Process and winding nozzle

Abstract

The invention relates to a method for manufacturing a winding nozzle (10) by means of a manufacturing device for winding a coil (12), in particular an electric motor, for example a stator (14) of the electric motor, with a coil wire (16), wherein in at least one process step (44) a winding nozzle geometry (20) is designed by means of a computing unit on the basis of a parameterized design model. It is proposed that the winding nozzle geometry (20) in at least one process step (44) is designed at least semi-automatically and with multi-objective optimization based on at least one parameter (22, 24, 26, 28, 30, 32, 34, 36, 38) from a parameter set, by specifying at least one parameter (22, 24, 26, 28, 30, 32, 34, 36, 38) from at least one coil geometry (40) to be wound and / or from the coil wire (16), and by taking into account at least one boundary condition, in particular a material property of a winding nozzle material.

Description

State of the art

[0001] A method for producing a winding nozzle by means of a manufacturing device for winding a coil, in particular of an electric motor, for example a stator of the electric motor, with a coil wire, wherein in at least one method step a geometry of the winding nozzle is designed by means of a computing unit on the basis of a parameterized design model, has already been proposed. Disclosure of the invention

[0002] The invention is based on a method for producing a winding nozzle by means of a manufacturing device for winding a coil, in particular of an electric motor, for example a stator of the electric motor, with a coil wire, wherein in at least one method step a geometry of the winding nozzle is designed by means of a computing unit on the basis of a parameterized design model.

[0003] It is proposed that the geometry of the winding nozzle is designed in the at least one method step on the basis of at least one parameter from a parameter set in an at least partially automatic and multi-objective optimised manner, in that the at least one parameter is specified at least by a coil geometry to be wound and / or by the coil wire, and in that at least one boundary condition, in particular a material characteristic of a winding nozzle material, is taken into account.

[0004] The inventive design of the method for producing the winding nozzle advantageously makes it possible to provide low-cost production, since in particular the geometry of the winding nozzle can be designed in just one iteration, thus eliminating the need for testing and iterative steps to adapt the geometry. Advantageously, particularly high efficiency can be provided, since in particular a winding nozzle with a new geometry can be designed and manufactured very quickly, and a particularly low susceptibility to errors is achieved. Advantageously, particularly high reliability / service life can be provided, since in particular the winding nozzle has a particularly high quality in terms of mechanical properties due to the multi-objective optimization design.Advantageously, a low level of complexity in the design and / or production can be provided, since in particular the design and production of the winding nozzle is carried out at least partially automatically, which is why a designer only needs very little specialist knowledge.

[0005] The winding nozzle is preferably designed as a production tool. Preferably, the winding nozzle is used to manufacture, in particular wind, a coil of an electric motor. Alternatively, the winding nozzle could also be designed for winding in comparable applications, such as for wire and / or cord guidance in the production of wire coils, in the stranding of wire ropes or the like. Preferably, a coil is wound using the winding nozzle. Preferably, the winding nozzle is arranged at least partially in the stator for winding the stator and moved, in particular around at least one stator tooth to be wound. Preferably, the winding nozzle guides the coil wire, which is wound around a component to be wound, such as the stator. Alternatively, a rotor or another component deemed appropriate by a person skilled in the art could also be wound.The winding nozzle preferably has at least one recess in which the coil wire is guided and / or tracked during the winding process. The coil wire is preferably formed as a copper wire. For example, a winding nozzle with a corresponding recess is used for each wire diameter. Preferably, the winding nozzle is first designed geometrically for production and the winding nozzle is then manufactured based on the previously designed winding nozzle geometry. Preferably, the winding nozzle geometry depends on a geometry of the component to be wound, in particular the stator. Preferably, the winding nozzle geometry is determined at least by the geometry of the stator and / or at least adapted to the geometry of the stator. Preferably, the at least one parameter of the parameter set is predetermined at least by the geometry of the component to be wound, in particular the stator.Preferably, the at least one parameter from the parameter set and the at least one boundary condition are taken into account when designing the winding nozzle geometry. The boundary condition could, for example, be a force and / or load occurring during winding operation. For example, the winding nozzle load occurring during winding operation could depend on a diameter of the coil wire and / or a winding speed and / or a winding nozzle movement or other influencing factors that appear appropriate to a person skilled in the art. In particular, the geometric data is transmitted digitally, for example as a STEP file (Standard for the Exchange of Product Data) or as a CAD model of the production machine or as another file format that appears appropriate to a person skilled in the art. Preferably, the winding nozzle is manufactured in a milling and / or eroding process after the winding nozzle geometry has been designed.The phrase “designing a winding nozzle” should be understood to mean, in particular, a geometric design of the winding nozzle taking into account design parameters such as radii, wall thicknesses, strength values, or the like. A “winding nozzle geometry” should be understood to mean, in particular, an overall shape of the winding nozzle, preferably at least the shape at relevant points, such as support points, of the winding nozzle, which is completely defined by lengths, radii, wall thicknesses, and / or other geometric dimensions. “Designed” should be understood to mean, in particular, specially programmed, designed, and / or equipped. The fact that an object is designed for a specific function should be understood to mean, in particular, that the object fulfills and / or executes this specific function in at least one application and / or operating state.

