Method for manufacturing a coil of an electric motor device, winding device for manufacturing the coil of the electric motor device, correspondingly manufactured electric motor device, and electric motor with such an electric motor device

Abstract

The invention relates to a method (10), in particular a coil winding method, for producing at least one coil (12-26, 110) of an electric motor device (28), in particular a stator, wherein in at least one method step (30) at least one receiving element (38-42), in particular a stator tooth, of the electric motor device (28) is wound with at least one electrical conductor (44), in particular a copper enamelled wire. It is proposed that the receiving element (38-42) is only partially wound with the electrical conductor (44) in at least one process step (30), in particular only with at least one wire layer, preferably with a maximum of two wire layers, wherein only after a further receiving element (46-56), in particular a further stator tooth, of the electric motor device (28) has been, in particular completely, wound with the electrical conductor (44) in at least one further process step (36) is the winding of the receiving element (38-42) with the electrical conductor (44) completed, in particular by winding the receiving element (38-42) with at least one further wire layer of the electrical conductor (44) onto the wire layer already present on the receiving element (38-42).

Description

State of the art

[0001] A method, in particular a coil winding method, for producing a coil of an electric motor device, in particular a stator, is already known, wherein in the already known method, in at least one method step, at least one receiving element, in particular a stator tooth, of the electric motor device is wound with at least one electrical conductor, in particular a copper enamel wire. Disclosure of the invention

[0002] The invention is based on a method, in particular a coil winding method, for producing a coil of an electric motor device, in particular a stator, wherein in at least one method step of the method at least one receiving element, in particular a stator tooth, of the electric motor device is wound with at least one electrical conductor, in particular a copper enamel wire.

[0003] It is proposed that the receiving element is wound with the electrical conductor only partially in the at least one method step, in particular only with at least one wire layer, preferably with a maximum of two wire layers, wherein only after a further receiving element, in particular a further stator tooth, of the electric motor device has been wound with the electrical conductor, in particular completely, in at least one further method step is the winding of the receiving element with the electrical conductor completed, in particular by winding the receiving element with at least one further wire layer of the electrical conductor onto the wire layer(s) already present on the receiving element.Preferably, in the at least one method step, the at least one receiving element is only partially wound with the electrical conductor, in particular only with at least one wire layer, preferably with a maximum of two wire layers, wherein, preferably subsequently, at least one further receiving element, in particular a further stator tooth, of the electric motor device is wound with the electrical conductor, in particular completely, wherein after completion of the, in particular complete, winding of the at least one further receiving element, the winding of the at least one receiving element with the electrical conductor is completed, in particular by winding the at least one receiving element with at least one further wire layer of the electrical conductor onto the wire layer already present on the at least one receiving element.The inventive design of the method advantageously makes it possible to achieve a high fill factor for the coil of the electric motor device. The high fill factor advantageously makes it possible to achieve high efficiency of the electric motor device. Furthermore, reliable and efficient heat dissipation from a winding of the coil can advantageously be enabled. A winding process can advantageously be implemented which enables high production efficiency. Blocking of a slot access, in particular a receiving space between two receiving elements, in particular between the receiving element and the further receiving element, of the electric motor device by transverse windings of the electrical conductor extending into a slot, in particular into the receiving space, can advantageously be counteracted, in particular reduced to a minimum.

[0004] The method is preferably intended for a stator winding for an electric motor, particularly one designed as a three-phase motor, with a 9-slot / 6-pole motor topology with a delta connection, particularly a star-delta connection. However, it is also conceivable that the method is intended for a different motor topology and / or a different electric motor configuration that would be deemed appropriate by a person skilled in the art.

[0005] The electric motor device is preferably designed as a stator, in particular as an inner rotor stator surrounding a rotor, preferably an inner rotor rotor, of an electric motor. However, it is also conceivable for the electric motor device to be designed as an outer rotor stator surrounded by a rotor, preferably an outer rotor rotor, of an electric motor. The electric motor device is preferably intended for use in EC motors (electrically commutated motors). “Intended” should be understood in particular to mean specially configured, specially programmed, specially designed and / or specially equipped. The fact that an object is intended for a specific function should be understood in particular to mean that the object fulfills and / or executes this specific function in at least one application and / or operating state.

[0006] The electric motor device preferably comprises a stator star pack that has or is formed from a plurality of T-segments. In particular, a T-segment forms a receiving element of the electric motor device that is designed as a stator tooth and that can be wound, in particular is wound, with an electrical conductor, in particular an enameled copper wire, preferably to form at least part of or an entire coil of the electric motor device. The electric motor device preferably comprises a plurality of receiving elements, in particular stator teeth, that are arranged uniformly distributed along a circumferential direction. The circumferential direction preferably runs in a plane that extends at least substantially perpendicular to a central axis, in particular an axis of rotational symmetry, of the electric motor device and / or to a rotational axis of the rotor.The term "substantially perpendicular" is intended, in particular, to define an orientation of a direction relative to a reference direction, wherein the direction and the reference direction, particularly viewed in a projection plane, enclose an angle of 90°, and the angle has a maximum deviation of, in particular, less than 8°, advantageously less than 5°, and particularly advantageously less than 2°. Preferably, the receiving elements are arranged uniformly distributed on a base body of the electric motor device and / or on a receiving ring of the electric motor device according to an n-fold, in particular a nine-fold, rotational symmetry.

