which is inserted or arranged in a receptacle of a slide 231, for example, and is connected to it in a form-fitting and / or is firmly bonded.
  • the slides 231 are arranged in a maximally retracted position, ie the third guide elements 234 are each arranged on the inner stop of a third guide groove 233 of the second rotary element 232 .
  • the clamping device 230 is set up to press the legs 12 of the conductor elements 10 of a hairpin braid inserted into the grooves 23 of the laminated core 21 against the positioning aid 240, which is parallel to the z-axis, whereby the frustoconical outer enveloping surface around the legs 12 of the conductor elements 10 a cylindrical lateral surface is generated.
  • the legs 12 can be completely pushed through the grooves 23 of the laminated core 21 parallel to the z-axis by means of a coaxial movement of the gripping device 210 from top to bottom, so that the free end 13 of the legs 12 of the U-shaped conductor elements 10 the exits from the grooves 23 opposite the predetermined or insertion side.
  • a laminated core 21 of the stator 20 with slots 23 is shown in a sectional view in a side view, similar to Figure 7.
  • a positioning aid 240 and a clamping device 230 Above the laminated core 21, as in Figure 7, are a positioning aid 240 and a clamping device 230, with the positioning aids 241 of the Positioning aid 240 and the slide 231 of the clamping device 230 are extended.
  • a positioning aid element 241 of the positioning aid device 240 is shown in a three-dimensional view in FIG.
  • the positioning aid element 241 has guide surfaces 242 and a recess 243, in particular a through hole or a bore, for receiving a second guide element 246.
  • the positioning aid element 241 is set up in each case to be arranged with the underside 249 above a web 22 of the laminated core 21 of the stator 20 and in particular to essentially cover it.
  • the positioning aid element 241 also covers the lateral areas of the insulating paper 25 which is arranged in the groove 23 of the laminated core 21 .
  • the guide surface 242 in particular the chamfer, is designed to be arranged at an angle or at an angle to the z-direction or to the z-axial direction of the hairpin braid or the laminated core when the positioning aid element 246 is arranged above the laminated core 21, so that if a free end 13 of a leg 12 of a conductor element 10 in a gripped hairpin braid 100, 101, 102, the free end 13 of the leg 12 is aligned with the respective groove 23.
  • the covering of the lateral areas of the insulating paper 25 by the positioning aid element 241 avoids damage to the insulating paper 25 when the free ends 13 of the legs 12 or the legs 12 of the conductor elements 10 are inserted into the grooves 23 of the laminated core 21.
  • FIG. 10 shows a section of a top view of the positioning aid 240 above the laminated core 21 of the stator 20 in a top view.
  • the positioning aid elements 241 of the positioning aid device 240 are each arranged with the underside 249 of the positioning aid elements 241 above a web 22 of the laminated core 21 of the stator 20 and parallel to or aligned with it, so that the positioning aid elements 241 essentially conceal the web 22.
  • the guide surfaces 242, which are arranged at an angle to the axial direction of the laminated core 21 and to the coaxially arranged hairpin braid 100, 101, 102, are arranged to align the free ends 13 of the legs 12 of the conductor elements 10 when the free ends 13 of the legs 12 are inserted into the grooves 23 of the laminated core 21 .
  • FIG. 11 shows a three-dimensional side view of a free end 13 of a leg 12 of a conductor element 10 when it is being inserted or introduced into the positioning aid device 240 above the laminated core 21 .
  • the inclined guide surfaces 242 of the positioning aids 241 align the free end 13 of the respective leg 12 to the respective groove 23, so that the positioning accuracy of the free ends 13 of the legs 12 is increased or ensured. This avoids damage to the insulating paper 25 in the grooves 23 despite very small tolerances between the dimensions of the groove 23 and the leg 12 .
  • FIG. 12 shows the free ends 13 of the legs 12 of the conductor elements 10 after they have been inserted into the grooves 23 of the laminated core 21, with the prestressing device 220, the positioning aid 240 and the clamping device 230 being arranged coaxially to and above the laminated core 21.
  • the hairpin braid 100, 101 and the laminated core 21 are also aligned coaxially.
  • the first guide elements 225 of the aligning elements 221 of the pretensioning device 220 are arranged in a middle position in the guide groove 224 of the rotary element 223, i.e. the aligning elements 221 were extended by the first rotary element 223 in a middle position.
  • the outer enveloping surface around the legs 12 of the conductor elements 10 of the hairpin braid 100, 101 advantageously has a frustoconical lateral surface in this operating state. In any case, there is a distance 400 between the free ends 13 of the legs 12 of the conductor elements 10 and the bottom surface of the grooves 23 .
  • Figure 13 shows the operating state after the legs 12 of the conductor elements 10 of the hairpin braid 100, 101 have been pressed in the radial direction outwards between the positioning aid elements 241 by means of the slide 231 of the clamping device 230. This changes the outer envelope surface of the hairpin braid from the frustoconical into a cylindrical lateral surface changed and a play free Concern of the leg 12 of the hairpin braid 100, 101 reaches the bottom surface 26 of the grooves 23.
  • the straight legs 12 of the conductor elements 10 are then pushed completely through the grooves 23 of the laminated core 21, with the position of the slide 231 of the clamping device 230 and the position of the alignment elements 221 of the pretensioning device 220 defining the radial position or position of the legs 12 in the grooves 23 .
  • a gripping device 210 is shown in FIG. In FIG. 14, the conductor elements 10 bent in a U-shape are gripped in such a way that they are rotatably mounted about their tangential axis.
  • the legs 12 of the conductor elements 10 are aligned with the free ends 13 in the tangential direction by a non-illustrated prestressing device 220 .
  • the free ends 13 are pushed inwards in the radial direction by means of the prestressing device 220 (not shown), see in particular arrows 98.
  • a lateral surface 99 of a truncated cone is formed as the outer envelope surface around the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102 .
  • Figure 14 shows how the conductor elements 10 with the legs 12 and the free ends 13 form the lateral surface 99 of a truncated cone as the outer envelope surface around the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102 by means of the prestressing device 220, the Biasing direction 220 is not shown in FIG.
  • the outer enveloping surface around the legs 12 of the conductor elements 10 is formed as a frustoconical lateral surface 99, preferably by means of the alignment element 221 of the prestressing device 220, with the free ends 13 of the legs 12 of the conductor elements 10 being extended in the radial direction inward when the plurality of alignment elements 221 are extended 340 be shifted, see in particular arrows 98, so that the lateral surface 99 of a truncated cone is formed as the outer envelope surface around the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102.
  • FIG. 15a shows the cylindrical outer enveloping surface before the aligning elements are extended.
  • FIG. 15b shows the configuration of the outer enveloping surface as a lateral surface 99 of a truncated cone after the aligning elements have been extended.
  • FIG. 16 shows a flow chart of the assembly process for inserting a hairpin braid of an insert winding into slots in a laminated core of a stator Block diagram shown.
  • the method begins with a provision 310 of the hairpin braid 100, 101, 102.
  • the hairpin braid 100, 101, 102 is gripped.
  • the conductor elements 10 of the hairpin braid 100, 101, 102 bent in a U-shape are mounted such that they can rotate about the tangential axis of the hairpin braid 100, 101, 102.
  • the legs 12 of the conductor elements 10 of the gripped hairpin braid 100, 101, 102 are introduced 330 into a pretensioning device 220 arranged coaxially to the z-axis of the hairpin braid 100, 101, 102.
  • the pretensioning device 220 is in particular ring-shaped.
  • the insertion 330 of the legs 12 of the conductor elements 10 of the gripped hairpin braid into the pretensioning device 220 preferably takes place until the pretensioning device 220 is arranged in the area between the center of the legs and the free ends of the legs.
  • step 340 a large number of alignment elements 221 of the prestressing device 220 are extended, with an alignment element 221 aligning at least one leg 12 of the conductor elements 10 in the tangential direction. Furthermore, when the plurality of alignment elements 221 is extended 340, the free ends 13 of the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102 are displaced inwards or outwards in the radial direction. This displacement of the free ends 13 in the radial direction during extension 340 forms or creates a lateral surface of a truncated cone as the outer envelope surface around the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102.
  • a laminated core 21 of a stator 20 of an electrical machine is provided, the laminated core having a multiplicity of slots 23.
  • the free ends 13 of the legs 12 or the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102 are placed in a positioning aid
  • the positioning aid device 240 introduced, which is arranged coaxially to the laminated core 21 of the stator 20 in the z-direction.
  • the positioning aid device 240 is provided by means of a large number of positioning aid elements
  • step 370 the free ends 13 of the legs 12 of the conductor elements 10 are inserted into the grooves 23 of the laminated core 21 .
  • the insertion in step 370 is preferably carried out by a movement of the gripping device 210 in the axial direction z from top to bottom. Provision can be made for the legs 12 of the conductor elements 10 of the hairpin braid to be pressed 380 in the radial direction outwards or inwards after the free ends 13 of the legs 12 of the conductor elements 10 have been inserted 370 into the grooves 23 of the laminated core 21 .
  • the pressing 380 takes place in particular between the positioning aid elements 241 against a bottom surface 25 of the grooves 23. This advantageously changes the outer envelope surface of the hairpin braid 100, 101, 102 from the frustoconical to a cylindrical lateral surface. Finally, the legs 12 are pushed through 390 Conductor elements 10 through the grooves 23 of the laminated core 21. The process is preferably repeated until at least two hairpin braids 100, 101, 102 are positioned in the grooves 23 of the laminated core 21.

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Abstract

The invention relates to an installation method for inserting a hairpin braid (100, 101) into stator pack slots of an electric machine, having the following process steps: providing the hairpin braid; gripping the hairpin braid, the conductor segments of the hairpin braid which are bent in a U-shaped manner being rotatable about the tangential axis; inserting the limbs (12) of the conductor segments into a pretensioning device (220) arranged coaxially to the main axis; extending a plurality of aligning elements (221) of the pretensioning device, each aligning element (221) aligning at least one limb (12) of the conductor segments in the tangential direction; providing a stator pack which has a plurality of slots; and inserting the free limb ends (13) of the conductor segments into the stator pack slots, wherein the free ends (13) of the limbs (12) are moved inwards or outwards in the radial direction upon extending the aligning elements (221) such that a truncated cone-shaped lateral surface is formed as an outer enveloping surface about the limbs (12) of the hairpin braid conductor segments.

Description

Beschreibung Description
MONTAGEVERFAHREN VON HAARNADELN EINER STECKWICKLUNG IN ZUGEHÖRIGE STATORKERNNUTEN SOWIE ZUGEHÖRIGES COMPUTERPROGRAMM UND ZUGEHÖRIGE MONTAGEANLAGE ASSEMBLY PROCEDURE OF HAIRPINS OF A PLUG-IN WINDING INTO RELATED STATOR CORE SLOTS, AS WELL AS RELATED COMPUTER PROGRAM AND RELATED ASSEMBLY EQUIPMENT
Die vorliegende Erfindung betrifft ein Montageverfahren zum Einstecken eines Hairpinzopfes einer Steckwicklung in Nuten eines Blechpakets eines Stators einer elektrischen Maschine. Die Erfindung betrifft auch ein Computerprogramm, umfassend Befehle, die bei einer Ausführung des Programms durch einen Computer diesen veranlassen, die Schritte des Montageverfahrens auszuführen. Die Erfindung betrifft des Weiteren eine Montageanlage zum Einstecken des Hairpinzopfes in die Nuten des Blechpakets des Stators, umfassend mindestens eine Greifvorrichtung und eine Vorspannvorrichtung. The present invention relates to an assembly method for inserting a hairpin braid of a plug-in winding into slots in a laminated core of a stator of an electrical machine. The invention also relates to a computer program comprising instructions which, when the program is executed by a computer, cause the latter to carry out the steps of the assembly method. The invention also relates to an assembly system for inserting the hairpin braid into the slots of the laminated core of the stator, comprising at least one gripping device and a pretensioning device.
Stand der Technik State of the art
Elektrische Maschinen können eine sogenannte Steckwicklung als elektrische Wicklung aufweisen. In Steckwicklungen weisen die Leiterelemente einen gegenüber herkömmlichen Drahtwicklungen vergleichsweise großen Leiterquerschnitt auf, wodurch der Füllfaktor in den Statornuten steigt. Als Füllfaktor bezeichnet man in der Spulenwickeltechnik das Verhältnis der effektiven Querschnittsfläche der Kupferleiter zur theoretisch maximalen Querschnittsfläche des verfügbaren Wickelfensters. Durch den höheren Füllfaktor wird unter anderem in der Regel Material eingespart, insbesondere relativ teures Kupfer. Elektrische Maschinen mit einer Steckwicklung weisen bei gleichem Bauraum auch eine höhere Effizienz beziehungsweise Leistung und eine geringere Geräuschentwicklung auf. Die typischerweise drei elektrischen Phasen einer Steckwicklung umfassen dabei vorzugsweise jeweils eine Vielzahl an U- förmigen Leiterelementen, welche an den freien Enden verschränkt sind. Die verschränkten Enden einer elektrischen Phase sind elektrisch miteinander so verbunden, dass eine Reihenschaltung der U-förmigen Leiterelemente der elektrischen Phase resultiert, wobei die Verbindung beispielsweise durch Laserschweißen erfolgt. Ein erster Teil der in Reihe verschalteten Leiterelemente einer Phase bildet so typischerweise eine erste Wellenform und ein zweiter Teil der in Reihe verschalteten Leiterelemente bildet so typischerweise eine dazu gegenläufige zweite Wellenform aus. Des Weiteren sind der erste und zweite Teil der in Reihe verschalteten Leiterelemente in der Regel in radialer Richtung nebeneinander beziehungsweise sich gegenseitig überlagernd in radialer Richtung hintereinander im Stator angeordnet und mittels eines Umkehr- oder Lagenverbinders miteinander elektrisch verbunden. Somit sind der erste und zweite Teil durch ihre gegenläufige Wellenform dazu eingerichtet, elektrische Schlaufen einer elektrischen Phase auszubilden. Demnach sind der erste und zweite Teil der in Reihe verschalteten Leiterelemente der jeweiligen elektrischen Phase der Steckwicklung bei Anregung mit Wechselstrom dazu eingerichtet, ein elektromagnetisches Statorfeld zur Anregung des Rotors der elektrischen Maschine zu erzeugen. Der Rotor kann beispielsweise alternierend angeordnete Permanentmagneten oder einen sogenannten Käfigläufer aufweisen. Im Betrieb der elektrischen Maschine werden durch eine Ansteuerung typischerweise dreier elektrischen Phasen mit jeweils phasenversetztem Wechselstrom in Umfangsrichtung umlaufende beziehungsweise rotierende magnetische Pole erzeugt, die in einer Rotation des Rotors der elektrischen Maschine resultieren. Electrical machines can have what is known as a plug-in winding as the electrical winding. In plug-in windings, the conductor elements have a comparatively large conductor cross-section compared to conventional wire windings, which increases the space factor in the stator slots. In coil winding technology, the fill factor is the ratio of the effective cross-sectional area of the copper conductor to the theoretically maximum cross-sectional area of the available winding window. Due to the higher fill factor, among other things, material is generally saved, in particular relatively expensive copper. Electrical machines with a plug-in winding also have higher efficiency or power and lower noise development with the same installation space. The typically three electrical phases of a plug-in winding preferably each comprise a large number of U-shaped conductor elements which are intertwined at the free ends. The intertwined ends of an electrical phase are electrically related to each other connected that a series connection of the U-shaped conductor elements of the electrical phase results, the connection being made, for example, by laser welding. A first part of the series-connected conductor elements of a phase thus typically forms a first waveform and a second part of the series-connected conductor elements thus typically forms a second waveform running in the opposite direction thereto. Furthermore, the first and second parts of the conductor elements connected in series are usually arranged one behind the other in the radial direction or overlapping one another in the radial direction and are electrically connected to one another by means of a reversing or layered connector. The first and second parts are therefore set up to form electrical loops of an electrical phase as a result of their opposing waveforms. Accordingly, the first and second parts of the series-connected conductor elements of the respective electrical phase of the plug-in winding are set up when excited with alternating current to generate an electromagnetic stator field for exciting the rotor of the electrical machine. The rotor can, for example, have permanent magnets arranged in alternation or a so-called squirrel-cage rotor. When the electrical machine is in operation, magnetic poles that rotate or revolve in the circumferential direction are generated by typically driving three electrical phases, each with a phase-shifted alternating current, which result in a rotation of the rotor of the electrical machine.