[0006] The parameterized design model preferably has a plurality of geometric configurations of the winding nozzle. The plurality of geometric configurations of the winding nozzle is preferably formed by varying the parameters of the parameter set. The design model is preferably parameterized at least by the parameters of the parameter set. The at least one boundary condition is preferably formed at least by a material characteristic and / or depends at least on the material characteristic. The material characteristic is preferably designed as a mechanical stress, in particular tensile strength, and / or as a fatigue strength. Alternatively or additionally, further material characteristics, such as wear resistance, material hardness, or the like, could be taken into account.In particular, a further boundary condition could be embodied as a force occurring during winding operation, which force could, for example, depend on at least one parameter of the parameter set, for example a coil wire diameter. Preferably, at least one parameter of the parameter set and at least one boundary condition are taken into account in the multi-objective optimization design of the winding nozzle geometry. Preferably, in the multi-objective optimization design, a winding nozzle geometry is determined which fulfills all specifications predetermined at least by the at least one parameter and the at least one boundary condition. Preferably, the boundary condition has at least one output parameter. Preferably, the at least one output parameter is compared with the at least one boundary condition. Preferably, the at least one output parameter must fulfill the boundary condition.Preferably, the at least one output parameter, in particular a calculated value of the output parameter, is at least output, preferably displayed graphically. Preferably, each boundary condition has an output parameter. It is conceivable that more output parameters are calculated and / or output than boundary conditions are specified. Preferably, the winding nozzle geometry is designed at least partially automatically, in particular program-based. Preferably, at least one of the parameters of the parameter set is specified by a user. In particular, the program suggests a plurality of permissible winding nozzle geometries, which are further narrowed down by the user and / or from which at least one winding nozzle geometry is selected by the user. It is conceivable that individual winding nozzle geometries are manually validated and / or recalculated.Alternatively, the winding nozzle geometry could be designed at least essentially automatically. It is conceivable that the design model automatically selects the best winding nozzle geometry, in particular from all permissible winding nozzle geometries. It is conceivable that at least one parameter is specified automatically, for example by reading in CAD data of the component to be wound, in particular the stator. A "support point" should be understood in particular as a sub-area of ​​a geometry which serves as a starting point for further creation of the geometry. "Semi-automatic" should be understood in particular as a partially automatic design, in particular an at least essentially program-based execution of calculation and / or selection processes, wherein at least in part the feedback of a specialist, for example a designer, can be requested.