[0007] The receiving elements can be designed as individual T-segments which are or will be connected to form a tooth chain by means of a positive, non-positive and / or material-locking connection in a manner already known to a person skilled in the art, or which are or will be arranged, in particular plugged, on the receiving ring of the electric motor device by means of a positive, non-positive and / or material-locking connection in a manner already known to a person skilled in the art, in particular before or after winding. Preferably, the receiving elements form a star-shaped or circularly arranged T-segment package even before winding with the electrical conductor. Preferably, the receiving elements are arranged as a star-shaped or circularly arranged T-segment package on a winding device, in particular on a flyer coil winding device, for winding with the electrical conductor.Preferably, the receiving elements, in particular the stator teeth, are wound with a continuous electrical conductor without interruption, preferably except for at least one respective strain relief winding step and / or one stator tooth winding change step, in particular in order to enable a small number of electrical contact points of the electric motor device, in particular to exactly two electrical contact points. The receiving elements, in particular the stator teeth, are wound with the electrical conductor in particular using a flyer coil winding technique. However, it is also conceivable for the receiving elements, in particular the stator teeth, to be wound with the electrical conductor using another coil winding technique that appears appropriate to a person skilled in the art, such as, for example, using a needle winding technique or the like.Particularly when using a flyer coil winding technique, a guide plate of the winding device, in particular of the flyer coil winding device, is preferably inserted at least partially into the spaces between two receiving elements that are directly adjacent, viewed along the circumferential direction, for winding an individual receiving element. Winding of the individual receiving elements is preferably carried out in a manner already known to a person skilled in the art, at least by rotating a flyer of the winding device, on which the electrical conductor is guided, relative to the receiving element.It is conceivable that during winding of the respective receiving element only the flyer is rotated about a winding axis, while the receiving element to be wound is arranged in a fixed position, that only the receiving element to be wound is rotated about the winding axis, while the flyer is arranged in a fixed position, or that the flyer and the receiving element to be wound are rotated about the winding axis during winding, in particular are rotated at least temporarily in opposite directions about the winding axis. The winding axis preferably runs at least substantially perpendicular to the central axis, in particular to the rotational symmetry axis, of the electric motor device and / or to the rotational axis. However, it is also conceivable that the winding axis or at least one axis of movement of a winding element of the winding device runs at least substantially parallel to the central axis, in particular to the rotational symmetry axis, and / or to the rotational axis."Substantially parallel" is understood to mean, in particular, an alignment of a direction relative to a reference direction, in particular in a plane, wherein the direction has a deviation from the reference direction of, in particular, less than 8°, advantageously less than 5°, and particularly advantageously less than 2°. The central axis, in particular the rotational symmetry axis, of the electric motor device preferably runs coaxially to the rotational axis of the rotor of the electric motor, at least in an assembled state of the electric motor device in a housing of the electric motor.

[0008] Furthermore, it is proposed that several receiving elements of the electric motor device, which are assigned to a common phase of the electric motor device or form this phase, are wound with the electrical conductor only partially, in particular one after the other, in particular only with at least one wire layer, preferably with a maximum of two wire layers. The receiving elements assigned to a common phase of the electric motor device or forming this phase are preferably arranged offset from one another by an angle of 120°, viewed along the circumferential direction.Preferably, the receiving elements are wound in phases, such as firstly, in particular partially, winding all receiving elements assigned to or forming a first phase, then, in particular completely, winding all receiving elements assigned to or forming a second phase, and then, in particular completely, winding all receiving elements assigned to or forming a third phase. By means of the inventive embodiment of the method, it is advantageously possible to minimize the influence of windings of the electrical conductor already present on the receiving element on an insertion area between the receiving element and the further receiving element, into which insertion area, in particular, a conducting plate of the winding device can be inserted for winding the further receiving element by means of the winding device.A high fill factor for the coil of the electric motor device can advantageously be achieved. The high fill factor can advantageously achieve high efficiency of the electric motor device. Furthermore, reliable and efficient heat dissipation from a winding of the coil can advantageously be enabled. A winding process that enables high production efficiency can advantageously be implemented.

[0009] It is further proposed that after partial winding of the receiving element, in particular of all receiving elements of the electric motor device assigned to a common phase of the electric motor device or forming this phase, with the electrical conductor, the further receiving element which is, in particular directly adjacent to the respective receiving element, viewed along a circumferential direction of the electric motor device, in particular the one already mentioned, is wound, in particular completely, with the electrical conductor. Preferably, the further receiving elements are assigned to a further phase of the electric motor device or form this phase. The further receiving elements are preferably arranged offset by an angle of 40° to the respective directly adjacent receiving element, viewed along the circumferential direction.The further receiving elements, which are arranged offset by an angle of 40° to the respective, in particular directly adjacent, receiving element, are in particular successively completely wound with the electrical conductor. The further receiving elements, which are arranged offset by an angle of 40° to the respective, in particular directly adjacent, receiving element, are preferably assigned to a further, in particular second, phase of the electric motor device or form this. Preferably, after a, in particular complete, winding of the further receiving elements, which are arranged offset by an angle of 40° to the respective, in particular directly adjacent, receiving element, additional receiving elements are wound, which are arranged offset by an angle of 40° to the respective, in particular directly adjacent, previously, in particular completely wound further receiving element, viewed along the circumferential direction.The additional further receiving elements are preferably assigned to an additional further, in particular third, phase of the electric motor device or form this. The inventive design of the method advantageously enables particularly efficient winding of the receiving elements. A high fill factor of the coil of the electric motor device can advantageously be realized. High efficiency of the electric motor device can advantageously be achieved due to the high fill factor. Furthermore, reliable and efficient heat dissipation from a winding of the coil can advantageously be enabled. A winding process that enables high production efficiency can advantageously be implemented.