Die Schrift DE 10 2019 122 550 Al offenbart eine elektrische Maschine mit haarnadelförmiger Wicklung beziehungsweise einer Steckwicklung. Die elektrische Maschine beinhaltet einen Statorkern, der Nuten und Haarnadeln definiert, die in den Nuten angeordnet und an Verbindungen selektiv verbunden sind, um Wicklungen zu bilden. Eine U-förmige Brücke weist beabstandete Schenkel auf, die durch einen U- Abschnitt miteinander verbunden sind. Document DE 10 2019 122 550 A1 discloses an electrical machine with a hairpin-shaped winding or a plug-in winding. The electric machine includes a stator core defining slots and hairpins disposed in the slots and selectively connected at junctions to form windings. A U-shaped bridge has spaced legs connected by a U-section.
Die U-förmigen Leiterelemente der Steckwicklung sind typischerweise mit den beiden parallelen geraden Schenkeln beziehungsweise Hairpins parallel zur Rotationsache des Stators beziehungsweise Rotors in die Nuten des Blechpakets des Stators eingefügt beziehungsweise gesteckt, wobei vorzugsweise alle gebogene Bereiche der Leiterelemente auf einer senkrecht zur Rotationsachse vorbestimmten Seite beziehungsweise Einsteckseite des Stators angeordnet werden. Anschließend werden die freien Enden der Schenkel auf der, der vorbestimmten Seite beziehungsweise Einsteckseite gegenüberliegenden Seite des Stators verschränkt und zur Wellenform beziehungsweise zur gegenläufigen Wellenform durch Schweißen miteinander elektrisch verbunden beziehungsweise in Reihe geschaltet. Vorzugsweise ist so ein erster Hairpinzopf ausgebildet, welcher den jeweils ersten Teil aller in Reihe verschalteten Leiterelemente dreier elektrischer Phasen umfasst. Des Weiteren ist vorzugsweise analog ein zweiter Hairpinzopf ausgebildet, welcher den jeweils zweiten Teil aller in Reihe verschalteten Leiterelemente dreier elektrischer Phasen umfasst. Ein sogenannter Hairpinkorb beziehungsweise Wickelkopf umfasst wenigstens den ersten und den zweiten Hairpinzopf. Es kann vorgesehen sein, dass der Hairpinkorb mehr als zwei Hairpinzöpfe umfasst. Anschließend wird gemäß dem bekannten Stand der Technik der erste und der zweite Hairpinzopf zusammen beziehungsweise der Hairpinkorb als Ganzes in die Nuten des Stators gesteckt. Anschließend werden nach der Anordnung des Hairpinkorbs im Stator die freien Enden der geraden Schenkel verschränkt und elektrisch verbunden sowie die jeweiligen elektrischen Wicklungen der gleichen elektrischen Phase der verschiedenen Hairpinzöpfe mittels eines Lagen- oder Umkehrverbinders miteinander elektrisch verbunden. Die Montage der Steckwicklung ist technisch und wirtschaftlich anspruchsvoll, da eine Vielzahl an Prozessschritten resultiert, beispielsweise durch das Anordnen der Vielzahl an Leiterelementen, mit dem ineinandergreifen der gebogenen Bereiche, zu dem Hairpinzopf beziehungsweise Hairpinkorb. The U-shaped conductor elements of the plug-in winding are typically inserted or plugged into the slots of the laminated core of the stator with the two parallel, straight legs or hairpins parallel to the axis of rotation of the stator or rotor, with preferably all curved areas of the conductor elements on a predetermined side or Plug-in side of the stator are arranged. Then the free ends of the legs are intertwined on the side of the stator opposite the predetermined side or the plug-in side and welded to one another to form the waveform or the opposite waveform electrically connected or connected in series. A first hairpin braid is preferably formed in this way, which encompasses the respective first part of all series-connected conductor elements of three electrical phases. Furthermore, a second hairpin braid is preferably formed analogously, which includes the respective second part of all series-connected conductor elements of three electrical phases. A so-called hairpin basket or winding head comprises at least the first and the second hairpin braid. It can be provided that the hairpin basket comprises more than two hairpin braids. Then, according to the known prior art, the first and the second hairpin braid or the hairpin basket as a whole is inserted into the slots of the stator. Then, after the arrangement of the hairpin basket in the stator, the free ends of the straight legs are intertwined and electrically connected, and the respective electrical windings of the same electrical phase of the different hairpin braids are electrically connected to one another by means of a layer or reversing connector. The assembly of the plug-in winding is technically and economically demanding, since a large number of process steps result, for example by arranging the large number of conductor elements with the interlocking of the curved areas to form the hairpin braid or hairpin basket.
Das Dokument DE 10 2018 121 745 Al offenbart ein Verfahren zum Herstellen einer Anordnung von Spulenelementen für eine Steckspule einer elektrischen Maschine, wobei eine mindestens einlagige Anordnung von stabförmig ausgebildeten Spulenelementen für eine Steckspule einer elektrischen Maschine an einem Werkstückträger hergestellt und die mindestens einlagige Anordnung der Spulenelemente nach dem Übernehmen der Spulenelemente mittels einer Greifeinrichtung an dem Werkstückträger gehalten wird. The document DE 10 2018 121 745 A1 discloses a method for producing an arrangement of coil elements for a plug-in coil of an electrical machine, wherein an at least single-layer arrangement of rod-shaped coil elements for a plug-in coil of an electrical machine is produced on a workpiece carrier and the at least single-layer arrangement of the coil elements is held on the workpiece carrier by means of a gripping device after the coil elements have been taken over.
Die Schrift DE 10 2019 120 261 Al offenbart eine Kranzanordnungs- und - fügevorrichtung zum Bilden und Einfügen einer Kranzanordnung aus wenigstens einem Kranz oder mehreren konzentrisch angeordneten Kränzen von vorzugsweise U- förmigen elektrischen Leitern in ein Bauteil einer elektrischen Maschine. Document DE 10 2019 120 261 A1 discloses a rim arrangement and joining device for forming and inserting a rim arrangement from at least one rim or a plurality of concentrically arranged rims of preferably U-shaped electrical conductors in a component of an electrical machine.
Die Schrift DE 10 2018 114 875 Al offenbart eine Vorrichtung zur Herstellung eines mit Wicklungen versehenen Maschinenelements für eine elektrische Maschine, umfassend: mindestens eine Hilfsvorrichtung zur Bereitstellung vorgesteckter Hairpins, die so zueinander ausgerichtet sind wie im herzustellenden Maschinenelement; und eine Fügeinrichtung zur Entnahme der zueinander ausgerichteten Hairpins aus der Hilfsvorrichtung und zum Einbringen in ein Maschinenelement. Document DE 10 2018 114 875 A1 discloses a device for producing a machine element provided with windings for an electrical machine, comprising: at least one auxiliary device for providing pre-inserted hairpins which are aligned with one another as in the machine element to be produced; and a joining device for removing the mutually aligned hairpins from the auxiliary device and for introducing them into a machine element.
Das Dokument DE 10 2019 124488 Al offenbart eine Vorrichtung zur Bestückung eines Statorkerns mit Leiterstücken, die insbesondere mit rechteckigem Leiterquerschnitt ausgebildet sind. Die Vorrichtung umfasst eine Aufnahme zur spielbehafteten Aufnahme der Leiterstücke. Die Leiterstücke sind dabei in einer Konfiguration, die einer zum Einsetzen in einen Statorkern vorgesehenen Konfiguration der Leiterstücke entspricht, in der Aufnahme angeordnet. Die Vorrichtung weist eine Greifvorrichtung auf, die dazu dient, die in der Aufnahme spielbehaftet gehaltenen Leiterstücke aus dieser zu entnehmen, und in einer vorgesehenen endgültigen Anordnung in den Statorkern einzusetzen. Es ist vorgesehen, dass die Greifvorrichtung eine Ausrichteinrichtung umfasst. Die Ausrichteinrichtung ist ausgebildet, um in einem Greifvorgang mehrere in der Aufnahme spielbehaftet gehaltene und radial erstreckt angeordnete Leiterstückreihen jeweils in ihrer vorgesehenen Reihenanordnung aneinander anliegend radial erstreckt auszurichten. Dabei liegt die jeweilige Leiterstückreihe in radialer Richtung an einem radialen Anschlag an und die einzelnen Leiterstücke der Leiterstückreihe werden umfänglich beidseitig durch die Ausrichteinrichtung kontaktiert. Eine separat ausgebildete Gegenlagereinrichtung ist ausgebildet und angeordnet, um in dem Greifvorgang der Greifvorrichtung einen radialen Anschlag auf einer zweiten radialen Seite zu bilden (der ersten radialen Seite gegenüberliegend angeordnet). Die Greifvorrichtung ist ausgebildet, um die Leiterstücke der jeweiligen Reihenanordnung bzw. Leiterstückreihe zwischen dem radialen Anschlag der Ausrichteinrichtung und dem radialen Anschlag der Gegenlagereinrichtung klemmend zu fixieren. Die aus DE 10 2019 124488 Al offenbarte Vorrichtung erlaubt einen Griff aller Haipins in einem Greifvorgang. Nach einer vorteilhaften Ausgestaltung der beanspruchten Vorrichtung, weist die Ausrichteinrichtung mehrere gabelförmige Aufnehmer auf, die jeweils dazu ausgebildet und angeordnet sind die Leiterstücke einer Reihenanordnung zu erfassen, wobei die Greifvorrichtung insbesondere derart ausgebildet ist, dass die jeweiligen gabelförmigen Aufnehmer im Greifvorgang jeweils in radialer Richtung auf die Leiterstücke einer jeweiligen Reihenanordnung aufgeschoben werden. Die Leiterstücke einer Reihenanordnung werden durch die Ausrichteinrichtung fluchtend zueinander ausgerichtet und die einzelnen Reihenanordnungen werden in ihrer Winkelstellung in Umfangsrichtung festgelegt. Die Aufgabe der vorliegenden Erfindung ist es, ein Montageverfahren zum Einstecken eines bereitgestellten Hairpinzopfes mit U-förmigen Leiterelementen in die Nuten eines Stators zu verbessern. The document DE 10 2019 124488 A1 discloses a device for equipping a stator core with conductor pieces which are designed in particular with a rectangular conductor cross section. The device includes a receptacle for receiving the conductor sections with play. The conductor pieces are arranged in the receptacle in a configuration which corresponds to a configuration of the conductor pieces intended for insertion into a stator core. The device has a gripping device, which is used to remove the conductor pieces held with play in the receptacle from the receptacle and to insert them into the stator core in the intended final arrangement. It is provided that the gripping device comprises an alignment device. The aligning device is designed to align, in a gripping process, a plurality of rows of conductor pieces which are held with play in the receptacle and which are arranged in a radially extending manner in their intended row arrangement so that they rest against one another in a radially extending manner. The respective row of conductor pieces bears against a radial stop in the radial direction and the individual conductor pieces of the row of conductor pieces are contacted circumferentially on both sides by the alignment device. A separately formed abutment means is formed and arranged to form a radial stop on a second radial side (located opposite the first radial side) in the gripping operation of the gripping device. The gripping device is designed to fix the conductor sections of the respective row arrangement or conductor section row in a clamping manner between the radial stop of the alignment device and the radial stop of the counter-bearing device. The device disclosed in DE 10 2019 124488 A1 allows all the shark pins to be gripped in one gripping process. According to an advantageous embodiment of the claimed device, the alignment device has a plurality of fork-shaped pickups, each of which is designed and arranged to grasp the conductor sections of a row arrangement, with the gripping device being designed in particular in such a way that the respective fork-shaped pickups each open in the radial direction during the gripping process the conductor pieces of a respective row arrangement are pushed on. The conductor sections of a row arrangement are aligned with one another by the alignment device and the individual row arrangements are fixed in their angular position in the circumferential direction. The object of the present invention is to improve an assembly method for inserting a provided hairpin braid with U-shaped conductor elements into the slots of a stator.
Offenbarung der Erfindung Disclosure of Invention
Die vorstehende Aufgabe wird erfindungsgemäß entsprechend der unabhängigen Ansprüche 1, 6 und 7 gelöst. The above object is achieved according to the invention according to independent claims 1, 6 and 7.