[0007] The computing unit is preferably designed as an internal and / or external computing unit. It is conceivable that at least one calculation, in particular the calculation underlying the design, is outsourced to an external computing unit. The internal and / or external computing unit could, for example, be designed as a workstation computer, a smartphone, a cloud, or a comparable computing unit. A “computing unit” should be understood in particular as a unit with an information input, an information processing unit, and an information output. The computing unit preferably has at least one processor, a memory, input and output means, further electrical components, an operating program, control routines, control routines, and / or calculation routines. The components of the computing unit are preferably arranged on a common circuit board and / or in a common housing.

[0008] It is further proposed that the parameter set has at least 2 parameters and at most 20 parameters. Advantageously, high efficiency can be provided, since in particular a maximum of 20 parameters must be taken into account during the design. Advantageously, high accuracy can be provided, since in particular up to 20 parameters can be taken into account during the design. In particular, the parameter set has at least 2 and at most 20, preferably at least 4 and at most 16, preferably at least 6 and at most 12 parameters. Preferably, the parameter set has at least a sufficient number of parameters that the winding nozzle geometry can be designed with sufficient accuracy. Preferably, the parameter set has at most so many parameters that the computing time for designing the winding nozzle geometry is limited, in particular to a few hours.It is conceivable that additional parameters can be added if necessary, for example, in an advanced mode. It is conceivable that only a few parameters are available in a simple mode and / or that a large portion of the parameters can be hidden. It is conceivable that the parameter set, especially in a simple mode, has only one parameter. It is conceivable that the number of parameters in the parameter set depends on the available computing power of the computing unit.

[0009] Furthermore, it is proposed that the parameter set comprise nine parameters. This advantageously provides high efficiency, especially since a maximum of nine geometric input parameters need to be considered during the design. This advantageously provides high accuracy, especially since up to nine parameters can be considered during the design.

[0010] In addition, it is proposed that the at least one parameter of the parameter set, preferably all parameters of the parameter set, be designed as at least one geometric input parameter, which can be specified as a fixed value or as a value range by the user and / or read in as measurement or geometric data, in particular of the stator to be wound. Advantageously, a high degree of flexibility can be provided, since in particular a value and / or value range can be specified as geometric input parameters. A "geometric input parameter" is to be understood in particular as a value with which a shape of the winding nozzle is described geometrically, in particular lengths, radii, wall thicknesses and / or the like. In particular, all geometric input parameters have the same unit. The geometric input parameter could be specified as an SI unit, for example in mm.A "value" should be understood in particular as a fixed quantity, such as a length. A "value range" should be understood in particular as a range limited by at least two values ​​or by at least one limit value, such as a maximum length.

[0011] Furthermore, it is proposed that the at least one boundary condition be designed as a preset, fixed value, in particular a maximum value, and / or as a value range. Advantageously, a high level of reliability in the operation of the winding nozzle can be provided, since the winding nozzle can be precisely designed, in particular, through the boundary conditions. Preferably, the at least one boundary condition is designed as a preset and / or fixed value that can be assigned or selected. Preferably, the boundary condition is designed as a maximum value, in particular a limit value, such as a maximum permissible mechanical winding nozzle load. Preferably, the boundary condition comprises at least one material characteristic, such as the fatigue strength and / or the tensile strength or the like. It is conceivable that the boundary condition has at least one safety factor.Preferably, a force occurring, in particular during operation of the winding nozzle, is selected at least as a function of the at least one parameter, for example, the wire diameter being processed. Preferably, the force occurring during operation of the winding nozzle is calculated or selected as a function of at least one geometric input parameter. Preferably, the calculated value for the output parameter is output and / or graphically displayed. It is conceivable that the value range is specified by a maximum value with two different signs.