[0010] It is also proposed that at least three receiving elements of the electric motor device, preferably those already mentioned, arranged offset from one another by an angle of 120°, are partially wound, in particular one after the other, with the electrical conductor. Subsequently, at least six further receiving elements, in particular the previously mentioned further receiving elements, are completely wound with the electrical conductor before the winding of the three receiving elements, in particular those initially only partially wound, with the electrical conductor is completed. The three receiving elements, arranged offset from one another by an angle of 120°, are preferably assigned to a common phase, in particular the first phase, of the electric motor device or form this phase.Three of the additional receiving elements, each offset by an angle of 120° from one another, are preferably assigned to or form a further common phase, in particular the second phase, of the electric motor device. The other three of the additional receiving elements, each offset by an angle of 120° from one another, are preferably assigned to or form an additional common phase, in particular the third phase, of the electric motor device. The inventive design of the method advantageously enables particularly efficient winding of the receiving elements.A high fill factor of the coil of the electric motor device can advantageously be realized, in particular since the influence of the windings of the electrical conductor already located on the receiving element on an insertion area, into which, in particular, a conductive sheet of the winding device can be inserted for winding, can be minimized. A winding process can advantageously be realized that enables high production efficiency, in particular with regard to a high fill factor.

[0011] Furthermore, it is proposed that all receiving elements of the electric motor device which are assigned to a common, in particular the first, phase of the electric motor device or which form this, in particular one after the other, are only partially wound with the electrical conductor, in particular only with at least one wire layer, preferably with a maximum of two wire layers, wherein only after all further receiving elements have been wound, in particular completely, with the electrical conductor, which are assigned to at least one or more further common phase(s) of the electric motor device or which form this, the winding of all receiving elements with the electrical conductor is completed in at least one further method step.Preferably, the receiving elements are wound in phases, such as, for example, firstly, a particularly partial winding of all receiving elements assigned to or forming a first phase, a subsequent, particularly complete winding of all receiving elements assigned to or forming a second phase, and a subsequent, particularly complete winding of all receiving elements assigned to or forming a third phase. Preferably, the particularly complete winding of all receiving elements assigned to or forming the third phase is followed by completion of the initially partial winding of all receiving elements assigned to or forming the first phase.Preferably, all of the receiving elements assigned to or forming the first phase are first wound with the electrical conductor only partially, in particular only with at least one wire layer, preferably with a maximum of two wire layers, in particular one after the other. Preferably, all of the receiving elements assigned to or forming a second and / or third phase are then completely wound with the electrical conductor, preferably before further winding of the receiving elements assigned to or forming the first phase takes place to complete the winding on the receiving elements assigned to or forming the first phase. The design of the method according to the invention advantageously makes it possible to implement a winding process which enables high production efficiency, in particular with regard to a high fill factor. Particularly efficient winding of the receiving elements can advantageously be made possible.Advantageously, a high fill factor of the coil of the electric motor device can be realized, in particular since an influence on an insertion area, into which in particular a conducting plate of the winding device can be inserted for winding, caused by windings of the electrical conductor already located on the receiving element, can be kept to a minimum.

[0012] It is further proposed that a winding tool, in particular a guide plate of the winding device, preferably a guide plate of the winding device cooperating with a flyer of the winding device, is at least partially inserted into a receiving space between the receiving element and the further receiving element to complete the winding of the receiving element with the electrical conductor, in particular after all further receiving elements have already been fully wound with the electrical conductor, wherein a maximum insertion distance of the winding tool is less than 80%, in particular less than 50%, of a maximum depth of the receiving space.Preferably, the maximum depth of the receiving space and / or the maximum insertion distance of the winding tool extends along a direction that is at least substantially perpendicular to the central axis, in particular the axis of rotational symmetry, of the electric motor device and / or to the axis of rotation of the rotor. The inventive design of the method advantageously enables effective winding of the receiving elements, in particular those previously only partially wound. It is advantageously possible to minimize the influence of windings of the electrical conductor already located on the further, already fully wound receiving elements upon completion of the winding on the receiving elements. This advantageously enables particularly efficient winding of the receiving elements.Advantageously, a high fill factor of the coil of the electric motor device can be realized, in particular since an influence on an insertion area, into which in particular a conducting plate of the winding device can be inserted for winding, caused by windings of the electrical conductor already located on the receiving element, can be kept to a minimum.

[0013] Furthermore, it is proposed that winding be terminated at the receiving element on which the, in particular partial, winding was started. Preferably, the receiving element that is first wound with the electrical conductor, in particular partially, is also the last receiving element to be wound with the electrical conductor. The inventive design of the method advantageously allows a winding process to be implemented that enables high production efficiency. Using the inventive method, an electric motor device with a high fill factor can advantageously be achieved.