Die vorliegende Erfindung betrifft ein Montageverfahren zum Einstecken beziehungsweise zur Positionierung eines Hairpinzopfes einer Steckwicklung in den Nuten eines Blechpaktes eines Stators. Das Montageverfahren umfasst eine Bereitstellung des Hairpinzopfes einer elektrischen Wicklung für eine elektrische Maschine. Der Hairpinzopf wurde vorteilhafterweise in einem in dieser Anmeldung nicht näher beschriebenen Vormontageprozess hergestellt. Der Hairpinzopf weist vorzugsweise eine Vielzahl an separaten kreisförmig nebeneinander angeordneten U- förmig gebogenen Leiterelementen mit jeweils zwei geraden Schenkeln beziehungsweise Hairpinfüßen beziehungsweise Haarnadeln auf, wobei vorzugsweise wenigstens zwei benachbarte U-förmig gebogene Leiterelemente in radialer Richtung hintereinander angeordnet sind und deren gebogene Bereiche ineinandergreifen. In einem anschließenden Schritt des Montageverfahrens wird der Hairpinzopf gegriffen, wobei das Greifen des Hairpinzopfes insbesondere im gebogenen Bereich der Leiterelemente erfolgt. Dabei werden bevorzugt die U-förmig gebogenen Leiterelemente an wenigstens einem jeweiligen Auflagepunkt im gebogenen Bereich der Leiterelemente gegriffen und somit in z-Richtung und in radialer Richtung positioniert beziehungsweise fixiert. Die U-förmig gebogenen Leiterelemente werden um die Tangentialachse drehbar gelagert. Durch das Greifen werden vorteilhafterweise die Lage der Schenkel sowie die Position der freien Enden der Schenkel der Leiterelemente des Hairpinzopfes im Wesentlichen durch die Gewichtskraft und die Auflagepunkte an der Greifvorrichtung definiert, weshalb vorteilhafterweise die Position der Schenkel sowie die Position der freien Enden der Schenkel der Leiterelemente des Hairpinzopfes zunächst eine hohe Lage- und Winkeltoleranz aufweisen. Anschließend werden die Schenkel der Leiterelemente des gegriffenen Hairpinzopfes in eine koaxial zur Achse des Hairpinzopfes angeordnete Vorspannvorrichtung eingeführt. Die Vorspannvorrichtung ist insbesondere ringförmig, das heißt die Schenkel der Leiterelemente des gegriffenen Hairpinzopfes werden vorzugsweise in die koaxial zur Achse des Hairpinzopfes angeordnete Vorspannvorrichtung eingeführt, so dass die Vorspannvorrichtung vorteilhafterweise um die Schenkel der Leiterelemente herum angeordnet ist. Die Vorspannvorrichtung ist bevorzugt senkrecht beziehungsweise koaxial zur Achse des Hairpinzopfes angeordnet. Danach werden eine Vielzahl von Ausrichtelementen der Vorspannvorrichtung ausgefahren, wobei ein Ausrichtelement zumindest einen Schenkel der Leiterelemente in tangentialer Richtung ausrichtet. Beispielsweise wird ein Ausrichtelement jeweils zwischen zwei Schenkeln angeordnet, so dass vorteilhafterweise die Schenkel der Leiterelemente in tangentialer Richtung positioniert beziehungsweise ausgerichtet sind. Des Weiteren werden beim Ausfahren der Vielzahl von Ausrichtelementen die freien Enden der Schenkel der Leiterelemente des Hairpinzopfes in radialer Richtung nach innen oder außen verschoben, insbesondere mittels eines mechanischen Anschlags der Ausrichteelemente, so dass als äußere Hüllfläche um die Schenkel des Hairpinzopfes eine Mantelfläche eines Kegelstumpfes ausgebildet wird. Die Verschiebung der freien Enden der Schenkel der Leiterelemente des Hairpinzopfes erfolgt insbesondere in radialer Richtung nach innen. Anschließend wird ein Blechpaket eines Stators einer elektrischen Maschine bereitgestellt, wobei das Blechpaket eine Vielzahl an geraden Nuten zur Aufnahme der Schenkel der Leiterelemente des Hairpinzopfes aufweist. Die Nuten umfassen insbesondere jeweils ein Isolationpapier, welches bevorzugt am äußeren Umfang der jeweiligen Nut angeordnet ist. Das Blechpaket des Stators und der Hairpinzopf werden vorteilhafterweise mit der Rotationsachse koaxial zueinander angeordnet beziehungsweise ausgerichtet. In einem anschließenden Schritt werden die freien Enden der Schenkel der Leiterelemente in die Nuten des Stators eingesteckt beziehungsweise eingeführt beziehungsweise in den Nuten positioniert, vorzugsweise durch eine Bewegung des Hairpinzopfes in z-Richtung von oben nach unten. Das Verfahren weist gegenüber bekannten Verfahren den Vorteil auf, dass ein direktes Einstecken der einzelnen Hairpinzöpfe in das Blechpaket des Stators mit erhöhter Geschwindigkeit erfolgt. Des Weiteren erleichtert die kegelstumpfförmige Mantelfläche der äußeren Hüllfläche des Hairpinzopfes das nacheinander Einstecken mehrerer Hairpinzöpfe, da die gebogenen Bereiche der Vielzahl der Leiterelemente eines Hairpinzopfes das Einstecken eines nachfolgenden Hairpinzopfs nicht behindert. Darüber hinaus resultiert der Vorteil, dass durch die geringere Lagetoleranz der Schenkel der Leiterelemente, welche auf der erzeugten kegelstumpfförmigen Mantelfläche der äußeren Hüllfläche des Hairpinzopfes basiert, in einer genaueren Einsteckposition beziehungsweise in einer geringeren Toleranz der Steckposition der geraden Schenkel der Leiterelemente in die Nuten resultiert, wodurch das Einstecken beziehungsweise Einführen der Schenkel in die Nuten, welche vorzugsweise ein Isolationspapier aufweisen, erleichtert ist. Es resultiert des Weiteren durch das Montageverfahren ein Kostenvorteil, da keine Hilfsvorrichtung benötigt wird, in der alle Hairpinzöpfe zu einem Hairpinkorb vereint werden. Außerdem weist die vorliegende Erfindung den Vorteil auf, dass die benötigte Einsteckkraft eines einzelnen Hairpinzopfes in den Stator beziehungsweise das Blechpaket des Stators gegenüber einem klassischen Stecken des ganzen Hairpinkorbs reduziert ist, wodurch auch das Einstecken der Schenkel in die Statornuten mit Isolationspapier vorteilhafterweise erleichtert beziehungsweise fehlerfreier wird, da das Isolationpapier dabei weniger beschädigt wird. Das Montageverfahren der vorliegenden Erfindung weist außerdem den Vorteil einer großen Flexibilität bezüglich der Größe der Hairpinzöpfe sowie bezüglich der Verschränkung der gebogenen Bereiche der U-förmigen Leiterelemente und bezüglich der Anzahl der Hairpinzöpfe auf. The present invention relates to an assembly method for inserting or for positioning a hairpin braid of a plug-in winding in the slots of a laminated core of a stator. The assembly method includes providing the hairpin braid of an electrical winding for an electrical machine. The hairpin braid was advantageously produced in a pre-assembly process that is not described in detail in this application. The hairpin braid preferably has a large number of separate U-shaped conductor elements arranged next to one another in a circle, each with two straight legs or hairpin feet or hairpins, with at least two adjacent U-shaped conductor elements preferably being arranged one behind the other in the radial direction and their curved areas interlocking. In a subsequent step of the assembly method, the hairpin braid is gripped, the hairpin braid being gripped in particular in the curved region of the conductor elements. In this case, the conductor elements bent in a U-shape are preferably gripped at at least one respective support point in the bent region of the conductor elements and thus positioned or fixed in the z-direction and in the radial direction. The U-shaped conductor elements are pivoted around the tangential axis. By gripping, the position of the legs and the position of the free ends of the legs of the conductor elements of the hairpin braid are advantageously essentially defined by the weight and the contact points on the gripping device, which is why the position of the legs and the position of the free ends of the legs of the conductor elements are advantageously defined of the hairpin braid initially have a high position and angle tolerance. Subsequently, the legs of the conductor elements of the gripped hairpin braid are introduced into a pretensioning device arranged coaxially to the axis of the hairpin braid. The biasing device is in particular ring-shaped, that is, the legs of the conductor elements of the gripped hairpin braid are preferably coaxial with the Axis of the hairpin braid arranged biasing device introduced so that the biasing device is advantageously arranged around the legs of the conductor elements. The prestressing device is preferably arranged perpendicularly or coaxially to the axis of the hairpin braid. A large number of alignment elements of the prestressing device are then extended, with one alignment element aligning at least one leg of the conductor elements in the tangential direction. For example, an alignment element is arranged in each case between two legs, so that the legs of the conductor elements are advantageously positioned or aligned in the tangential direction. Furthermore, when the plurality of alignment elements are extended, the free ends of the legs of the conductor elements of the hairpin braid are shifted inwards or outwards in the radial direction, in particular by means of a mechanical stop of the alignment elements, so that a lateral surface of a truncated cone is formed as the outer envelope surface around the legs of the hairpin braid becomes. The displacement of the free ends of the legs of the conductor elements of the hairpin braid takes place in particular in the radial direction inwards. A laminated core of a stator of an electrical machine is then provided, the laminated core having a multiplicity of straight grooves for receiving the legs of the conductor elements of the hairpin braid. In particular, the grooves each comprise an insulating paper which is preferably arranged on the outer circumference of the respective groove. The laminated core of the stator and the hairpin braid are advantageously arranged or aligned coaxially to one another with the axis of rotation. In a subsequent step, the free ends of the legs of the conductor elements are inserted or introduced into the slots of the stator or positioned in the slots, preferably by moving the hairpin braid in the z-direction from top to bottom. The method has the advantage over known methods that the individual hairpin braids are inserted directly into the laminated core of the stator at increased speed. Furthermore, the truncated cone-shaped lateral surface of the outer enveloping surface of the hairpin plait facilitates the successive insertion of several hairpin plaits, since the curved areas of the plurality of conductor elements of a hairpin plait do not prevent the insertion of a subsequent hairpin plait. In addition, there is the advantage that the lower positional tolerance of the legs of the conductor elements, which is based on the generated frustoconical lateral surface of the outer envelope surface of the hairpin braid, results in a more precise insertion position or in a lower tolerance of the insertion position of the straight legs of the conductor elements in the grooves, whereby the insertion or insertion of the legs into the grooves, which preferably a Have insulation paper is facilitated. Furthermore, the assembly method results in a cost advantage, since no auxiliary device is required in which all hairpin braids are combined to form a hairpin basket. In addition, the present invention has the advantage that the required insertion force of an individual hairpin braid into the stator or the laminated core of the stator is reduced compared to a classic insertion of the entire hairpin basket, which also advantageously makes it easier or more error-free to insert the legs into the stator slots with insulating paper , since the insulation paper is less damaged. The assembly method of the present invention also has the advantage of great flexibility in terms of the size of the hairpins, the interlacing of the bent portions of the U-shaped conductor members, and the number of hairpins.
In einer bevorzugten Ausführung wird beim Einführen des Hairpinzopfes in die Vorspannvorrichtung die Vorspannvorrichtung im Bereich zwischen der Mitte der geraden Schenkel der Leiterelemente und den freien Enden der Schenkel der Leiterelemente angeordnet. In dieser Ausgestaltung wird die kegelstumpfförmige Mantelfläche der äußeren Hüllfläche des Hairpinzopfes mit einer höheren Maßtoleranz erzeugt, wodurch das Einstecken der Schenkel in die Statornuten beziehungsweise der Gesamtprozess fehlerfreier wird beziehungsweise die Prozesssicherheit des Verfahrens gesteigert wird. Außerdem wird eine geringere Kraft zu Verschiebung der freien Enden der Schenkel in radialer Richtung benötigt. In a preferred embodiment, when inserting the hairpin braid into the pretensioning device, the pretensioning device is arranged in the area between the middle of the straight legs of the ladder elements and the free ends of the legs of the ladder elements. In this embodiment, the truncated cone-shaped lateral surface of the outer envelope surface of the hairpin braid is produced with a higher dimensional tolerance, which means that the insertion of the legs into the stator slots or the overall process becomes more error-free or the process reliability of the method is increased. In addition, less force is required to move the free ends of the legs in the radial direction.