[0012] In addition, it is proposed that the design model for multi-objective optimization of the winding nozzle design be supported by at least a plurality of pre-designed base models, in particular between 100 and 1000, preferably between 300 and 400. This advantageously provides high efficiency, since an unnecessarily large number of base models do not have to be taken into account, particularly during the design. This advantageously provides high accuracy, since a sufficient number of base models are taken into account, particularly during the design. Preferably, for each parameter of the parameter set, several base models with different values ​​for each parameter are simulated and / or tested in advance. The design model is preferably supported by exactly 353 base models. This advantageously provides at least a sufficient number of base models for the winding nozzle geometry to be designed with sufficient accuracy.Preferably, the design model has a maximum of enough base models to limit the computing time for designing the geometry of the winding nozzle, in particular to a few hours. A "base model" is understood in particular to mean a winding nozzle geometry that has at least the parameters of the parameter set and that has already been calculated, in particular simulated and / or measured, in advance. In particular, the base models are implemented in the design model. "Multi-objective optimization" is understood in particular to mean that a winding nozzle geometry is designed that takes into account the at least one boundary condition and the at least one parameter of the parameter set.

[0013] Furthermore, it is proposed that a number of permissible winding nozzle geometries be preselected at least based on the base models, taking into account the at least one parameter of the parameter set and the at least one boundary condition, using a Pareto analysis. Advantageously, low complexity can be provided, since, in particular for further design, only winding nozzle geometries preselected using the Pareto analysis are taken into account. Preferably, the permissible winding nozzle geometries satisfy the boundary conditions. Preferably, the winding nozzle geometries that satisfy the boundary conditions are designed based on the at least one parameter. Preferably, the winding nozzle geometry is preselected using a Pareto analysis. Preferably, the designed winding nozzle geometries are represented graphically, for example, in a Pareto front.A "Pareto analysis" is understood in particular as the design of a large number of winding nozzle geometries, taking into account the Pareto principle, which, in particular, relates the calculation effort of the winding nozzle geometries to the calculation accuracy of the winding nozzle geometry. In particular, as many winding nozzle geometries are created until sufficient accuracy is achieved for the winding nozzle geometry, in particular until calculations of the design model converge. For example, approximately 2,000 to 4,000 winding nozzle geometries are created from the design model.

[0014] It is further proposed that an optimal winding nozzle geometry be approximated at least by averaging at least between the preselected base models. Advantageously, a high level of reliability can be provided since, in particular, the winding nozzle can be designed particularly precisely by averaging at least between the base models. Averaging is preferably carried out if at least one parameter, in particular a geometric input parameter, is arranged between two base models. Preferably, the user predefines one or more winding nozzle geometries from the predefined permissible winding nozzle geometries, in particular by readjusting the parameters. “Averaging” is to be understood in particular as a mathematical method, preferably an interpolation, whereby at least one data point is determined between at least two further data points.It is conceivable that the design of the winding nozzle geometry is carried out without averaging, for example if the parameters of the parameter set are covered by a base model.

[0015] Furthermore, it is proposed that the at least one boundary condition be designed as at least one, in particular maximum, deformation of the winding nozzle. Advantageously, a high level of reliability / operational safety can be provided since, in particular by taking the mechanical deformation into account, faulty operation, in particular increased wear and / or jamming of the winding nozzle with the stator, can be prevented. Preferably, a deformation of the winding nozzle, which is dependent in particular on the winding nozzle geometry, is at least substantially limited by the at least one boundary condition designed as a deformation of the winding nozzle. Preferably, the deformation of the winding nozzle, in particular the maximum deformation, depends at least on the designed winding nozzle geometry. In particular, the maximum permissible deformation depends on the geometry of the stator to be wound.Preferably, the deformation, in particular the maximum deformation, is at least partially predetermined by the at least one parameter of the parameter set. In particular, the maximum permissible deformation prevents contact between the winding nozzle and the component to be wound, in particular the stator, during operation. Preferably, the deformation, in particular the maximum permissible deformation, of the winding nozzle is designed as an elastic deformation. In particular, the deformation of the winding nozzle depends on the force acting during operation, which is predetermined at least by the at least one parameter.