[0014] Furthermore, it is proposed that, after the winding of the receiving element with the electrical conductor has been completed, electrical contact is made between a start of the electrical conductor and an end of the electrical conductor. Preferably, the electrical contact between the start of the electrical conductor and the end of the electrical conductor takes place after all receiving elements that are assigned to or form the first phase of the electric motor device have been completely wound with the electrical conductor, in particular after all other receiving elements that are assigned to or form the second and third phases of the electric motor device have already been completely wound with the electrical conductor.The electrical contacting of the beginning of the electrical conductor and the end of the electrical conductor is preferably carried out in a manner already known to a person skilled in the art, in particular to enable an electrical current to flow through the electric motor device, preferably to create an electrical circuit through the star-delta connection. The inventive design of the method advantageously allows for a winding process to be implemented that enables high production efficiency. An electric motor device can advantageously be implemented that has an advantageously small number of contact points.

[0015] Furthermore, a winding device for producing a coil of an electric motor device, in particular of the aforementioned electric motor device, in particular of a stator, is proposed, comprising at least one computing unit having an operating program provided for producing the coil according to a method according to the invention. The winding device is designed in particular as a flyer coil winding device. However, it is also conceivable for the winding device to have a different configuration that appears expedient to a person skilled in the art, such as a needle winding device or the like. The computing unit is preferably configured to control or regulate, preferably move, a winding tool, in particular at least the aforementioned one, as well as a flyer of the winding device in such a way that the electric motor device is wound with the electrical conductor according to the method according to the invention.The design according to the invention advantageously allows efficient winding of the electric motor device to be realized in order to achieve a high fill factor of the coil of the electric motor device.

[0016] Furthermore, an electric motor device, in particular a stator, manufactured using a method according to the invention, in particular the one already mentioned above, is proposed. The inventive design advantageously allows for a high fill factor of the coil of the electric motor device. The high fill factor advantageously allows for high efficiency of the electric motor device. Furthermore, reliable and efficient heat dissipation from a winding of the coil can advantageously be enabled.

[0017] Furthermore, an electric motor, in particular an EC motor (electrically commutated motor), with at least one electric motor device according to the invention is proposed. The electric motor preferably comprises at least one housing in which the electric motor device is arranged. The electric motor preferably comprises at least one return ring which surrounds the electric motor device, in particular completely. The electric motor preferably comprises at least one rotor, in particular the one already mentioned, which is rotatably mounted within the electric motor device, in particular in a manner already known to a person skilled in the art. The electric motor can be used in various devices, machines or motor vehicles, such as, for example, in hand-held power tools, in gardening equipment, in machine tools, in household appliances, in cars, in trucks or the like.The electric motor is preferably intended for use in a windshield washer system of a motor vehicle. The design according to the invention advantageously allows a high degree of efficiency and / or high efficiency of the electric motor to be achieved.

[0018] The method according to the invention, the winding device according to the invention, the electric motor device according to the invention, and / or the electric motor according to the invention are not intended to be limited to the application and embodiment described above. In particular, the method according to the invention, the winding device according to the invention, the electric motor device according to the invention, and / or the electric motor according to the invention can have a number of individual elements, components, units, and method steps that differs from the number stated herein in order to fulfill a function described herein. Furthermore, in the value ranges specified in this disclosure, values ​​within the stated limits are also to be considered disclosed and can be used arbitrarily. drawing

[0019] Further advantages will become apparent from the following description of the drawings. The drawings illustrate an exemplary embodiment of the invention. The drawings, the description, and the claims contain numerous features in combination. Those skilled in the art will also expediently consider the features individually and combine them into useful further combinations.

[0020] They show: Fig. 1 shows an electric motor according to the invention with an electric motor device according to the invention in a schematic representation, wherein possible applications in various devices, machines or motor vehicles are shown by way of example, Fig. 2 shows a process sequence of a method according to the invention for winding receiving elements of the electric motor device according to the invention in a schematic representation, Fig. 3 a winding device according to the invention with an electric motor device according to the invention arranged thereon, which is wound with an electrical conductor according to a method according to the invention, in a schematic representation, Fig. 4a-4c show a partial winding of receiving elements of the electric motor device according to the invention with an electrical conductor by means of the winding device according to the invention in accordance with the method according to the invention in a schematic representation, Fig. 5 a sectional view of a receiving element partially wound with the electrical conductor of the receiving elements from the Fig. 4a-4c in a schematic representation, Fig. 6a-6c show a complete winding of further receiving elements of the electric motor device according to the invention with the electrical conductor by means of the winding device according to the invention in accordance with the method according to the invention in a schematic representation, Fig. 7a-7c show a complete winding of additional further receiving elements of the electric motor device according to the invention with the electrical conductor by means of the winding device according to the invention in accordance with the method according to the invention in a schematic representation, Fig. 8a-8c a completion of the winding of the previously only partially wound receiving elements from the Fig. 3a-3c in a schematic representation and Fig. 9 a circuit diagram of the electric motor device according to the invention in a schematic representation. Description of the embodiment

[0021] Fig. 1 shows an electric motor 90 with an electric motor device 28 in a schematic representation, illustrating by way of example possible devices, machines, or motor vehicles in which the electric motor 90 can be used, in particular installed. The electric motor 90 can be used, in particular installed, for example, in handheld power tools 92, in gardening equipment, in machine tools 94, in household appliances 96, in cars 98, in trucks, or the like. The electric motor 90 is preferably intended for use in a windshield wiper drive of a motor vehicle. The electric motor 90 is preferably designed as an EC motor (electrically commutated motor).