In einer weiteren vorteilhaften Ausführung erfolgt vor dem Einstecken der Schenkel der Leiterelemente in die Nuten des Stators eine Einführung der freien Enden der Schenkel der Leiterelemente des Hairpinzopfes in eine Positionierhilfseinrichtung. Die Positionierhilfseinrichtung wird in z-Richtung koaxial zum Stator angeordnet, wobei die Positionierhilfseinrichtung mittels einer Vielzahl an Positionierhilfselementen dazu eingerichtet ist, die Schenkel der Leiterelemente oberhalb der Nuten des Stators auszurichten. Zu diesem Zweck weisen die Positionierhilfselemente jeweils an der Oberseite zur Vorspanneinrichtung hin mindestens eine zur z-Richtung abgewinkelte Führungsfläche auf. Durch diese Ausführung wird die Positioniergenauigkeit des Einsteckens beziehungsweise der Einführung der freien Enden der Schenkel der Leiterelemente in die Nuten des Blechpakets des Stators gesteigert und somit beispielsweise die Beschädigung eines Isolationspapiers in den Nuten des Blechpakets zuverlässig vermieden. In einer Weiterführung der Erfindung wird nach dem Einstecken beziehungsweise nach der Einführung der freien Enden der Schenkel der Leiterelemente in die Nuten des Blechpakets des Stators eine Anpressung der Schenkel der Leiterelemente des Hairpinzopfes in radialer Richtung nach außen oder innen durchgeführt. Die vorherige Einführung beziehungsweise das Einstecken der Schenkel der Leiterelemente in die Nuten erfolgt insbesondere nur für eine kurze Strecke, das heißt beispielsweise werden die freien Enden der Schenkel nur für eine Strecke kleiner oder gleich fünf Zentimeter eingesteckt und anschließend angepresst, insbesondere erfolgt das Einstecken der freien Enden der Schenkel in die Nuten für eine Strecke kleiner oder gleich drei Zentimeter und besonderes bevorzugt für eine Strecke kleiner oder gleich einem Zentimeter. Insbesondere erfolgt die Anpressung jeweils zwischen zwei Positionierhilfselementen und gegen den Stator oder gegen einen bereits vorher in die Nuten des Stators durchgesteckten beziehungsweise vollständig eingeführten Hairpinzopf. Durch die Anpressung wird vorteilhafterweise die äußere Hüllfläche des Hairpinzopfes von der kegelstumpfförmigen in eine zylindrische Mantelfläche geändert beziehungsweise überführt. Anschließend werden die Schenkel der Leiterelemente durch die Nuten des Stators durchgesteckt beziehungsweise vollständig durch die Nuten des Stators geführt, insbesondere bis die freien Enden der Schenkel die Nuten auf einer zur Einsteckseite gegenüberliegenden Seite des Stators verlassen. Vorzugsweise erfolgt die Anpressung zumindest eines Teils der Schenkel oder jedes Schenkels der Leiterelemente des Hairpinzopfes in radialer Richtung von innen nach außen zwischen jeweils zwei Positionierhilfselementen, insbesondere mittels einer Spannvorrichtung. Vorzugsweise werden nach dem Einstecken beziehungsweise nach der Einführung der Schenkel der Leiterelemente in die Nuten des Stators die Ausrichtelemente zumindest in radialer Richtung zumindest teilweise eingefahren beziehungsweise entfernt. Durch die Anpressung wird vorteilhafterweise die äußeren Hüllfläche des Hairpinzopfes von der kegelstumpfförmigen Mantelfläche zu einer näherungsweise zylindrischen Mantelfläche überführt beziehungsweise geändert, so dass die geraden Schenkel der Leiterelemente vollständig durch die Nuten des Stators geführt beziehungsweise durchgesteckt werden können. Die Anpressung, insbesondere mittels der Spanneinrichtung, ist des Weiteren vorteilhafterweise dazu eingerichtet, einen aktuell eingesteckten Hairpinzopf an den letzten eingesteckten Hairpinzopf aufzuschieben und/oder anzudrücken. Durch die Anpressung kann vorteilhafterweise der Füllfaktor weiter gesteigert werden, da ein Luftspalt minimiert werden kann. In einer Weiterführung kann eine zusätzliche Klebung zwischen den Hairpinzöpfen durch eine Andrückkraft unterstützt werden, wobei eine zusätzliche Klebung zwischen Hairpinzöpfen auch Vibrationen der elektrischen Maschine im Betrieb minimiert. In a further advantageous embodiment, before the legs of the conductor elements are inserted into the slots of the stator, the free ends of the legs of the conductor elements of the hairpin braid are introduced into a positioning aid. The positioning aid is arranged coaxially to the stator in the z-direction, with the positioning aid being set up by means of a large number of positioning aids to align the legs of the conductor elements above the slots of the stator. For this purpose, the positioning aid elements each have at least one guide surface angled toward the z-direction on the upper side toward the prestressing device. This design increases the positioning accuracy of the insertion or the introduction of the free ends of the legs of the conductor elements into the slots of the laminated core of the stator and thus, for example, damage to insulating paper in the slots of the laminated core is reliably avoided. In a further development of the invention, after the insertion or after the introduction of the free ends of the legs of the conductor elements into the grooves of the laminated core of the stator, the legs of the conductor elements of the hairpin braid are pressed radially outwards or inwards. The previous insertion or insertion of the legs of the conductor elements into the grooves takes place in particular only for a short distance, i.e. for example the free ends of the legs are only inserted for a distance less than or equal to five centimeters and then pressed on, in particular the free ends are inserted The legs end in the grooves for a distance of less than or equal to three centimeters, and more preferably for a distance of less than or equal to one centimeter. In particular, the pressing takes place in each case between two positioning aids and against the stator or against a hairpin braid that has already been pushed through or completely inserted into the slots of the stator. The pressing action advantageously changes or converts the outer envelope surface of the hairpin braid from the frustoconical to a cylindrical surface. The legs of the conductor elements are then pushed through the slots of the stator or guided completely through the slots of the stator, in particular until the free ends of the legs leave the slots on a side of the stator opposite the insertion side. Preferably, at least part of the legs or each leg of the conductor elements of the hairpin braid are pressed on in the radial direction from the inside to the outside between two positioning aids, in particular by means of a clamping device. Preferably, after the legs of the conductor elements have been inserted or introduced into the slots of the stator, the alignment elements are at least partially retracted or removed at least in the radial direction. The contact pressure advantageously converts or changes the outer envelope surface of the hairpin braid from the frustoconical lateral surface to an approximately cylindrical lateral surface, so that the straight legs of the conductor elements can be guided or inserted completely through the slots of the stator. The pressing, in particular by means of the tensioning device, is also advantageously set up to push and/or press a currently inserted hairpin braid onto the last inserted hairpin braid. The filling factor can advantageously be further increased by the contact pressure, since an air gap can be minimized. In a further development, additional adhesion between the hairpin braids can be supported by a pressing force, with an additional Bonding between hairpin braids also minimizes vibrations of the electric machine during operation.
Vorzugsweise wird das Verfahren so oft wiederholt, bis mindestens zwei Hairpinzöpfe in den Nuten des Blechpakets des Stators positioniert sind. Durch das Hintereinander Einstecken mehrere Hairpinzöpfe können Fertigungsschritte parallelisiert werden, wodurch Fertigungskosten reduziert werden. The method is preferably repeated until at least two hairpin braids are positioned in the slots of the laminated core of the stator. By inserting several hairpin braids one after the other, production steps can be parallelized, which reduces production costs.
Die Erfindung betrifft auch ein Computerprogramm, umfassend Befehle, die bei der Ausführung des Programms durch einen Computer diesen veranlassen, die Schritte des Verfahrens nach einem der vorhergehenden Ansprüche auszuführen. The invention also relates to a computer program comprising instructions which, when the program is executed by a computer, cause the latter to carry out the steps of the method according to one of the preceding claims.
Die Erfindung betrifft des Weiteren eine Montageanlage zum Einstecken beziehungsweise zur Positionierung eines Hairpinzopfes in den Nuten eines Blechpakets eines Stators. Die Montageanlage weist zumindest eine Greifvorrichtung auf, welche dazu eingerichtet ist, einen bereitgestellten Hairpinzopf zu greifen. Der bereitgestellte Hairpinzopf weist vorzugsweise die Vielzahl an separaten kreisförmig nebeneinander angeordneten U-förmig gebogenen Leiterelementen mit jeweils zwei geraden Schenkeln beziehungsweise Hairpinfüßen auf. Die Greifvorrichtung ist ferner insbesondere dazu eingerichtet, die U-förmig gebogenen Leiterelemente im gebogenen Bereich an zumindest einem Auflagepunkt in z-Richtung und in radialer Richtung zu greifen beziehungsweise zu positionieren. Die Greifvorrichtung ist dazu eingerichtet, die U-förmig gebogenen Leiterelemente des Hairpinzopfes um die Tangentialachse drehbar zu lagern. Die Montageanlage umfasst des Weiteren zumindest eine Vorspannvorrichtung, welche eine Vielzahl von Ausrichtelementen aufweist. Die Ausrichteelemente sind jeweils dazu eingerichtet, zumindest einen Schenkel der Leiterelemente in tangentialer Richtung auszurichten. Beispielsweise sind die Vielzahl von Ausrichtelementen dazu eingerichtet, in radialer Richtung nach innen oder außen zwischen jeweils zwei Schenkel der Leiterelemente des Hairpinzopfes ausgefahren zu werden, wobei die Schenkel in tangentialer Richtung positioniert beziehungsweise ausgerichtet werden. Die Vorspannvorrichtung ist insbesondere ringförmig. Erfindungsgemäß weist zumindest ein Teil der Ausrichtelemente mindestens einen mechanischen Anschlag auf. Die Vorspannvorrichtung ist mittels der mechanischen Anschläge der Ausrichtelemente dazu eingerichtet, die freien Enden der Schenkel in radialer Richtung nach innen oder außen zu verschieben, so dass als äußere Hüllfläche um die Schenkel der U-förmig gebogenen Leiterelemente des Hairpinzopfes eine kegelstumpfförmige Mantelfläche resultiert. Die Greifvorrichtung ist weiter dazu eingerichtet, zumindest in z-Richtung bewegt zu werden, um die freien Enden der Schenkel der U-förmig gebogenen Leiterelemente des gegriffenen Hairpinzopfes in z-Richtung von oben nach unten in die Nuten eines bereitgestellten Stators einer elektrischen Maschine einzuführen beziehungsweise einzustecken. Durch die erfindungsgemäße Montageanlage wird eine hohe Lagegenauigkeit der freien Enden der Schenkel der Leiterelemente beim Einstecken von U-förmig gebogenen Leiterelementen einer Steckwicklung in mit Isolationspapier aufweisende Nuten eines Stators erzielt, wodurch die Prozesssicherheit steigt und die Fehlerquote des Einsteckprozesses, beispielsweise durch Beschädigung des Isolationspapiers, einer Steckwicklung reduziert wird. Des Weiteren resultieren die Vorteile des oben beschriebenen erfindungsgemäßen Verfahrens. Darüber hinaus erlaubt die erfindungsgemäße Montageanlage eine größere Parallelisierung der Prozessschritte in der Fertigung der elektrischen Maschine beziehungsweise des Stators, da unterschiedliche Hairpinzöpfe nacheinander eingesteckt und damit eine höhere Taktgeschwindigkeit des Gesamtprozesses erzielt werden kann, wodurch Fertigungskosten reduziert werden. The invention also relates to an assembly system for inserting or for positioning a hairpin braid in the slots of a laminated core of a stator. The assembly system has at least one gripping device which is set up to grip a provided hairpin braid. The hairpin braid provided preferably has the multiplicity of separate U-shaped conductor elements arranged next to one another in a circle, each with two straight legs or hairpin feet. The gripping device is also set up in particular to grip or position the conductor elements bent in a U-shape in the bent area at at least one support point in the z-direction and in the radial direction. The gripping device is set up to mount the conductor elements of the hairpin braid, which are bent in a U-shape, so that they can rotate about the tangential axis. The assembly system also includes at least one pretensioning device, which has a large number of alignment elements. The alignment elements are each set up to align at least one leg of the conductor elements in the tangential direction. For example, the plurality of aligning elements are set up to be extended in the radial direction inwards or outwards between each two legs of the conductor elements of the hairpin braid, the legs being positioned or aligned in the tangential direction. The prestressing device is in particular ring-shaped. According to the invention, at least some of the alignment elements have at least one mechanical stop. The prestressing device is set up by means of the mechanical stops of the alignment elements to move the free ends of the legs inwards or outwards in the radial direction, so that the outer envelope surface around the legs of the U-shaped conductor elements of the hairpin braid is a truncated cone-shaped lateral surface results. The gripping device is also set up to be moved at least in the z-direction in order to insert the free ends of the legs of the U-shaped conductor elements of the gripped hairpin braid in the z-direction from top to bottom into the slots of a provided stator of an electrical machine plug in The assembly system according to the invention achieves high positional accuracy of the free ends of the legs of the conductor elements when inserting U-shaped conductor elements of a plug-in winding into slots in a stator that have insulating paper, which increases process reliability and reduces the error rate of the plug-in process, for example due to damage to the insulating paper. a plug-in winding is reduced. Furthermore, the advantages of the method according to the invention described above result. In addition, the assembly system according to the invention allows greater parallelization of the process steps in the production of the electrical machine or the stator, since different hairpin braids can be inserted one after the other and thus a higher cycle speed of the overall process can be achieved, thereby reducing production costs.
In einer besonders bevorzugten Weiterführung weist die Montageanlage zusätzlich eine Positionierhilfseinrichtung auf. Die Positionierhilfseinrichtung ist dazu eingerichtet, in z-Richtung unterhalb der Vorspannvorrichtung und oberhalb des bereitgestellten Blechpakets des Stators beziehungsweise zwischen der der Vorspannvorrichtung und dem Blechpaket koaxial zum Blechpaket des Stators und koaxial zur Vorspannvorrichtung angeordnet zu sein. Die Positionierhilfseinrichtung ist insbesondere dazu eingerichtet, unmittelbar oberhalb des Stators angeordnet zu sein. Die Positionierhilfseinrichtung ist insbesondere ringförmig. Die Positionierhilfseinrichtung weist eine Vielzahl an Positionierhilfselementen auf. Jedes Positionierhilfselement wird oberhalb eines Stegs des Stators angeordnet und weist insbesondere an der Oberseite zur Vorspanneinrichtung hin mindestens eine zur z- Richtung abgewinkelte Führungsfläche auf. Die Positionierhilfselemente sind dazu eingerichtet, die freien Enden der Schenkel der Leiterelemente zu den Nuten des Blechpakets auszurichten. Durch die Anordnung der Positionierhilfseinrichtung resultiert eine hohe Maßgenauigkeit bezüglich der Positionierung der freien Enden der Schenkel der Leiterelemente während des Einsteckens in die Nuten des Stators, so dass insbesondere ein Verknicken oder eine Beschädigung eines Isolationspapiers in den Nuten des Stators sehr zuverlässig vermieden wird. Vorzugsweise umfasst die Montageanlage des Weiteren eine Spannvorrichtung, welche koaxial zum Stator und innerhalb oder außerhalb des Hairpinzopfes angeordnet und dazu eingerichtet ist, die eingeführten Schenkel der U-förmig gebogenen Leiterelemente des Hairpinzopfes in radialer Richtung mittels einer Vielzahl von Schiebern nach außen oder innen zu verschieben beziehungsweise an eine Fläche anzupressen, insbesondere erfolgt diese Anpressung zwischen den Positionierhilfselementen und gegen die jeweiligen Bodenflächen der Nuten des Blechpakets des Stators oder gegen die äußere Fläche eines bereits durchgesteckten und im Blechpaket angeordneten anderen Hairpinzopf. Die Spannvorrichtung ist vorzugsweise dazu eingerichtet, innerhalb des Hairpinzopfes und vorteilhafterweise unmittelbar oberhalb oder im oberen Bereich des Blechpakets auf der Einsteckseite und vorteilhafterweise zumindest teilweise innerhalb des Stators angeordnet zu sein. Die Spannvorrichtung ist vorzugsweise dazu eingerichtet, die eingeführten Schenkel der U-förmig gebogenen Leiterelemente des Hairpinzopfes in radialer Richtung mittels einer Vielzahl von Schiebern von innen nach außen zu drücken. Die Spannvorrichtung ist vorzugsweise dazu eingerichtet, die äußere Hüllfläche des Hairpinzopfes von der kegelstumpfförmigen Mantelfläche in die zylindrische Form zu überführen beziehungsweise zu ändern, so dass eine Durchsteckung beziehungsweise Einführung der Leiterelemente durch die Nuten des Stators vollständig durchgeführt werden kann. In a particularly preferred development, the assembly system also has a positioning aid. The positioning aid is set up to be arranged in the z-direction below the prestressing device and above the provided laminated core of the stator or between the prestressing device and the laminated core coaxially to the laminated core of the stator and coaxially to the pretensioning device. The positioning aid is designed in particular to be arranged directly above the stator. The positioning aid is in particular ring-shaped. The positioning aid has a large number of positioning aids. Each positioning aid element is arranged above a web of the stator and has at least one guide surface angled toward the z-direction, in particular on the upper side toward the prestressing device. The positioning aids are set up to align the free ends of the legs of the conductor elements with the slots in the laminated core. The arrangement of the positioning aid results in high dimensional accuracy with regard to the positioning of the free ends of the legs of the conductor elements during insertion into the slots of the stator, so that buckling or damage to insulating paper in the slots of the stator is very reliably avoided. The assembly system preferably also includes a clamping device which is arranged coaxially to the stator and inside or outside the hairpin braid and is set up to move the inserted legs of the U-shaped conductor elements of the hairpin braid in the radial direction outwards or inwards by means of a large number of slides or to press against a surface, in particular this pressing takes place between the positioning aids and against the respective bottom surfaces of the grooves of the laminated core of the stator or against the outer surface of another hairpin braid already inserted and arranged in the laminated core. The tensioning device is preferably set up to be arranged within the hairpin braid and advantageously directly above or in the upper region of the laminated core on the insertion side and advantageously at least partially within the stator. The tensioning device is preferably set up to press the inserted legs of the U-shaped conductor elements of the hairpin braid from the inside outwards in the radial direction by means of a large number of slides. The clamping device is preferably set up to convert or change the outer envelope surface of the hairpin braid from the frustoconical lateral surface to the cylindrical shape, so that the conductor elements can be pushed through or inserted completely through the slots of the stator.