[0016] It is additionally proposed that the at least one boundary condition be designed as at least one, in particular maximum, mechanical stress in the winding nozzle. Advantageously, a high level of reliability can be provided since, in particular, component failure can be prevented by taking the mechanical stress into account. Preferably, a mechanical stress in the winding nozzle, which is dependent in particular on the winding nozzle geometry, is at least substantially limited by the at least one boundary condition designed as a, in particular maximum, mechanical stress in the winding nozzle. Preferably, the maximum mechanical stress in the winding nozzle is dependent at least on the designed winding nozzle geometry and / or on a material used. Preferably, the, in particular maximum, mechanical stress is at least partially predetermined by the at least one parameter of the parameter set.In particular, the maximum mechanical stress during operation prevents damage and / or failure of the winding nozzle. In particular, the mechanical stress in the winding nozzle depends on the force acting during operation, which is specified by at least one parameter.

[0017] It is also proposed that a maximum deviation from calculation results of the design model is less than 15% for at least substantially all calculation points. A high design quality can advantageously be provided since, in particular, the maximum deviation from the calculation results is less than 15%. Preferably, the calculation results, in particular the output parameters limited by the boundary conditions, of the designed winding nozzle geometry have a maximum deviation of less than 15% from comparable results determined by measurement and / or simulation. In particular, at least a large proportion of the calculation points have a maximum deviation of, in particular, less than 10% and preferably less than 5%. In particular, the maximum deviation of less than 15% is achieved by the design model with at least 353 base models.The expression “at least to a large extent” is to be understood as meaning in particular at least 55%, advantageously at least 65%, preferably at least 75%, particularly preferably at least 85% and particularly advantageously at least 95%.

[0018] Furthermore, it is proposed that the maximum deviation of at least substantially 15% be taken into account as a safety factor for the boundary conditions, in particular a permissible mechanical load and / or deformation. Advantageously, a high level of safety can be provided since, in particular, the maximum deviation of less than 15% is taken into account as a safety factor. Preferably, the maximum deviation is taken into account by reducing the maximum permissible mechanical stress at least by the safety factor, in particular by at least 15%. In particular, the safety factor is taken into account for all boundary conditions, in particular output parameters. In particular, a value for the boundary condition is reduced to 85% so that the safety factor is taken into account.A “safety factor” is to be understood in particular as a factor which increases the distance to a limit value and thus reduces the probability of exceeding the limit value in real operation, in particular due to deviations in the design and / or manufacturing tolerances and / or the like.

[0019] It is further proposed that in at least one further method step, the winding nozzle geometry determined in the at least one method step is transferred, in particular automatically, to a production machine for manufacturing the winding nozzle. Advantageously, a high level of convenience can be provided, since in particular the user does not have to manually enter the geometry data into the system. Advantageously, a low susceptibility to errors can be provided, since in particular the, in particular automatic, transfer of the winding nozzle geometry can prevent transmission errors. Preferably, the winding nozzle is manufactured on one and / or more production machines using a milling and / or erosion process. Other manufacturing processes for producing the winding nozzle that appear appropriate to a person skilled in the art are conceivable.Preferably, the winding nozzle geometry is transferred from the processing unit to the production machine via a data connection, such as a LAN, Wi-Fi, intranet, or the like. In particular, it is conceivable that the data could also be transferred to the production machine via a storage medium, such as a USB stick. Alternatively, the geometry could also be printed out and manually transferred to a production program on the production machine.

[0020] Furthermore, a winding nozzle is proposed which was manufactured according to the method described above. Advantageously, a winding nozzle can be provided at low cost, since in particular the geometry of the winding nozzle can be designed in just one iteration, thus eliminating the need for testing and adjusting the geometry. Advantageously, high efficiency can be provided, since in particular a winding nozzle with a new geometry can be designed and manufactured very quickly and there is a particularly low susceptibility to errors. Advantageously, particularly high reliability / service life can be provided, since in particular the winding nozzle has a particularly high quality in terms of mechanical properties due to the multi-objective optimization design.

[0021] The method according to the invention and the winding nozzle 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 and the winding nozzle according to the invention may comprise a number of individual elements, components, units, and method steps that differs from the number stated herein 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

[0022] 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.