[0022] The electric motor device 28 is preferably designed as a stator, in particular as an internal rotor stator surrounding a rotor (not shown in detail here), preferably an internal rotor rotor, of the electric motor 90. However, it is also conceivable for the electric motor device 28 to have a different configuration that would be deemed appropriate by a person skilled in the art. The electric motor device 28 preferably comprises a stator star pack that has or is formed from a plurality of T-segments (see, for example, Fig. 3 and 4a to 4c). In particular, a T-segment forms a receiving element 38, 40, 42, 46, 48, 50, 52, 54, 56 of the electric motor device 28, which receiving element is designed as a stator tooth and which can be wound, in particular is wound, with an electrical conductor 44, in particular a copper enamel wire, preferably to form at least a part of or an entire coil 12, 14, 16, 18, 20, 22, 24, 26, 110 of the electric motor device 28 (cf. for example Fig. 4a to 8c). The electric motor device 28 preferably comprises a plurality of receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56, in particular stator teeth, which are arranged uniformly distributed along a circumferential direction 64 of the electric motor device 28. The circumferential direction 64 preferably runs in a plane extending at least substantially perpendicular to a central axis 100, in particular a rotational symmetry axis, of the electric motor device 28 and / or to a rotational axis 102 of the rotor (cf., for example, Fig. 4a to 4c). Preferably, the receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56 are arranged uniformly distributed on a base body of the electric motor device 28 and / or on a receiving ring of the electric motor device 28 according to an n-fold, in particular a nine-fold, rotational symmetry (cf., for example, Fig. 3 and 4a to 8c).

[0023] The receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56 can be designed as individual T-segments, which are or will be connected to a toothed chain by means of a positive, non-positive and / or material connection in a manner already known to a person skilled in the art, or which are or will be arranged, in particular plugged, on the receiving ring of the electric motor device 28 by means of a positive, non-positive and / or material connection in a manner already known to a person skilled in the art, in particular before or after winding. Preferably, the receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56 already form a star-shaped or circularly arranged T-segment package before winding with the electrical conductor 44 (cf. Fig. 4a to 8c).

[0024] Preferably, the receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56 are arranged on a winding device 86, in particular on a flyer coil winding device, for winding with the electrical conductor 44 as a star-shaped or circular T-segment package (cf. Fig. 3). Preferably, the receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56, in particular the stator teeth, are wound with a continuous electrical conductor 44 in a continuous manner, preferably except for at least one respective strain relief winding step and / or one stator tooth winding change step. The receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56, in particular the stator teeth, are wound with the electrical conductor 44, in particular using a flyer coil winding technique. However, it is also conceivable that the receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56, in particular the stator teeth, are wound with the electrical conductor 44 by means of another coil winding technique that appears appropriate to a person skilled in the art, such as, for example, by means of a needle winding technique or the like.In particular when using a flyer coil winding technique, a winding tool 66, in particular a guide plate 104, of the winding device 86, in particular of the flyer coil winding device, is preferably introduced at least partially into spaces between two receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56 that are directly adjacent when viewed along the circumferential direction 64 (cf. Fig. 3 and 4a to 8c). Winding of the individual receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56 preferably takes place in a manner already known to a person skilled in the art, at least by rotating a flyer (not shown in detail here) of the winding device 86, on which the electrical conductor 44 is guided, relative to the receiving element 38, 40, 42, 46, 48, 50, 52, 54, 56.It is conceivable that during winding of the respective receiving element 38, 40, 42, 46, 48, 50, 52, 54, 56, only the flyer is rotated about a winding axis 106 of the winding device 86, while the receiving element 38, 40, 42, 46, 48, 50, 52, 54, 56 to be wound is arranged in a fixed position, that only the receiving element 38, 40, 42, 46, 48, 50, 52, 54, 56 to be wound is rotated about the winding axis 106, while the flyer is arranged in a fixed position, or that the flyer and the receiving element 38, 40, 42, 46, 48, 50, 52, 54, 56 to be wound are rotated about the winding axis 106 during winding rotated, in particular at least temporarily rotated in opposite directions around the winding axis 106. The winding axis 106 preferably extends at least substantially perpendicular to the central axis 100, in particular to the rotational symmetry axis, of the electric motor device 28 and / or to the rotation axis 102.However, it is also conceivable that the winding axis 106 or at least one movement axis of a winding element, in particular of the flyer, of the winding device 86 runs at least substantially parallel to the central axis 100, in particular to the rotational symmetry axis, and / or to the rotational axis 102. The central axis 100, in particular the rotational symmetry axis, of the electric motor device 28 runs, at least in an assembled state of the electric motor device 28 in a housing of the electric motor 90, preferably coaxially to the rotational axis 102 of the rotor of the electric motor 90.

