WO2023061687A1 - Procédé de montage d'épingles à cheveux d'un enroulement enfichable dans des rainures de noyau de stator correspondantes et programme informatique correspondant et installation de montage correspondante - Google Patents

Procédé de montage d'épingles à cheveux d'un enroulement enfichable dans des rainures de noyau de stator correspondantes et programme informatique correspondant et installation de montage correspondante 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)
English (en)
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/fr

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

Abstract

L'invention concerne un procédé de montage pour insérer une tresse en épingle à cheveux (100, 101) dans des rainures de paquets statoriques d'une machine électrique, comprenant les étapes de procédé qui consistent à : fournir la tresse en épingle à cheveux ; saisir la tresse en épingle à cheveux, les segments conducteurs de la tresse en épingle à cheveux étant recourbés en forme de U et pouvant tourner autour de l'axe tangentiel ; introduire les branches (12) des segments conducteurs dans un dispositif de précontrainte disposé coaxialement à l'axe principal (220) ; étendre une pluralité d'éléments d'alignement (221) du dispositif de précontrainte, chaque élément d'alignement (221) alignant au moins une branche (12) des segments conducteurs dans la direction tangentielle ; fournir un paquet statorique présentant une pluralité de rainures ; et insérer les extrémités libres (13) des branches des segments conducteurs dans les rainures de paquet statorique, les extrémités libres (13) des branches (12) étant déplacées vers l'intérieur ou vers l'extérieur dans la direction radiale lors de l'extension des éléments d'alignement (221), de sorte qu'une surface d'enveloppe en forme de cône tronqué soit formée en tant que surface enveloppante externe autour des branches (12) des segments conducteurs de tresse en épingle à cheveux.
PCT/EP2022/075502 2021-10-14 2022-09-14 Procédé de montage d'épingles à cheveux d'un enroulement enfichable dans des rainures de noyau de stator correspondantes et programme informatique correspondant et installation de montage correspondante WO2023061687A1 (fr)

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DE102021211589.6 2021-10-14
DE102021211589.6A DE102021211589A1 (de) 2021-10-14 2021-10-14 Montageverfahren zum Einstecken eines Hairpinzopfes einer Steckwicklung in Nuten eines Blechpakets eines Stators, Computerprogramm und Montageanlage

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DE102018114875A1 (de) 2017-06-20 2018-12-20 Grob-Werke Gmbh & Co. Kg Vorrichtung und Verfahren zur Herstellung eines mit Wicklungen versehenen Maschinenelements für eine elektrische Maschine
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DE102019122550A1 (de) 2018-08-23 2020-02-27 Ford Global Technologies, Llc Elektrische maschine mit haarnadelförmiger wicklung
DE102018121745A1 (de) 2018-09-06 2020-03-12 Aumann AG Verfahren und Vorrichtung zum Herstellen einer Anordnung von Spulenelementen für eine Steckspule einer elektrischen Maschine
DE102019120261A1 (de) 2019-07-26 2021-01-28 Grob-Werke Gmbh & Co. Kg Kranzanordnungs- und -fügevorrichtung sowie Kranzanordnungs- und -fügeverfahren
DE102019124488A1 (de) 2019-09-12 2021-03-18 Gehring E-Tech Gmbh Vorrichtung und Verfahren zum Einsetzen von Leiterstücken in einen Stator

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JP4600508B2 (ja) 2008-04-21 2010-12-15 株式会社デンソー インナーロータ型回転電機のステータ製造方法
JP5458627B2 (ja) 2009-03-30 2014-04-02 アイシン・エィ・ダブリュ株式会社 ステータの製造方法及び製造装置
JP5530121B2 (ja) 2009-05-15 2014-06-25 日特エンジニアリング株式会社 ステータコイル及びその製造方法及び巻き線機
CN106575895B (zh) 2014-09-19 2018-11-30 三菱电机株式会社 定子以及使用了该定子的旋转电机
DE102017123670A1 (de) 2017-10-11 2019-04-11 Aumann AG Verfahren zum Herstellen einer Anordnung für eine Steckspule einer elektrischen Maschine, Greifvorrichtung und Fertigungsvorrichtung
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0945962A1 (fr) * 1997-10-16 1999-09-29 Denso Corporation Procede et dispositif permettant de fabriquer un stator d'alternateur pour vehicule
US20190103792A1 (en) * 2016-03-22 2019-04-04 Honda Motor Co., Ltd. Alignment method and alignment device
DE102018114875A1 (de) 2017-06-20 2018-12-20 Grob-Werke Gmbh & Co. Kg Vorrichtung und Verfahren zur Herstellung eines mit Wicklungen versehenen Maschinenelements für eine elektrische Maschine
DE102019122550A1 (de) 2018-08-23 2020-02-27 Ford Global Technologies, Llc Elektrische maschine mit haarnadelförmiger wicklung
DE102018121745A1 (de) 2018-09-06 2020-03-12 Aumann AG Verfahren und Vorrichtung zum Herstellen einer Anordnung von Spulenelementen für eine Steckspule einer elektrischen Maschine
DE102019120261A1 (de) 2019-07-26 2021-01-28 Grob-Werke Gmbh & Co. Kg Kranzanordnungs- und -fügevorrichtung sowie Kranzanordnungs- und -fügeverfahren
DE102019124488A1 (de) 2019-09-12 2021-03-18 Gehring E-Tech Gmbh Vorrichtung und Verfahren zum Einsetzen von Leiterstücken in einen Stator

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