[0023] They show: Fig. 1 A schematic representation of a manufacturing device, Fig. 2 a schematic representation of the manufacturing device with a winding nozzle and a stator, Fig. 3 a schematic representation of the winding nozzle with parameters, Fig. 4 a schematic flow diagram of a method for producing the winding nozzle and Fig. 5 a schematic representation of a Pareto diagram with a Pareto front. Description of the embodiment

[0024] The Fig. 1 shows a schematic representation of a manufacturing device. The manufacturing device has a design model. The manufacturing device has a computing unit 18. The computing unit 18 is designed as an internal and / or external computing unit 18. The internal and / or external computing unit 18 could, for example, be designed as a workstation computer, a smartphone, a cloud, or a comparable computing unit 18. It is conceivable that one or all of the calculations underlying the design are / are outsourced to an external computing unit 18. The design model can be executed on any computing unit 18. The computing unit 18 is configured to execute the design model. The manufacturing device is configured to design a winding nozzle 10. The manufacturing device is configured to design the winding nozzle 10 based on a geometry of a stator 14 to be wound.The design model is configured to design the winding nozzle 10. The manufacturing device comprises a manufacturing machine 54. The manufacturing device is configured to manufacture the winding nozzle 10.

[0025] The Fig. 2 shows a schematic representation of the winding nozzle 10 in a winding operation. The winding nozzle 10 is designed as a production tool. The winding nozzle 10 is configured to wind a coil 12 of an electric motor. The winding nozzle 10 is configured to wind the stator 14 with a coil wire 16. The coil wire 16 is designed as a copper wire. The coil wire 16 has a wire diameter of 52. Alternatively, the winding nozzle 10 could also be configured for winding in comparable applications, such as for wire and / or cord guidance for the production of wire coils, for stranding wire ropes or balls of wool, or the like. For winding the stator 16, the winding nozzle 10 is partially arranged in the stator 14 to be wound. The winding nozzle 10 is configured to be moved around a stator tooth 48 of the stator 14 to be wound. The coil wire 16 is guided by the winding nozzle 10.The coil wire 16 is wound around the stator 14 using the winding nozzle 10.

[0026] The Fig. Figure 3 shows a schematic representation of the winding nozzle 10. The winding nozzle 10 has a winding nozzle geometry 20. The winding nozzle 10 has a recess 50. The coil wire 16 is guided in the recess 50 during a winding process, see Figure 1. Fig. 2. The recess 50 of the winding nozzle 10 is larger than the wire diameter 52 of the coil wire 16. The design model has nine parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 from a parameter set. The nine parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 are configured as geometric input parameters. The parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 are configured as a fixed value or as a range of values. The geometric input parameters have the same unit. The geometric input parameters are specified as an SI unit in mm. The nine parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 are designed to partially describe the winding nozzle geometry 20. The winding nozzle geometry 20 depends on the geometry of the stator 14 to be wound. Parameter 22 is designed as a shaft height of the winding nozzle 10. Parameter 24 is designed as a bionic rounding height of the winding nozzle 10.Parameter 26 is designed as a diameter of the recess of the winding nozzle 10. Parameter 28 is designed as a head width of the winding nozzle 10. Parameter 30 is designed as an outer head radius of the winding nozzle 10. Parameter 32 is designed as a base extension of the winding nozzle 10. Parameter 34 is designed as a base extension of the winding nozzle 10. Parameter 36 is designed as a base extension of the winding nozzle 10. Parameter 38 is designed as a head length of the winding nozzle 10. It is conceivable that the parameter set has more or fewer than 9 parameters 22, 24, 26, 28, 30, 32, 34, 36, 38. The parameter set has at least 2 parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 and fewer than 20 parameters 22, 24, 26, 28, 30, 32, 34, 36, 38. The parameter set has a sufficient number of parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 that the winding nozzle geometry 20 can be designed with sufficient accuracy.The parameter set has a maximum of so many parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 that the computing time for designing the winding nozzle geometry 20 is limited to a few hours. It is conceivable that the nine parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 are partially dependent on one another. It is conceivable that, if necessary, for example in an extended mode, additional parameters 66 can be added. It is conceivable that in a simple mode only a few parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 are available and / or a large part of the parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 can be hidden. It is conceivable that the parameter set in a simple mode has only one parameter 22, 24, 26, 28, 30, 32, 34, 36, 38. It is conceivable that the number of parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 of the parameter set depends on the available computing power of the computing unit 18.