Weitere Vorteile ergeben sich aus der nachfolgenden Beschreibung von Ausführungsbeispielen mit Bezug zu den Figuren. Further advantages result from the following description of exemplary embodiments with reference to the figures.
Figur 1: U-förmig gebogenes Leiterelement eines Hairpinzopfes FIG. 1: U-shaped conductor element of a hairpin braid
Figur 2: Seitliche Aufsicht eines Stator mit zwei Hairpinzöpfen des Wickelkopfes Figure 2: Side view of a stator with two hairpin braids of the end winding
Figur 3: dreidimensionale Darstellung der Montageanlage in schräger Seitenansicht FIG. 3: three-dimensional representation of the assembly plant in an oblique side view
Figur 4: Greifvorrichtung mit einem Hairpinzopf Figure 4: Gripping device with a hairpin braid
Figur 5: Vorspannvorrichtung mit Ausrichteelementen Figure 5: Pretensioning device with alignment elements
Figur 6: Detaildarstellung der Vorspannvorrichtung mit Schenkeln der Leiterelemente FIG. 6: Detailed view of the prestressing device with legs of the conductor elements
Figur 7: Blechpaket des Stators und Positionierhilfseinrichtung sowie Spannvorrichtung Figur 8: Schnittansicht zu Positionierhilfseinrichtung sowie Spannvorrichtung Figure 7: Laminated core of the stator and positioning aid as well as clamping device FIG. 8: Sectional view of the positioning aid and clamping device
Figur 9: Positionierhilfselement der Positionierhilfseinrichtung FIG. 9: Auxiliary positioning element of the auxiliary positioning device
Figur 10: Aufsicht auf Positionierhilfseinrichtung oberhalb des Blechpakets des Stators Figure 10: Top view of the positioning aid above the laminated core of the stator
Figur 11: seitliche Ansicht auf Positionierhilfseinrichtung oberhalb des Blechpakets FIG. 11: Side view of the positioning aid above the laminated core
Figur 12: Einstecken des Hairpinzopfs in die Nuten des Stators Figure 12: Inserting the hairpin braid into the slots of the stator
Figur 13: Spannvorrichtung mit ausgefahrenen Schiebern bei eingeführtem Hairpinzopf Figure 13: Tensioning device with extended sliders with inserted hairpin braid
Figur 14: äußere Hüllfläche bildet Mantelfläche eines Kegelstumpfes aus FIG. 14: outer enveloping surface forms the lateral surface of a truncated cone
Figur 15a: zylindrische äußere Hüllfläche vor dem Ausfahren der Ausrichtelemente FIG. 15a: Cylindrical outer enveloping surface before the alignment elements are extended
Figur 15b: Ausbildung der äußeren Hüllfläche als Mantelfläche eines Kegelstumpfes FIG. 15b: Formation of the outer enveloping surface as the lateral surface of a truncated cone
Figur 16: Ablaufdiagramm des Verfahrens als Blockschaltbild FIG. 16: Flow chart of the method as a block diagram
Ausführungsbeispiele exemplary embodiments
In Figur 1 ist ein U-förmig gebogenes Leiterelement 10 eines Hairpinzopfes in dreidimensionaler Ansicht dargestellt. Das Leiterelement 10 weist zwei gerade und zueinander parallele Schenkel 12 beziehungsweise Hairpinfüße, einen gebogenen Bereich 11 sowie an jedem der Schenkel 12 jeweils ein freies Ende 13 der Schenkel 12 auf. A U-shaped conductor element 10 of a hairpin braid is shown in a three-dimensional view in FIG. The conductor element 10 has two straight legs 12 or hairpin feet parallel to one another, a curved region 11 and a free end 13 of the legs 12 on each of the legs 12 .
Figur 2 zeigt eine seitliche Aufsicht eines Stators 20 einer elektrischen Maschine mit zwei in den Nuten 23 des Stators 21 in radialer Richtung hintereinander beziehungsweise nebeneinander angeordneten Hairpinzöpfen 100, 101, 102. Der Stator 20 umfasst ein Blechpaket 21 mit einer Vielzahl von Stegen 22, wobei das Blechpaket 21 zwischen zwei Stegen 22 jeweils eine Nut 23 aufweist. In einer Nut 23 wird typischerweise ein Isolationspapier 25 angeordnet. Der äußere Hairpinzopf 100, 101 weist einen größeren Durchmesser als der innere Hairpinzopf 100, 102 auf. In Figur 2 ist außerdem dargestellt, wie die einzelnen U-förmig gebogenen Bereiche 11 der U-förmig gebogenen Leiterelemente 10 in einem Hairpinzopf benachbarter Leiterelemente 10 ineinandergreifen, so dass die radiale und axiale Ausdehnung des jeweiligen Hairpinzopfes 100 außerhalb des Blechpakets 21 des Stators 20 minimiert wird. Das Blechpaket 21 des Stators 20 weist typischerweise einen leeren zylindrischen Innenbereich 24 auf, welcher dazu eingerichtet ist einen Rotor der elektrischen Maschine aufzunehmen. Figure 2 shows a side view of a stator 20 of an electrical machine with two hairpin braids 100, 101, 102 arranged one behind the other or next to one another in the radial direction in the slots 23 of the stator 21. The stator 20 comprises a laminated core 21 with a plurality of webs 22, wherein the laminated core 21 has a groove 23 between each of two webs 22 . An insulating paper 25 is typically arranged in a groove 23 . The outer hairpin braid 100, 101 has a larger diameter than the inner hairpin braid 100, 102. Figure 2 also shows how the individual U-shaped areas 11 of the conductor elements 10 bent in a U-shape intermesh in a hairpin braid of adjacent conductor elements 10, so that the radial and axial expansion of the respective hairpin braid 100 outside of the laminated core 21 of the stator 20 is minimized. The laminated core 21 of the stator 20 typically has an empty cylindrical inner area 24 which is set up to accommodate a rotor of the electric machine.
In Figur 3 ist eine dreidimensionale Darstellung von Komponenten einer Montageanlage 200 in schräger Seitenansicht gezeigt. Eine Greifvorrichtung 210 ist dazu eingerichtet, einen Hairpinzopf 100, 101, 102 zu greifen und diesen zumindest in z-Richtung zu bewegen. Eine Vorspannvorrichtung 220 der Montageanlage 200 ist mittels einer Vielzahl von Ausrichtelementen 221 dazu eingerichtet ist, die Schenkel 12 der Leiterelemente 10 des Hairpinzopfes 100, 101, 102 auszurichten, so dass die Schenkel 12 in tangentialer Richtung des Hairpinzopfes 100, 101, 102 vorpositioniert beziehungsweise ausgerichtet und die freien Enden 13 der Schenkel 12 in radialer Richtung nach innen oder außen verschoben werden, so dass als äußere Hüllfläche um die Schenkel 12 des Hairpinzopfes 100, 101, 102 eine Mantelfläche eines Kegelstumpfes ausgebildet ist, siehe auch Figur 14 und Figur 15b. Vorzugsweise können die Ausrichtelemente 221 durch einen Drehmechanismus mittels gebogener Nuten, in welchen ein mit einem jeweiligen Ausrichtelement 221 verbundener Pin geführt wird, ausgefahren werden. Des Weiteren umfasst die Montageanlage 200 eine Positionierhilfseinrichtung 240. Die Positionierhilfseinrichtung 240 ist dazu eingerichtet, Positionierhilfselemente 241 oberhalb der Stege 22 des Blechpakets 21 des Stators 20 anzuorden, beispielsweise können diese Positionierhilfselemente 241 ebenfalls durch einen Drehmechanismus ausgefahren werden. Die Positionierhilfselemente 241 sind dazu eingerichtet, beim Einstecken der Schenkel 12 der Leiterelememente 10 des Hairpinzopfes 100, 101, 102 die Leiterelemente 10 in die Nuten 23 zu führen. Zu diesem Zweck weisen die Positionierhilfselemente 241 Führungsflächen 242 auf. Die Führungsflächen erstrecken sich unter einem schrägen Winkel zur axialen Richtung z des Hairpinzopfes 100, 101, 102. Zusätzlich umfasst die Montageanlage eine Spannvorichtung 230. Die Spannvorrichtung 230 ist mittels einer Vielzahl an Schiebern 231 dazu eingerichtet, die Schenkel 12 der Leiterelemente 10 eines bereits eingestecketen Hairpinzopfes 100, 101, 102 und noch durch die Nuten durchzusteckenden Hairpinzopfes 100, 101, 102 in radialer Richtung von innen nach außen oder umgekehrt zu verschieben, wobei die Leiterelemente 10 gegen einen Anschlag des Positionierhilfseinrichtung 240 oder gegen eine Bodenfläche der Nuten 23 des Stators oder gegen eine Außenfläche eines bereits in den Nuten des Blechpakets 21 des Stators 20 angeordneten Hairpinzopf 100, 101, 102 gedrückt wird, wodurch die äußere Hüllfläche um die Schenkel 12 des Hairpinzopfes 100, 101, 102 in eine zylindrische Mantelfläche überführt wird. Mit anderen Worten ist die Spannvorrichtung 230 dazu eingerichtet, die Schenkel 12 der Leiterelemente 10 achsparallel zur z-Richtung auszurichten, wobei diese achsparallele Ausrichtung der Schenkel 12 durch ein Verschieben beziehungsweise Andrücken der Schenkel 12 an einen achsparallelen Anschlag erfolgt, wobei der achsparallele Anschlag insbesondere ein Anschlag der Positionierhilfseinrichtung 240, die Bodenfläche 26 der Nuten 23 des Blechpakets 21 des Stators 20 oder eine Außenfläche eines bereits in den Nuten des Stators 20 angeordneten Hairpinzopfs 100, 101, 102 ist. Die Montageanlage umfasst außerdem eine Aufnahme 250 für ein Blechpaket 21 des Stators 20. FIG. 3 shows a three-dimensional representation of components of an assembly system 200 in an oblique side view. A gripping device 210 is set up to grip a hairpin braid 100, 101, 102 and to move it at least in the z-direction. A pretensioning device 220 of the assembly system 200 is set up by means of a large number of alignment elements 221 to align the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102, so that the legs 12 are pre-positioned or aligned in the tangential direction of the hairpin braid 100, 101, 102 and the free ends 13 of the legs 12 are shifted inwards or outwards in the radial direction, so that a lateral surface of a truncated cone is formed as the outer envelope surface around the legs 12 of the hairpin braid 100, 101, 102, see also FIG. 14 and FIG. 15b. Preferably, the alignment elements 221 can be extended by a rotary mechanism by means of curved grooves in which a pin connected to a respective alignment element 221 is guided. The assembly system 200 also includes a positioning aid 240. The positioning aid 240 is set up to arrange positioning aids 241 above the webs 22 of the laminated core 21 of the stator 20; for example, these positioning aids 241 can also be extended by a rotary mechanism. The positioning aid elements 241 are designed to guide the conductor elements 10 into the grooves 23 when the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102 are inserted. The positioning aids 241 have guide surfaces 242 for this purpose. The guide surfaces extend at an oblique angle to the axial direction z of the hairpin braid 100, 101, 102. In addition, the assembly system includes a clamping device 230. The clamping device 230 is set up by means of a large number of slides 231, the legs 12 of the conductor elements 10 of an already inserted Hairpin braids 100, 101, 102 and hairpin braids 100, 101, 102 still to be pushed through the grooves in the radial direction from the inside to the outside or vice versa, with the conductor elements 10 against a stop of the positioning aid 240 or against a bottom surface of the grooves 23 of the stator or against an outer surface of one already in the grooves of Laminated core 21 of the stator 20 arranged hairpin plait 100, 101, 102 is pressed, whereby the outer envelope surface around the legs 12 of the hairpin plait 100, 101, 102 is converted into a cylindrical lateral surface. In other words, the clamping device 230 is set up to align the legs 12 of the conductor elements 10 axially parallel to the z-direction, with this axially parallel alignment of the legs 12 taking place by displacing or pressing the legs 12 against an axially parallel stop, the axially parallel stop in particular being a Stop of the positioning aid 240, the bottom surface 26 of the grooves 23 of the laminated core 21 of the stator 20 or an outer surface of a hairpin braid already arranged in the grooves of the stator 20 100, 101, 102. The assembly system also includes a receptacle 250 for a laminated core 21 of the stator 20.