[0025] Fig. 2 shows a schematic process flow of a method 10 for at least producing at least one of the coils 12, 14, 16, 18, 20, 22, 24, 26, 110 (cf. Fig. 8c and Fig. 9), in particular all coils 12, 14, 16, 18, 20, 22, 24, 26, 110, of the electric motor device 28. The method 10 is preferably designed as a coil winding method. The method 10 is preferably provided for winding the electric motor device 28 designed as a stator by means of the winding device 86. The method 10 is preferably provided for winding the electric motor device 28 designed as a stator for the electric motor 90, in particular designed as a three-phase motor, with a 9-slot / 6-pole motor topology with a delta connection, in particular a star-delta connection (cf. for example also Fig. 4a to 4c and 9). However, it is also conceivable that the method 10 is provided for a different motor topology that appears reasonable to a person skilled in the art and / or a different configuration of the electric motor 90 that appears reasonable to a person skilled in the art. The electric motor device 28 can be manufactured or is manufactured using the method 10.

[0026] In at least one method step 30 of the method 10, at least one of the receiving elements 38, 40, 42 of the electric motor device 28 is wound with the electrical conductor 44, wherein the at least one receiving element 38, 40, 42 is wound only partially in the at least one method step 30, in particular only with at least one wire layer, preferably with a maximum of two wire layers (cf. Fig. 5), with which the electrical conductor 44 is wound (cf. Fig. 4a to 4c), wherein only after a, in particular complete, winding of at least one further receiving element 46, 48, 50, 52, 54, 56 of the electric motor device 28 with the electrical conductor 44 (cf. Fig. 6a to 7c; preferably corresponds to at least one additional method step 32, 34 of the method 10) in at least one further method step 36, winding of the at least one receiving element 38, 40, 42 with the electrical conductor 44 is completed, in particular by winding the at least one receiving element 38, 40, 42 with at least one further wire layer of the electrical conductor 44 onto the wire layer already present on the at least one receiving element 38, 40, 42 (cf. Fig. 8a to 8c). Preferably, the at least one receiving element 38, 40, 42 is only partially welded in the at least one method step 30, in particular only with at least one wire layer, preferably with a maximum of two wire layers (cf. Fig. 5), wound with the electrical conductor 44 (cf. Fig. 4a to 4c), wherein, preferably subsequently, in at least one of the additional method steps 32, 34, at least the at least one further receiving element 46, 48, 50, 52, 54, 56 is wound with the electrical conductor 44, in particular completely (cf. Fig. 6a to 7c), wherein after completion of the, in particular complete, winding of the at least one further receiving element 46, 48, 50, 52, 54, 56, the winding of the at least one receiving element 38, 40, 42 with the electrical conductor 44 is completed, in particular by winding the at least one receiving element 38, 40, 42 with at least one further wire layer of the electrical conductor 44 onto the wire layer already present on the at least one receiving element 38, 40, 42 (cf. Fig. 8a to 8c).

[0027] Preferably, several receiving elements 38, 40, 42 of the electric motor device 28 are provided, which correspond to a common phase 58 (cf. Fig. 9) are assigned to the electric motor device 28 or form it, in particular one after the other, only partially, in particular only with at least one wire layer, preferably with a maximum of two wire layers, wound with the electrical conductor 44 (cf. Fig. 4a to 4c), preferably in at least one process step 30, which may also be divided into sub-steps. The steps of a common phase 58, 60, 62 (cf. Fig. 9) The receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56 assigned to or forming the electric motor device 28 are, viewed along the circumferential direction 64, preferably arranged offset from one another by an angle of 120°. Preferably, the receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56 are wound in phases, such as, for example, firstly, a particularly partial winding of all receiving elements 38, 40, 42 assigned to or forming a first phase 58 (cf. Fig. 4a to 4c), a subsequent, in particular complete, winding of all receiving elements 46, 48, 50 assigned to or forming a second phase 60 (cf. Fig. 6a to 6c) and a subsequent, in particular complete, winding of all receiving elements 52, 54, 56 assigned to or forming a third phase 62 (cf. Fig. 7a to 7c).

[0028] Preferably, after a partial winding of the at least one receiving element 38, 40, 42, in particular of all receiving elements 38, 40, 42 assigned to or forming a common, in particular first, phase 58, with the electrical conductor 44, the further receiving element 46, 48, 50, which is adjacent to, in particular directly adjacent to, the respective receiving element 38, 40, 42, viewed along the circumferential direction 64, is wound with the electrical conductor 44, in particular completely (cf. Fig. 6a to 6c). Preferably, the further receiving elements 46, 48, 50 are assigned to or form a further, in particular a second, phase 60 of the electric motor device 28. The further receiving elements 46, 48, 50 are preferably arranged offset by an angle of 40° relative to the respective directly adjacent receiving element 38, 40, 42, viewed along the circumferential direction 64 (cf. Fig. 6a to 6c). The further receiving elements 46, 48, 50, which are arranged offset by an angle of 40° to the respective, in particular directly adjacent, receiving element 38, 40, 42, are wound completely with the electrical conductor 44, in particular one after the other. The further receiving elements 46, 48, 50, 52, which are arranged offset by an angle of 40° to the respective, in particular directly adjacent, receiving element 38, 40, 42, are preferably assigned to or form a further, in particular second, phase 60 of the electric motor device 28.Preferably, after a, in particular complete, winding of the further receiving elements 46, 48, 50 arranged offset by an angle of 40° to the respective, in particular directly adjacent receiving element 38, 40, 42, additional further receiving elements 52, 54, 56 are wound, which are arranged offset by an angle of 40° to the respective, in particular directly adjacent, previously, in particular completely wound further receiving element 46, 48, 50, viewed along the circumferential direction 64 (cf. . Fig. 7a to 7c). The additional receiving elements 52, 54, 56 are preferably assigned to or form an additional, in particular third, phase 62 of the electric motor device 28.