[0027] The design model has four boundary conditions. The design model could also have more or fewer than four boundary conditions. The boundary conditions are designed as a preset, fixed value or value range. The boundary conditions are designed as a maximum value and / or limit value. The boundary conditions are designed as a preset and / or fixed value. One of the boundary conditions is maximum deformation of the winding nozzle 10 during winding operation. The maximum deformation of the winding nozzle 10 depends on the designed winding nozzle geometry 20. The maximum permissible deformation depends on the geometry of the stator 14 to be wound. The maximum deformation is partially specified by parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 of the parameter set. The maximum permissible deformation prevents contact between the winding nozzle 10 and the stator 14 during operation.The maximum permissible deformation of the winding nozzle 10 is designed as an elastic deformation of a winding nozzle material. The deformation of the winding nozzle 10 depends on the force acting during operation. One of the boundary conditions is designed as a maximum mechanical stress in the winding nozzle 10. The maximum mechanical stress in the winding nozzle 10 depends on the designed winding nozzle geometry 20. The maximum mechanical stress depends on the parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 of the parameter set. The maximum mechanical stress during operation prevents damage and / or failure of the winding nozzle 10. The mechanical stress in the winding nozzle 10 depends on the force acting during operation, which is specified by at least one parameter 22, 24, 26, 28, 30, 32, 34, 36, 38. It is conceivable that the boundary conditions are applicable to parameters 22, 24, 26, 28, 30, 32, 34, 36, 38.For example, the boundary conditions could specify a value range and / or a maximum value for parameters 22, 24, 26, 28, 30, 32, 34, 36, 38. For example, the bionic fillet height of the winding nozzle 10 could be limited by the boundary conditions. For example, the boundary conditions could specify the narrowest possible nozzle design.

[0028] The boundary conditions include a material parameter. The material parameter is configured as a fatigue strength and / or tensile strength or the like. It is conceivable that the boundary conditions have a safety factor. The force occurring during operation of the winding nozzle 10 is calculated or selected depending on at least one geometric input parameter. The force is determined by the wire diameter 52. A force occurring during operation of the winding nozzle 10 is selected or assigned depending on the wire diameter 52. It is conceivable that the force is configured depending on further influencing factors, such as a winding nozzle movement and / or winding nozzle speed or the like.

[0029] The design model exhibits a maximum deviation from the calculation results. The maximum deviation of the calculation results is less than 15%. The output parameters of the designed winding nozzle geometry 20, limited by the boundary conditions, exhibit a maximum deviation of less than 15% from comparable results. The comparable results could have been determined by measurement and / or simulation. The maximum deviation of less than 15% is achieved by supporting the design model with at least 353 base models. The maximum deviation of 15% is considered as a safety factor for the boundary conditions of the permissible mechanical load and / or deformation. The maximum deviation is taken into account by reducing the maximum permissible mechanical stress in the winding nozzle 10 by the safety factor. The safety factor is considered for all boundary conditions.To take the safety factor into account, the value for the boundary condition is reduced to 85%.

[0030] The design model is supported by exactly 353 base models 42. The design model could have more or fewer than 353 base models 42. However, the design model has at least 100 and fewer than 1000 pre-designed base models 42. Each base model has a winding nozzle geometry 20 that has been simulated and / or tested in advance. The design model has a sufficient number of base models 42 that the winding nozzle geometry 20 can be designed with sufficient accuracy. The design model has a maximum of so many base models 42 that the computing time for designing the winding nozzle geometry 20 is limited to a few hours.