In Figur 4 ist dreidimensional eine Greifvorrichtung 210 mit einem gegriffenen Hairpinzopf 100, 101, 102 in seitlicher Aufsicht dargestellt. Die Greifvorrichtung 210 umfasst Lamellenschieber beziehungsweise Greifelemente 211 zum Greifen der Leiterelemente 10 des Hairpinzopfes 100, 101, 102. Die in Figur 4 gezeigte Greifvorrichtung 210 greift jedes U-förmig gebogene Leiterelement 10 in dem jeweiligen gebogenen Bereich 11 mit jeweils zwei Lammellenschiebern beziehungsweise Greifelementen 211. Der Hairpinzopf umfasst eine Vielzahl an U- förmig gebogenen Leiterelementen 10, welche kreisförmig nebeneinander angeordnet sind. Der jeweilige gebogenen Bereich 11 jedes Leiterelements 10 ist so gebogen, dass ein Ineinandergreifen der gebogenen Bereich 11 der einzelnen Leiterelemente 10 und die achsparallele Ausrichtung aller Schenkel 12 beziehungsweise Hairpinfüße ermöglicht wird. FIG. 4 shows a three-dimensional side view of a gripping device 210 with a gripped hairpin braid 100, 101, 102. The gripping device 210 comprises lamella slides or gripping elements 211 for gripping the conductor elements 10 of the hairpin braid 100, 101, 102. The gripping device 210 shown in Figure 4 grips each U-shaped conductor element 10 in the respective curved area 11 with two lamella slides or gripping elements 211. The hairpin braid comprises a multiplicity of conductor elements 10 bent in a U-shape, which are arranged next to one another in a circle. The respective curved area 11 of each conductor element 10 is curved in such a way that the curved areas 11 of the individual conductor elements 10 can intermesh and the axis-parallel alignment of all legs 12 or hairpin feet is made possible.
In Figur 5 ist eine Vorspannvorrichtung 220 mit Ausrichteelementen 221 dargestellt. Die Vorspannvorrichtung weist ein erstes Drehelement 223 mit ersten Führungsnuten 224 auf. Die Ausrichteelementen 221 sind jeweils mit einem ersten Pin 225 beziehungsweise ersten Stift beziehungsweise erstem Führungselement verbunden, welches in eine jeweilige erste Führungsnut eingreift und durch diese bei einer Drehbewegung des ersten Drehelements 223 geführt wird. Durch diese Führung der Ausrichteelemente 221 bei der Drehbewegung des ersten Drehelements 223 können alle Ausrichteelemente 221 parallel ein und ausgefahren werden. A prestressing device 220 with alignment elements 221 is shown in FIG. The pretensioning device has a first rotary element 223 with first guide grooves 224 . The alignment elements 221 are each connected to a first pin 225 or first pin or first guide element, which engages in a respective first guide groove and is guided by this when the first rotary element 223 rotates. This guidance of the alignment elements 221 during the rotary movement of the first rotary element 223 allows all the alignment elements 221 to be moved in and out in parallel.
Figur 6 stellt eine vergrößerte Darstellung eines Ausschnitt der Vorspannvorrichtung 220 gemäß Figur 5 dar, wobei in der Vorspannvorichtung 220 die Schenkeln 12 der Leiterelemente 10 eingeführt beziehungsweise angeordnet sind. Die Ausrichteelemente 221 befinden sich in einer mittleren Stellung, da die ersten Pins 225 beziehungsweise die Führungselemente jeweils in einer mittleren Lage der Führungsnut 224 des ersten Drehelements 223 positioniert ist. Ein mechanischer Anschlag 222 eines jeweiligen Ausrichteelementes 221 ist bei einem Ausfahren der Ausrichteelemente 221 dazu eingerichtet, die Schenkel 12 der Leiterelemente 10 in radialer Richtung nach innen zu verschieben. Durch diese Verschiebung der Schenkel 12 in radialer Richtung von außen nach innen wird als äußere Hüllfläche um die Schenkel 12 der Leiterelemente 10 eine kegelstumpfförmige Mantelfläche erzeugt. FIG. 6 shows an enlarged representation of a section of the prestressing device 220 according to FIG. 5, the legs 12 of the conductor elements 10 being inserted or arranged in the prestressing device 220 . The Alignment elements 221 are in a middle position, since the first pins 225 or the guide elements are each positioned in a middle position of the guide groove 224 of the first rotary element 223 . A mechanical stop 222 of a respective alignment element 221 is set up to move the legs 12 of the conductor elements 10 inwards in the radial direction when the alignment elements 221 are extended. This displacement of the legs 12 in the radial direction from the outside to the inside produces a frustoconical lateral surface as the outer envelope surface around the legs 12 of the conductor elements 10 .
In Figur 7 ist ein Blechpaket 21 des Stators 20 mit Nuten 23 in der Aufnahmevorrichtung 250 in dreidimensionaler Ansicht dargestellt, wobei in jeder Nut 23 insbesondere jeweils ein Isolationspapier 25 angeordnet ist. Oberhalb des Blechpakets 21 sind eine Positionierhilfseinrichtung 240 sowie eine Spannvorrichtung 230 angeordnet. Die Positionierhilfseinrichtung 240 weist ein zweites Drehelement 244 mit zweite Führungsnuten 245 zur Führung von zweiten Führungselementen 246 auf, wobei die zweiten Führungselemente 246 beispielsweise jeweils ein zweiter Pin sind, welcher beispielsweise jeweils in einer Aufnahme eines Positionierhilfselementes 241 eingesteckt beziehungsweise angeordnet und mit dieser form- und/oder stoffschlüssig verbunden ist. In Figur 7 sind die Positionierhilfselemente 241 in einer maximal eingefahrenen Lage dargestellt, d.h. die zweiten Führungselemente 246 sind jeweils am äußeren Anschlag einer zweiten Führungsnut 245 des zweiten Drehelements 244 angeordnet. Die Spannvorrichtung 230 weist ein drittes Drehelement 232 mit dritten Führungsnuten 233 zur Führung von dritten Führungselementen 234 auf, wobei die dritten Führungselemente 233 beispielsweise jeweils ein dritter Pin sind, welcher beispielsweise jeweils in einer Aufnahme eines Schiebers 231 eingesteckt beziehungsweise angeordnet und mit dieser form- und/oder stoffschlüssig verbunden ist. In Figur 7 sind die Schieber 231 in einer maximal eingefahrenen Lage angeordnet, d.h. die dritten Führungselemente 234 sind jeweils am inneren Anschlag einer dritten Führungsnut 233 des zweiten Drehelements 232 angeordnet. Die Spannvorrichtung 230 ist dazu eingerichtet, die Schenkel 12 der Leiterelemente 10 eines in die Nuten 23 des Blechpakets 21 eingesteckten Hairpinzopfes gegen die zur z-Achse parallele Positionierhilfseinrichtung 240 zu drücken, wodurch aus der kegelstumpf-förmigen äußeren Hüllfläche um die Schenkel 12 der Leiterelemente 10 eine zylindrische Mantelfläche erzeugt wird. Dadurch können die Schenkel 12 durch die Nuten 23 des Blechpakets 21 vollständig parallel zur z-Achse mittels einer koaxialen Bewegung der Greifvorrichtung 210 von oben nach unten vollständig durchgesteckt werden, so dass das freie Ende 13 der Schenkel 12 der U-förmig gebogenen Leiterelemente 10 auf der der vorbestimmten beziehungsweise Einsteckseite gegenüberliegenden Seite aus den Nuten 23 austritt. FIG. 7 shows a three-dimensional view of a laminated core 21 of the stator 20 with slots 23 in the receiving device 250, with an insulating paper 25 being arranged in each slot 23 in particular. A positioning aid 240 and a clamping device 230 are arranged above the laminated core 21 . Auxiliary positioning device 240 has a second rotary element 244 with second guide grooves 245 for guiding second guide elements 246, the second guide elements 246 each being a second pin, for example, which is inserted or arranged in a receptacle of an auxiliary positioning element 241, for example, and is shaped and shaped with it / or is firmly bonded. The positioning aid elements 241 are shown in FIG. Clamping device 230 has a third rotary element 232 with third guide grooves 233 for guiding third guide elements 234, with the third guide elements 233 each being a third pin, for example, which is inserted or arranged in a receptacle of a slide 231, for example, and is connected to it in a form-fitting and / or is firmly bonded. In FIG. 7, the slides 231 are arranged in a maximally retracted position, ie the third guide elements 234 are each arranged on the inner stop of a third guide groove 233 of the second rotary element 232 . The clamping device 230 is set up to press the legs 12 of the conductor elements 10 of a hairpin braid inserted into the grooves 23 of the laminated core 21 against the positioning aid 240, which is parallel to the z-axis, whereby the frustoconical outer enveloping surface around the legs 12 of the conductor elements 10 a cylindrical lateral surface is generated. As a result, the legs 12 can be completely pushed through the grooves 23 of the laminated core 21 parallel to the z-axis by means of a coaxial movement of the gripping device 210 from top to bottom, so that the free end 13 of the legs 12 of the U-shaped conductor elements 10 the exits from the grooves 23 opposite the predetermined or insertion side.
In Figur 8 ist ein Blechpaket 21 des Stators 20 mit Nuten 23 im Schnittbild in seitlicher Ansicht dargestellt, ähnlich zu Figur 7. Oberhalb des Blechpakets 21 sind, wie in Figur 7, eine Positionierhilfseinrichtung 240 sowie eine Spannvorrichtung 230 angeordnet, wobei die Positionierhilfselemente 241 der Positionierhilfseinrichtung 240 und die Schieber 231 der Spannvorrichtung 230 ausgefahren sind. In Figure 8, a laminated core 21 of the stator 20 with slots 23 is shown in a sectional view in a side view, similar to Figure 7. Above the laminated core 21, as in Figure 7, are a positioning aid 240 and a clamping device 230, with the positioning aids 241 of the Positioning aid 240 and the slide 231 of the clamping device 230 are extended.
In Figur 9 ist ein Positionierhilfselement 241 der Positionierhilfseinrichtung 240 in dreidimensionaler Ansicht dargestellt. Das Positionierhilfselement 241 weist Führungsflächen 242 und eine Vertiefung 243, insbesondere ein Durchgangsloch oder eine Bohrung, zur Aufnahme eines zweiten Führungselements 246 auf. Das Positionierhilfselement 241 ist jeweils dazu eingerichtet, mit der Unterseite 249 oberhalb eines Stegs 22 des Blechpakets 21 des Stators 20 angeordnet zu sein und diesen insbesondere im Wesentlichen zu verdecken. Das Positionierhilfselement 241 verdeckt des Weiteren die seitlichen Bereiche des Isolationspapiers 25, welches in der Nut 23 des Blechpakets 21 angeordnet ist. Die Führungsfläche 242, insbesondere Fase, ist dazu eingerichtete, bei Anordnung des Positionierhilfselements 246 oberhalb des Blechpakets 21 schräg beziehungsweise abgewinkelt zur z-Richtung beziehungsweise zur z-Axialrichtung des Hairpinzopfes beziehungsweise des Blechpakets angeordnet zu sein, so dass bei einem Versatz eines freien Endes 13 eines Schenkels 12 eines Leiterelements 10 in einem gegriffenen Hairpinzopf 100, 101, 102 das freie Ende 13 des Schenkels 12 zur jeweiligen Nut 23 hin ausgerichtet wird. Die Verdeckung der seitlichen Bereiche des Isolationspapiers 25 durch das Positionierhilfselement 241 vermeidet eine Beschädigung des Isolationspapiers 25 beim Einstecken der freien Enden 13 der Schenkel 12 beziehungsweise der Schenkel 12 der Leiterelemente 10 in die Nuten 23 des Blechpakets 21. A positioning aid element 241 of the positioning aid device 240 is shown in a three-dimensional view in FIG. The positioning aid element 241 has guide surfaces 242 and a recess 243, in particular a through hole or a bore, for receiving a second guide element 246. The positioning aid element 241 is set up in each case to be arranged with the underside 249 above a web 22 of the laminated core 21 of the stator 20 and in particular to essentially cover it. The positioning aid element 241 also covers the lateral areas of the insulating paper 25 which is arranged in the groove 23 of the laminated core 21 . The guide surface 242, in particular the chamfer, is designed to be arranged at an angle or at an angle to the z-direction or to the z-axial direction of the hairpin braid or the laminated core when the positioning aid element 246 is arranged above the laminated core 21, so that if a free end 13 of a leg 12 of a conductor element 10 in a gripped hairpin braid 100, 101, 102, the free end 13 of the leg 12 is aligned with the respective groove 23. The covering of the lateral areas of the insulating paper 25 by the positioning aid element 241 avoids damage to the insulating paper 25 when the free ends 13 of the legs 12 or the legs 12 of the conductor elements 10 are inserted into the grooves 23 of the laminated core 21.
In Figur 10 ist ein Ausschnitt einer Aufsicht auf die Positionierhilfseinrichtung 240 oberhalb des Blechpakets 21 des Stators 20 in Aufsicht dargestellt. Die Positionierhilfselemente 241 der Positionierhilfseinrichtung 240 sind jeweils mit der Unterseite 249 der Positionierhilfselemente 241 oberhalb eines Stegs 22 des Blechpakets 21 des Stators 20 und zu diesem parallel beziehungsweise fluchtend angeordnet, so dass die Positionierhilfselemente 241 den Steg 22 im Wesentlichen verdecken. Die Führungsflächen 242, welche schräg zur Axialrichtung des Blechpakets 21 und zum koaxial angeordneten Hairpinzopf 100, 101, 102 angeordnet sind, sind dazu eingerichtet, die freien Enden 13 der Schenkel 12 der Leiterelemente 10 beim Einstecken der freien Enden 13 der Schenkel 12 in die Nuten 23 des Blechpakets 21 auszurichten. FIG. 10 shows a section of a top view of the positioning aid 240 above the laminated core 21 of the stator 20 in a top view. The positioning aid elements 241 of the positioning aid device 240 are each arranged with the underside 249 of the positioning aid elements 241 above a web 22 of the laminated core 21 of the stator 20 and parallel to or aligned with it, so that the positioning aid elements 241 essentially conceal the web 22. The guide surfaces 242, which are arranged at an angle to the axial direction of the laminated core 21 and to the coaxially arranged hairpin braid 100, 101, 102, are arranged to align the free ends 13 of the legs 12 of the conductor elements 10 when the free ends 13 of the legs 12 are inserted into the grooves 23 of the laminated core 21 .