[0029] Preferably, at least three receiving elements 38, 40, 42 of the electric motor device 28, in particular arranged offset by an angle of 120° to one another, are partially wound with the electrical conductor 44 (cf. Fig. 4a to 4c), wherein subsequently at least six further receiving elements 46, 48, 50, 52, 54, 56 are completely wound with the electrical conductor 44 (cf. Fig. 6a to 7c) before the winding of the three receiving elements 38, 40, 42 with the electrical conductor 44 is completed (cf. Fig. 8a to 8c). The three receiving elements 38, 40, 42, which are arranged offset from one another in particular by an angle of 120°, are preferably assigned to the first phase 58 of the electric motor device 28 or form this phase. Three of the further receiving elements 46, 48, 50, which are each arranged offset from one another by an angle of 120°, are preferably assigned to the second phase 60 of the electric motor device 28 or form this phase. The other three of the further receiving elements 52, 54, 56, which are each arranged offset from one another by an angle of 120°, are preferably assigned to the third phase 62 of the electric motor device 28 or form this phase.

[0030] Preferably, all receiving elements 38, 40, 42 of the electric motor device 28 which are assigned to a common, in particular the first, phase 58 of the electric motor device 28 or which form this, in particular one after the other, are only partially wound with the electrical conductor 44, in particular only with at least one wire layer, preferably with a maximum of two wire layers, wherein only after all further receiving elements 46, 48, 50, 52, 54, 56 have been wound, in particular completely, with the electrical conductor 44, which are assigned to at least one or more further common, in particular the second and third, phase(s) 60, 62 of the electric motor device 28 or which form this, in at least one further method step 36, the winding of all receiving elements 38, 40, 42 with the electrical conductor 44 is completed.Preferably, the receiving elements 38, 40, 42, 46, 48, 50, 52, 54, 56 are wound in phases, for example, first, in particular partially, all receiving elements 38, 40, 42 assigned to or forming the first phase 58 are wound, then, in particular completely, all receiving elements 46, 48, 50 assigned to or forming the second phase 60 are wound, and then, in particular completely, all receiving elements 52, 54, 56 assigned to or forming a third phase 62 are wound. Preferably, the, in particular completely, winding of all receiving elements 52, 54, 56 assigned to or forming the third phase 62 is followed by a completion of the winding of all receiving elements 38, 40, 42 that were initially partially wound and that are assigned to or forming the first phase 58.Preferably, all of the receiving elements 38, 40, 42 assigned to or forming the first phase 58 are first wound with the electrical conductor 44 only partially, in particular only with at least one wire layer, preferably with a maximum of two wire layers, in particular one after the other. Preferably, all of the receiving elements 46, 48, 50, 52, 54, 56 assigned to or forming the second and / or third phase 60, 62 are then completely wound with the electrical conductor 44, preferably before further winding of the receiving elements 38, 40, 42 assigned to or forming the first phase 58 takes place to complete the winding on the receiving elements 38, 40, 42 assigned to or forming the first phase 58.

[0031] A winding tool 66 for completing the winding of the receiving element / receiving elements 38, 40, 42, in particular all of the first phase 58 assigned to or forming this, with the electrical conductor 44 is at least partially inserted into a receiving space 68, 70, 72, 74, 76, 78, 80, 82, 84 between the receiving element 38, 40, 42 and the further receiving element 46, 48, 50, 52, 54, 56, wherein a maximum insertion distance of the winding tool 66 is less than 80%, in particular less than 50%, of a maximum depth of the receiving space 68, 70, 72, 74, 76, 78, 80, 82, 84 (cf. in particular Fig. 8a to 8c). Preferably, the maximum depth of the receiving space 68, 70, 72, 74, 76, 78, 80, 82, 84 and / or the maximum insertion distance of the winding tool 66 extends along a direction that is at least substantially perpendicular to the central axis 100, in particular the rotational axis of symmetry, of the electric motor device 28 and / or to the rotational axis 102 of the rotor.

[0032] In the at least one further method step 36, winding is preferably completed on the receiving element 38, 40, 42 on which the, in particular partial, winding was started in the at least one method step 30. Preferably, the receiving element 38 that is first wound with the electrical conductor 44 in the method step 30, in particular partially, is also the last receiving element 38 that is wound with the electrical conductor 44 in the further method step 36, in particular to complete a winding process.

[0033] Preferably, in at least one additional method step 108 of method 10, after completion of the, in particular complete, winding of the receiving element 38, in particular the first partially wound and then finally fully wound receiving element 38, with the electrical conductor 44, an electrical contact is made between a start of the electrical conductor 44 and an end of the electrical conductor 44. Preferably, the electrical contact between the start of the electrical conductor 44 and the end of the electrical conductor 44 takes place as the last method step 108 of method 10.The electrical contacting of the beginning of the electrical conductor 44 and the end of the electrical conductor 44 is preferably carried out in a manner already known to a person skilled in the art, in particular in order to enable an electrical current to flow through the electric motor device 28, preferably in order to form an electrical circuit through the star-delta connection (cf. Fig. 9) to be realized.