In Figur 11 ist ein freies Ende 13 eines Schenkels 12 eines Leiterelementes 10 beim Einstecken beziehungsweise der Einführung in die Positionierhilfseinrichtung 240 oberhalb des Blechpakets 21 in seitlicher dreidimensionaler Ansicht dargestellt. Die schrägen Führungsflächen 242 der Positionierhilfselemente 241 richten das freie Ende 13 des jeweiligen Schenkels 12 zur jeweiligen Nut 23 hin aus, so dass die Positionsgenauigkeit der freien Enden 13 der Schenkel 12 erhöht beziehungsweise sichergestellt wird. Dadurch wird eine Beschädigung des Isolationspapiers 25 in den Nuten 23 trotz sehr geringer Toleranzen zwischen den Abmessungen der Nut 23 und des Schenkels 12 vermieden. FIG. 11 shows a three-dimensional side view of a free end 13 of a leg 12 of a conductor element 10 when it is being inserted or introduced into the positioning aid device 240 above the laminated core 21 . The inclined guide surfaces 242 of the positioning aids 241 align the free end 13 of the respective leg 12 to the respective groove 23, so that the positioning accuracy of the free ends 13 of the legs 12 is increased or ensured. This avoids damage to the insulating paper 25 in the grooves 23 despite very small tolerances between the dimensions of the groove 23 and the leg 12 .
In Figur 12 sind die freien Enden 13 der Schenkel 12 der Leiterelemente 10 nach dem Einstecken in die Nuten 23 des Blechpakets 21 dargestellt, wobei die Vorspannvorrichtung 220, die Positionierhilfseinrichtung 240 und die Spannvorrichtung 230 koaxial zum und oberhalb des Blechpaket 21 angeordnet sind. Der Hairpinzopf 100, 101 und das Blechpaket 21 sind ebenfallls koaxial ausgerichtet. In Figur 12 sind die ersten Führungselemente 225 der Ausrichteelemente 221 der Vorspannvorrichtung 220 in einer mittleren Stellung in der Führungsnut 224 des Drehelements 223 angeordnet, das heißt die Ausrichteelemente 221 wurden durch das erste Drehelement 223 in einer mittleren Stellung ausgefahren. Die äußere Hüllfläche um die Schenkel 12 der Leiterelemente 10 des Hairpinzopfes 100, 101 weist in diesem Betriebszustand vorteilhafterweise eine kegelstumpffömige Mantelfläche auf. Zwischen den freien Enden 13 der Schenkel 12 der Leiterelemente 10 und der Bodenfläche der Nuten 23 liegt jedenfalls ein Abstand 400 vor. FIG. 12 shows the free ends 13 of the legs 12 of the conductor elements 10 after they have been inserted into the grooves 23 of the laminated core 21, with the prestressing device 220, the positioning aid 240 and the clamping device 230 being arranged coaxially to and above the laminated core 21. The hairpin braid 100, 101 and the laminated core 21 are also aligned coaxially. In Figure 12, the first guide elements 225 of the aligning elements 221 of the pretensioning device 220 are arranged in a middle position in the guide groove 224 of the rotary element 223, i.e. the aligning elements 221 were extended by the first rotary element 223 in a middle position. The outer enveloping surface around the legs 12 of the conductor elements 10 of the hairpin braid 100, 101 advantageously has a frustoconical lateral surface in this operating state. In any case, there is a distance 400 between the free ends 13 of the legs 12 of the conductor elements 10 and the bottom surface of the grooves 23 .
In Figur 13 sind, wie in Figur 12, die Schenkel 12 der Leiterelemente 10 nach dem Einstecken der freien Enden 13 in die Nuten 23 des Blechpakets 21 dargestellt, wobei die Vorspannvorrichtung 220, die Positionierhilfseinrichtung 240 und die Spannvorrichtung 230 koaxial zum und oberhalb des Blechpaket 21 angeordnet sind. Figur 13 zeigt den Betriebszustand nach der Anpressung der Schenkel 12 der Leiterelemente 10 des Hairpinzopfes 100, 101 in radialer Richtung nach außen zwischen den Positionierhilfselementen 241 mittels der Schieber 231 der Spannvorrichtung 230. Dadurch wird die äußere Hüllfläche des Hairpinzopfes von der kegelstumpfförmigen in eine zylindrische Mantelfläche geändert und ein spielfreies Anliegen der Schenkel 12 des Hairpinzopfes 100, 101 an die Bodenfläche 26 der Nuten 23 erreicht. Anschließend werden die geraden Schenkel 12 der Leiterelemente 10 durch die Nuten 23 des Blechpakets 21 vollständig durchgesteckt, wobei die Position der Schieber 231 der Spannvorrichtung 230 und die Position der Ausrichteelemente 221 der Vorspannvorrichtung 220 die radiale Lage beziehungsweise Position der Schenkel 12 in den Nuten 23 definiert. In Figure 13, as in Figure 12, the legs 12 of the conductor elements 10 are shown after the free ends 13 have been inserted into the grooves 23 of the laminated core 21, with the prestressing device 220, the positioning aid 240 and the clamping device 230 being coaxial with and above the laminated core 21 are arranged. Figure 13 shows the operating state after the legs 12 of the conductor elements 10 of the hairpin braid 100, 101 have been pressed in the radial direction outwards between the positioning aid elements 241 by means of the slide 231 of the clamping device 230. This changes the outer envelope surface of the hairpin braid from the frustoconical into a cylindrical lateral surface changed and a play free Concern of the leg 12 of the hairpin braid 100, 101 reaches the bottom surface 26 of the grooves 23. The straight legs 12 of the conductor elements 10 are then pushed completely through the grooves 23 of the laminated core 21, with the position of the slide 231 of the clamping device 230 and the position of the alignment elements 221 of the pretensioning device 220 defining the radial position or position of the legs 12 in the grooves 23 .
In Figur 14 ist eine Greifvorrichtung 210 dargestellt, welche eine Vielzahl an U-förmig gebogenen Leiterelementen 10 des Hairpinzopfs 100, 101, 102 greift. In Figur 14 sind die U-förmig gebogenen Leiterelemente 10 so gegriffen, dass sie um deren Tangentialachse drehbar gelagert sind. Außerdem sind die Schenkel 12 der Leiterelemente 10 mit den freien Enden 13 durch eine nicht dargestellte Vorspannvorrichtung 220 in tangentialer Richtung ausgerichtet. Des Weiteren werden mittels der nicht dargestellten Vorspannvorrichtung 220 die freien Enden 13 in radialer Richtung nach innen verschoben, siehe insbesondere Pfeile 98. Dadurch ist als äußere Hüllfläche um die Schenkel 12 der Leiterelemente 10 des Hairpinzopfes 100, 101, 102 eine Mantelfläche 99 eines Kegelstumpfes ausgebildet. Mit anderen Worten zeigt Figur 14, wie die Leiterelemente 10 mit den Schenkeln 12 und den freien Enden 13 mittels der Vorspannrichtung 220 die Mantelfläche 99 eines Kegelstumpfes als äußere Hüllfläche um die Schenkel 12 der Leiterelemente 10 des Hairpinzopfes 100, 101, 102 ausbilden, wobei die Vorspannrichtung 220 in Figur 14 nicht dargestellt ist. Die Ausbildung der äußeren Hüllfläche um die Schenkel 12 der Leiterelemente 10 als kegelstumpfförmige Mantelfläche 99 erfolgt vorzugsweise mittels der Ausrichtelement 221 der Vorspannvorrichtung 220, wobei beim Ausfahren 340 der Vielzahl von Ausrichtelementen 221 die freien Enden 13 der Schenkel 12 der Leiterelemente 10 in radialer Richtung nach innen verschoben werden, siehe insbesondere Pfeile 98, so dass als äußere Hüllfläche um die Schenkel 12 der Leiterelemente 10 des Hairpinzopfes 100, 101, 102 die Mantelfläche 99 eines Kegelstumpfes ausgebildet wird. A gripping device 210 is shown in FIG. In FIG. 14, the conductor elements 10 bent in a U-shape are gripped in such a way that they are rotatably mounted about their tangential axis. In addition, the legs 12 of the conductor elements 10 are aligned with the free ends 13 in the tangential direction by a non-illustrated prestressing device 220 . Furthermore, the free ends 13 are pushed inwards in the radial direction by means of the prestressing device 220 (not shown), see in particular arrows 98. As a result, a lateral surface 99 of a truncated cone is formed as the outer envelope surface around the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102 . In other words, Figure 14 shows how the conductor elements 10 with the legs 12 and the free ends 13 form the lateral surface 99 of a truncated cone as the outer envelope surface around the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102 by means of the prestressing device 220, the Biasing direction 220 is not shown in FIG. The outer enveloping surface around the legs 12 of the conductor elements 10 is formed as a frustoconical lateral surface 99, preferably by means of the alignment element 221 of the prestressing device 220, with the free ends 13 of the legs 12 of the conductor elements 10 being extended in the radial direction inward when the plurality of alignment elements 221 are extended 340 be shifted, see in particular arrows 98, so that the lateral surface 99 of a truncated cone is formed as the outer envelope surface around the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102.
Figur 15a stellt die zylindrischen äußere Hüllfläche vor dem Ausfahren der Ausrichtelemente dar. Figur 15b zeigt demgegenüber die Ausbildung der äußeren Hüllfläche als Mantelfläche 99 eines Kegelstumpfes nach dem Ausfahren der Ausrichtelemente. FIG. 15a shows the cylindrical outer enveloping surface before the aligning elements are extended. FIG. 15b, in contrast, shows the configuration of the outer enveloping surface as a lateral surface 99 of a truncated cone after the aligning elements have been extended.
In Figur 16 ist ein Ablaufdiagramm des Montageverfahrens zum Einstecken eines Hairpinzopfes einer Steckwicklung in Nuten eines Blechpakets eines Stators als Blockschaltbild dargestellt. Das Verfahren beginnt mit einer Bereitstellung 310 des Hairpinzopfes 100, 101, 102. Anschließend wird im Schritt 320 der Hairpinzopfes 100, 101, 102 gegriffen. Beim Greifen 320 werden die U-förmig gebogenen Leiterelemente 10 des Hairpinzopfes 100, 101, 102 um die Tangentialachse des Hairpinzopfes 100, 101, 102 drehbar gelagert. Anschließend erfolgt eine Einführung 330 der Schenkel 12 der Leiterelemente 10 des gegriffenen Hairpinzopfes 100, 101, 102 in eine koaxial zur z-Achse des Hairpinzopfes 100, 101, 102 angeordnete Vorspannvorrichtung 220. Die Vorspannvorrichtung 220 ist insbesondere ringförmig. Das Einführen 330 der Schenkel 12 der Leiterelemente 10 des gegriffenen Hairpinzopfes in die Vorspannvorrichtung 220 erfolgt vorzugsweise bis die Vorspannvorrichtung 220 im Bereich zwischen der Mitte der Schenkel und den freien Enden der Schenkel angeordnet ist. Danach werden im Schritt 340 eine Vielzahl von Ausrichtelementen 221 der Vorspannvorrichtung 220 ausgefahren, wobei ein Ausrichtelement 221 zumindest einen Schenkel 12 der Leiterelemente 10 in tangentialer Richtung ausrichtet. Des Weiteren werden beim Ausfahren 340 der Vielzahl von Ausrichtelementen 221 die freien Enden 13 der Schenkel 12 der Leiterelemente 10 des Hairpinzopfes 100, 101, 102 in radialer Richtung nach innen oder außen verschoben. Durch diese Verschiebung der freien Enden 13 in radialer Richtung beim Ausfahren 340 wird als äußere Hüllfläche um die Schenkel 12 der Leiterelemente 10 des Hairpinzopfes 100, 101, 102 eine Mantelfläche eines Kegelstumpfes ausgebildet beziehungsweise erzeugt. In einem weiteren Schritt 350 wird ein Blechpaket 21 eines Stators 20 einer elektrischen Maschine bereitgestellt, wobei das Blechpaket eine Vielzahl an Nuten 23 aufweist. In einem optionalen anschließenden Schritt 360 werden die freien Enden 13 der Schenkel 12 oder die Schenkel 12 der Leiterelemente 10 des Hairpinzopfes 100, 101, 102 in eine PositionierhilfseinrichtungFIG. 16 shows a flow chart of the assembly process for inserting a hairpin braid of an insert winding into slots in a laminated core of a stator Block diagram shown. The method begins with a provision 310 of the hairpin braid 100, 101, 102. Then, in step 320, the hairpin braid 100, 101, 102 is gripped. When gripping 320, the conductor elements 10 of the hairpin braid 100, 101, 102 bent in a U-shape are mounted such that they can rotate about the tangential axis of the hairpin braid 100, 101, 102. Subsequently, the legs 12 of the conductor elements 10 of the gripped hairpin braid 100, 101, 102 are introduced 330 into a pretensioning device 220 arranged coaxially to the z-axis of the hairpin braid 100, 101, 102. The pretensioning device 220 is in particular ring-shaped. The insertion 330 of the legs 12 of the conductor elements 10 of the gripped hairpin braid into the pretensioning device 220 preferably takes place until the pretensioning device 220 is arranged in the area between the center of the legs and the free ends of the legs. Then, in step 340, a large number of alignment elements 221 of the prestressing device 220 are extended, with an alignment element 221 aligning at least one leg 12 of the conductor elements 10 in the tangential direction. Furthermore, when the plurality of alignment elements 221 is extended 340, the free ends 13 of the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102 are displaced inwards or outwards in the radial direction. This displacement of the free ends 13 in the radial direction during extension 340 forms or creates a lateral surface of a truncated cone as the outer envelope surface around the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102. In a further step 350, a laminated core 21 of a stator 20 of an electrical machine is provided, the laminated core having a multiplicity of slots 23. In an optional subsequent step 360, the free ends 13 of the legs 12 or the legs 12 of the conductor elements 10 of the hairpin braid 100, 101, 102 are placed in a positioning aid
240 eingeführt, welche in z-Richtung koaxial zum Blechpaket 21 des Stator 20 angeordnet wird. Die Positionierhilfseinrichtung 240 ist mittels einer Vielzahl an Positionierhilfselementen240 introduced, which is arranged coaxially to the laminated core 21 of the stator 20 in the z-direction. The positioning aid device 240 is provided by means of a large number of positioning aid elements
241 dazu eingerichtet ist, die freien Enden 13 der Schenkel 12 der Leiterelemente 10 oberhalb der Nuten 23 des Blechpakets 21 zur Nut 23 hin auszurichten. Danach werden im Schritt 370 die freien Enden 13 der Schenkel 12 der Leiterelemente 10 in die Nuten 23 des Blechpakets 21 eingesteckt. Das Einstecken im Schritt 370 erfolgt bevorzugt durch eine Bewegung der Greifvorrichtung 210 in axialer Richtung z von oben nach unten. Es kann vorgesehen sein, dass nach dem Einstecken 370 der freien Enden 13 der Schenkel 12 der Leiterelemente 10 in die Nuten 23 des Blechpakets 21 eine Anpressung 380 der Schenkel 12 der Leiterelemente 10 des Hairpinzopfes in radialer Richtung nach außen oder innen erfolgt. Die Anpressung 380 erfolgt insbesondere zwischen den Positionierhilfselementen 241 gegen eine Bodenfläche 25 der Nuten 23. Dadurch wird vorteilhafterweise die äußere Hüllfläche des Hairpinzopfes 100, 101, 102 von der kegelstumpfförmigen in eine zylindrische Mantelfläche geändert. Abschließend erfolgt ein Durchstecken 390 der Schenkel 12 der Leiterelemente 10 durch die Nuten 23 des Blechpakets 21. Das Verfahren wird vorzugsweise so oft wiederholt, bis mindestens zwei Hairpinzöpfe 100, 101, 102 in den Nuten 23 des Blechpakets 21 positioniert sind. 241 is set up to align the free ends 13 of the legs 12 of the conductor elements 10 above the grooves 23 of the laminated core 21 towards the groove 23 . Then in step 370 the free ends 13 of the legs 12 of the conductor elements 10 are inserted into the grooves 23 of the laminated core 21 . The insertion in step 370 is preferably carried out by a movement of the gripping device 210 in the axial direction z from top to bottom. Provision can be made for the legs 12 of the conductor elements 10 of the hairpin braid to be pressed 380 in the radial direction outwards or inwards after the free ends 13 of the legs 12 of the conductor elements 10 have been inserted 370 into the grooves 23 of the laminated core 21 . The pressing 380 takes place in particular between the positioning aid elements 241 against a bottom surface 25 of the grooves 23. This advantageously changes the outer envelope surface of the hairpin braid 100, 101, 102 from the frustoconical to a cylindrical lateral surface. Finally, the legs 12 are pushed through 390 Conductor elements 10 through the grooves 23 of the laminated core 21. The process is preferably repeated until at least two hairpin braids 100, 101, 102 are positioned in the grooves 23 of the laminated core 21.