[0034] It is conceivable that the method 10 comprises further method steps that appear reasonable to a person skilled in the art and / or that a sequence of method steps is carried out in a manner that appears reasonable to a person skilled in the art, deviating from the list of method steps listed above.

[0035] The winding device 86, in particular the flyer coil winding device, for producing one or all of the coils 12, 14, 16, 18, 20, 22, 24, 26, 110 (cf. Fig. 8c and Fig. 9) of the electric motor device 28 preferably comprises at least one computing unit 88 (cf. Fig. 3; computing unit 88 shown only in dashed lines), which has an operating program provided for producing the or all coils 12, 14, 16, 18, 20, 22, 24, 26, 110 according to the previously described method 10. The computing unit 88 is preferably configured to control or regulate, preferably move, the winding tool 66, in particular the guide plate 104, as well as the flyer of the winding device 86 such that the electric motor device 28 is wound with the electrical conductor 44 according to the previously described method 10. The winding device 86 can have further elements and / or operating programs already known to a person skilled in the art, which are useful for producing the electric motor device 28 and / or the electric motor 90.

Claims

[1] Method (10), in particular coil winding method, for producing at least one coil (12-26, 110) of an electric motor device (28), in particular a stator, wherein in at least one method step (30) at least one receiving element (38-42), in particular a stator tooth, of the electric motor device (28) is wound with at least one electrical conductor (44), in particular a copper enamel wire, characterized bythat the receiving element (38-42) is wound with the electrical conductor (44) only partially in the at least one method step (30), in particular only with at least one wire layer, preferably with a maximum of two wire layers, wherein only after a further receiving element (46-56), in particular a further stator tooth, of the electric motor device (28) has been wound with the electrical conductor (44), in particular completely, in at least one further method step (36), the winding of the receiving element (38-42) with the electrical conductor (44) is completed, in particular by winding the receiving element (38-42) with at least one further wire layer of the electrical conductor (44) onto the wire layer already present on the receiving element (38-42). [2] Method (10) according to claim 1, characterized bythat a plurality of receiving elements (38-42) of the electric motor device (28), which are assigned to a common phase (58) of the electric motor device (28) or form this, in particular one after the other, are only partially wound with the electrical conductor (44), in particular only with at least one wire layer, preferably with a maximum of two wire layers. [3] Method (10) according to claim 1 or 2, characterized by that after a partial winding of the receiving element (38-42), in particular of all receiving elements (38-42) of the electric motor device (28) assigned to or forming a common phase (58) of the electric motor device (28), with the electrical conductor (44), the further receiving element (46-56) which is adjacent to, in particular directly adjacent to, the respective receiving element (38-42) as viewed along a circumferential direction (64) of the electric motor device (28) is wound with the electrical conductor (44), in particular completely. [4] Method (10) according to one of the preceding claims, characterized by that at least three receiving elements (38-42) of the electric motor device (28), in particular arranged offset by an angle of 120° to one another, are partially wound with the electrical conductor (44), wherein subsequently at least six further receiving elements (46-56) are completely wound with the electrical conductor (44) before the winding of the three receiving elements (38-42) with the electrical conductor (44) is completed. [5] Method (10) according to one of the preceding claims, characterized bythat all receiving elements (38-42) of the electric motor device (28) which are assigned to a common, in particular first, phase (58) of the electric motor device (28) or form this, in particular one after the other, are only partially wound with the electrical conductor (44), in particular only with at least one wire layer, preferably with a maximum of two wire layers, wherein only after all further receiving elements (46-56) have been wound, in particular completely, with the electrical conductor (44), which are assigned to at least one or more further common phase(s) (60, 62) of the electric motor device (28) or form this, the winding of all receiving elements (38-42) with the electrical conductor (44) is completed in at least one further method step (36). [6] Method (10) according to one of the preceding claims, characterized byin that a winding tool (66) is inserted at least partially into a receiving space (68-84) between the receiving element (38-42) and the further receiving element (46-56) to complete the winding of the receiving element (38-42) with the electrical conductor (44), wherein a maximum insertion distance of the winding tool (66) is less than 80%, in particular less than 50%, of a maximum depth of the receiving space (68-84). [7] Method (10) according to one of the preceding claims, characterized by that winding is terminated on the receiving element (38-42) on which the, in particular partial, winding was started. [8] Method (10) according to one of the preceding claims, characterized by that after completion of the winding of the receiving element (38-42) with the electrical conductor (44), electrical contact is made between a start of the electrical conductor and an end of the electrical conductor. [9] Winding device (86), in particular flyer coil winding device, for producing a coil (12-26, 110) of an electric motor device (28), in particular a stator, with at least one computing unit (88) which has an operating program which is provided for producing the coil (12-26, 110) according to a method according to one of the preceding claims. [10] Electric motor device (28), in particular stator, manufactured using a method according to one of claims 1 to 8. [11] Electric motor (90), in particular EC motor, with at least one electric motor device (28) according to claim 10.

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