Claims

Ansprüche Expectations
1. Montageverfahren zum Einstecken eines Hairpinzopfes (100, 101, 102) einer Steckwicklung in Nuten (23) eines Blechpakets (21) eines Stators (20), umfassend folgende Prozessschritte 1. Assembly method for inserting a hairpin braid (100, 101, 102) of an inserted winding into slots (23) of a laminated core (21) of a stator (20), comprising the following process steps
• Bereitstellung (310) des Hairpinzopfes (100, 101, 102), • Provision (310) of the hairpin braid (100, 101, 102),
• Greifen (320) des Hairpinzopfes (100, 101, 102), wobei U-förmig gebogene Leiterelemente (10) des Hairpinzopfes (100, 101, 102) um die Tangentialachse des Hairpinzopfes (100, 101, 102) drehbar gelagert sind, • gripping (320) of the hairpin braid (100, 101, 102), wherein U-shaped conductor elements (10) of the hairpin braid (100, 101, 102) are mounted rotatably about the tangential axis of the hairpin braid (100, 101, 102),
• Einführung (330) der Schenkel (12) der Leiterelemente (10) des gegriffenen Hairpinzopfes (100, 101, 102) in eine koaxial zur Achse (z) des Hairpinzopfes (100, 101, 102) angeordnete Vorspannvorrichtung (220), • Introduction (330) of the legs (12) of the conductor elements (10) of the gripped hairpin braid (100, 101, 102) into a pretensioning device (220) arranged coaxially to the axis (z) of the hairpin braid (100, 101, 102),
• Ausfahren (340) einer Vielzahl von Ausrichtelementen (221) der Vorspannvorrichtung (220), wobei ein Ausrichtelement (221) zumindest einen Schenkel (12) der Leiterelemente (10) in tangentialer Richtung ausrichtet,• Extending (340) a large number of aligning elements (221) of the prestressing device (220), with one aligning element (221) aligning at least one leg (12) of the conductor elements (10) in the tangential direction,
• Bereitstellung (350) eines Blechpakets (21) eines Stators (20) einer elektrischen Maschine, aufweisend eine Vielzahl an Nuten (23), und • Provision (350) of a laminated core (21) of a stator (20) of an electrical machine, having a multiplicity of slots (23), and
• Einstecken (370) der freien Enden (13) der Schenkel (12) der Leiterelemente (10) in die Nuten (23) des Blechpakets (21), dadurch gekennzeichnet, dass • Inserting (370) the free ends (13) of the legs (12) of the conductor elements (10) into the grooves (23) of the laminated core (21), characterized in that
• beim Ausfahren (340) der Vielzahl von Ausrichtelementen (221) die freien Enden (13) der Schenkel (12) der Leiterelemente (10) des Hairpinzopfes (100, 101, 102) in radialer Richtung nach innen oder außen verschoben werden, wobei als äußere Hüllfläche um die Schenkel (12) der Leiterelemente (10) des Hairpinzopfes (100, 101, 102) eine Mantelfläche eines Kegelstumpfes ausgebildet wird. • When the plurality of alignment elements (221) are extended (340), the free ends (13) of the legs (12) of the conductor elements (10) of the hairpin braid (100, 101, 102) are displaced inwards or outwards in the radial direction, with the outer envelope surface around the legs (12) of the conductor elements (10) of the hairpin braid (100, 101, 102) a lateral surface of a truncated cone is formed.
2. Verfahren nach einem der vorhergehenden Ansprüche, wobei beim Einführen (330) der Schenkel (12) der Leiterelemente (10) des gegriffenen Hairpinzopfes (100, 101, 102) in die Vorspannvorrichtung (220) die Vorspannvorrichtung (220) im Bereich zwischen der Mitte der Schenkel (12) und den freien Enden (13) der Schenkel (12) angeordnet wird. 2. The method according to any one of the preceding claims, wherein when inserting (330) the legs (12) of the conductor elements (10) of the gripped hairpin braid (100, 101, 102) into the pretensioning device (220), the pretensioning device (220) in the area between the Center of the legs (12) and the free ends (13) of the legs (12) is arranged.
3. Verfahren nach einem der vorhergehenden Ansprüche, wobei vor der Einführung (370) der Schenkel (12) der Leiterelemente (10) in die Nuten (23) des Blechpakets (21) des Stators (20) folgender Schritt durchgeführt wird • Einführung (360) der freien Enden (13) der Schenkel (12) der Leiterelemente (10) des Hairpinzopfes (100, 101, 102) in eine Positionierhilfseinrichtung (240), welche in z-Richtung koaxial zum Blechpaket (21) des Stator (20) angeordnet wird, wobei die Positionierhilfseinrichtung (240) mittels einer Vielzahl an Positionierhilfselementen (241) dazu eingerichtet ist, die freien Enden (13) der Schenkel (12) der Leiterelemente (10) zu den Nuten (23) des Blechpakets (21) auszurichten. Verfahren nach einem der vorhergehenden Ansprüche, wobei nach dem Einstecken (370) der freien Enden (13) der Schenkel (12) der Leiterelemente (10) in die Nuten (23) des Blechpakets (21) folgender Schritt durchgeführt wird 3. The method according to any one of the preceding claims, wherein before the introduction (370) of the legs (12) of the conductor elements (10) into the grooves (23) of the laminated core (21) of the stator (20), the following step is carried out • Introduction (360) of the free ends (13) of the legs (12) of the conductor elements (10) of the hairpin braid (100, 101, 102) in a positioning aid (240) which is coaxial to the laminated core (21) of the stator in the z-direction (20), the positioning aid device (240) being set up by means of a large number of positioning aid elements (241) to move the free ends (13) of the legs (12) of the conductor elements (10) to the grooves (23) of the laminated core (21 ) to align. Method according to one of the preceding claims, wherein after the insertion (370) of the free ends (13) of the legs (12) of the conductor elements (10) into the grooves (23) of the laminated core (21), the following step is carried out
• Anpressung (380) der Schenkel (12) der Leiterelemente (10) des Hairpinzopfes(100, 101, 102) in radialer Richtung nach außen oder innen, insbesondere zwischen den Positionierhilfselementen, und • pressing (380) of the legs (12) of the conductor elements (10) of the hairpin braid (100, 101, 102) in the radial direction outwards or inwards, in particular between the positioning aid elements, and
• Durchstecken (390) der Schenkel (12) der Leiterelemente (10) durch die Nuten (23) des Blechpakets (21). Verfahren nach einem der vorhergehenden Ansprüche, wobei das Verfahren so oft wiederholt wird, bis mindestens zwei Hairpinzöpfe (100, 101, 102) in den Nuten (23) des Blechpakets (21) positioniert sind. Computerprogramm, umfassend Befehle, die bei der Ausführung des Programms durch einen Computer diesen veranlassen, die Schritte des Verfahrens nach einem der vorhergehenden Ansprüche auszuführen. Montageanlage zum Einstecken eines Hairpinzopfes (100, 101, 102) einer Steckwicklung in Nuten (23) eines Blechpakets (21) eines Stators (20), umfassend• Inserting (390) the legs (12) of the conductor elements (10) through the grooves (23) of the laminated core (21). Method according to one of the preceding claims, the method being repeated until at least two hairpin braids (100, 101, 102) are positioned in the grooves (23) of the laminated core (21). Computer program comprising instructions which, when the program is executed by a computer, cause it to carry out the steps of the method according to any one of the preceding claims. Assembly system for inserting a hairpin braid (100, 101, 102) of an insert winding into slots (23) of a laminated core (21) of a stator (20), comprising
• eine Greifvorrichtung (210), welche dazu eingerichtet ist, einen bereitgestellten Hairpinzopf (100, 101, 102) zu greifen, wobei beim Greifen eine Vielzahl an Eiförmig gebogenen Leiterelemente (10) des Hairpinzopf (100, 101, 102) um die Tangentialachse des Hairpinzopfes (100, 101, 102) drehbar gelagert werden, wobei die Greifvorrichtung (210) dazu eingerichtet ist, in z-Richtung bewegt zu werden, wodurch die freien Enden (13) der geraden Schenkel (12) der Leiterelemente (10) des gegriffenen Hairpinzopfes in z-Richtung von oben nach unten in die Nuten (23) eines bereitgestellten Blechpakets (21) eines Stators (20) einer elektrischen Maschine eingesteckt werden, und • eine Vorspannvorrichtung (220), welche eine Vielzahl von Ausrichtelementen (221) aufweist, welche jeweils dazu eingerichtet sind, zumindest einen Schenkel (12) der Leiterelemente (10) in tangentialer Richtung auszurichten, dadurch gekennzeichnet, dass • a gripping device (210) which is set up to grip a provided hairpin braid (100, 101, 102), wherein when gripping a plurality of egg-shaped curved conductor elements (10) of the hairpin braid (100, 101, 102) around the tangential axis of the Hairpin braids (100, 101, 102) are rotatably mounted, the gripping device (210) being set up to be moved in the z-direction, whereby the free ends (13) of the straight legs (12) of the conductor elements (10) of the gripped Hairpin braids are inserted in the z-direction from top to bottom into the slots (23) of a provided laminated core (21) of a stator (20) of an electrical machine, and • a prestressing device (220) which has a multiplicity of alignment elements (221), which are each set up to align at least one leg (12) of the conductor elements (10) in the tangential direction, characterized in that
• zumindest ein Teil der Ausrichtelemente (221) mindestens einen mechanischen Anschlag (222) aufweisen, wodurch sie dazu eingerichtet sind, die freien Enden (13) der Schenkel (12) in radialer Richtung nach innen oder außen zu verschieben, so dass als äußere Hüllfläche um die Schenkel (12) der Leiterelemente (10) des Hairpinzopfes (100, 101, 102) eine Mantelfläche eines Kegelstumpfes ausgebildet wird. Montageanlage nach Anspruch 7, aufweisend folgende Komponente • at least some of the alignment elements (221) have at least one mechanical stop (222), whereby they are set up to move the free ends (13) of the legs (12) inwards or outwards in the radial direction, so that as an outer envelope surface a lateral surface of a truncated cone is formed around the legs (12) of the conductor elements (10) of the hairpin braid (100, 101, 102). Assembly system according to Claim 7, having the following components
• eine Positionierhilfseinrichtung (240), welche dazu eingerichtet ist, in z-Richtung zwischen der Vorspannvorrichtung (220) und dem Blechpakets (21) des Stators (20) koaxial angeordnet zu sein, wobei die Positionierhilfseinrichtung (240) eine Vielzahl an Positionierhilfselementen (241) aufweist, wobei jedes Positionierhilfselement (241) oberhalb eines Stegs (22) des Blechpakets (21) angeordnet und dazu eingerichtet ist, die freien Enden (13) der Schenkel (12) der Leiterelemente (10) zu den Nuten (23) des Blechpakets (21) auszurichten. Montageanlage nach einem der Ansprüche 7 oder 8, aufweisend folgende Komponente • an auxiliary positioning device (240), which is set up to be arranged coaxially in the z-direction between the prestressing device (220) and the laminated core (21) of the stator (20), the auxiliary positioning device (240) having a large number of auxiliary positioning elements (241 ), each positioning aid element (241) being arranged above a web (22) of the laminated core (21) and set up to move the free ends (13) of the legs (12) of the conductor elements (10) to the grooves (23) of the laminated core (21) to align. Assembly plant according to one of Claims 7 or 8, having the following components
• eine Spannvorrichtung (230), welche koaxial zu dem Blechpaket (21) des Stators (20) angeordnet und dazu eingerichtet ist, die Schenkel (12) der Leiterelemente (10) des Hairpinzopfes(100, 101, 102) in radialer Richtung mittels einer Vielzahl von Schiebern (231) nach außen oder nach innen zu verschieben. • a clamping device (230) which is arranged coaxially to the laminated core (21) of the stator (20) and is adapted to the legs (12) of the conductor elements (10) of the hairpin braid (100, 101, 102) in the radial direction by means of a To move a plurality of slides (231) outwards or inwards.
PCT/EP2022/075502 2021-10-14 2022-09-14 Method for installing hairpins of a plug-in winding into corresponding stator core slots, corresponding computer program, and corresponding installation system WO2023061687A1 (en)

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