[0031] The Fig. 4 shows a schematic flow diagram of a method for producing the winding nozzle 10.

[0032] In at least one process step 44, the winding nozzle geometry 20 is designed. The winding nozzle 10 is first geometrically designed for production.

[0033] In at least one input step 68 of the at least one method step 44, the parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 are provided to the design model. The parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 of the parameter set are predetermined by the geometry of the stator 14. The geometry of the stator 14 is entered by a user. The parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 are provided to the design model by the user. Alternatively, the parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 could be read in as measurement or geometry data of the stator 14 to be wound. The winding nozzle geometry 20 is determined by the geometry of the stator 14.

[0034] The winding nozzle geometry 20 is adapted to the geometry of the stator 14 by providing the geometry of the stator 14 to the design model.

[0035] In at least one design step 70 of the at least one method step 44, the winding nozzle geometry 20 is designed semi-automatically by the design model. The parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 from the parameter set and the boundary conditions are taken into account in the multi-objective optimization design of the winding nozzle geometry 20. During the multi-objective optimization design, a winding nozzle geometry 20 is determined that meets all the specifications specified by the parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 and the boundary conditions. During the design of the winding nozzle geometry 20, output parameters are determined. The output parameters are compared with the boundary conditions. The output parameters of a permissible winding nozzle geometry 20 must satisfy the boundary condition. Each boundary condition has an output parameter. It is conceivable that more output parameters are calculated and / or output than boundary conditions are specified.

[0036] The winding nozzle geometry 20 is designed program-based. The program suggests a variety of possible winding nozzle geometries 20. The user either specifies further limitations by changing and / or adding values ​​for parameters 22, 24, 26, 28, 30, 32, 34, 36, 38, or one or more winding nozzle geometries 20 are selected manually. It is conceivable that individual winding nozzle geometries 20 are manually validated and / or recalculated. Alternatively, the winding nozzle geometry 20 could be designed at least essentially automatically. It is conceivable that parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 are specified automatically. The automatic design could, for example, be carried out by reading in CAD data of the stator 14 to be wound.

[0037] A number of permissible winding nozzle geometries 20 are preselected using a Pareto analysis based on the base models 42, taking into account the parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 of the parameter set and the boundary conditions. The permissible winding nozzle geometries 20 satisfy the boundary conditions. The winding nozzle geometry 20 is preselected using a Pareto analysis. The permissible winding nozzle geometries 20 are arranged in a Pareto front 64. The winding nozzle geometries 20 contained in the Pareto front 64 satisfy the parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 and the boundary conditions.

[0038] The optimal winding nozzle geometry 20 is approximated by averaging between the preselected base models 42. The averaging is performed as a linear interpolation. Approximately 1,500 to 5,000 winding nozzle geometries 20 are created. However, depending on the parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 and / or the boundary conditions, more or fewer winding nozzle geometries 20 can be created. As many winding nozzle geometries 20 are created until convergence is achieved. As many winding nozzle geometries 20 are created until sufficient design accuracy is achieved. If convergence is not achieved, the process is aborted, and the designed winding nozzle geometries 20 are manually inspected by the user.The user predefines one or more winding nozzle geometries 20 from the predefined permissible winding nozzle geometries 20 by readjusting the parameters 22, 24, 26, 28, 30, 32, 34, 36, 38. It is conceivable that the design of the winding nozzle geometry 20 is carried out without averaging, for example if the parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 of the parameter set are covered by a base model 42. It is conceivable that the design model has a graphical user interface with controllers that enable parameter variation of the already calculated winding nozzle geometries 20 in real time. It is possible that parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 are adjusted iteratively in several design steps.

[0039] In at least one output step 72 of the at least one method step 44, winding nozzle geometries 20 are output. The designed winding nozzle geometries 20 are graphically displayed in a Pareto front 64. The calculated values ​​for the output parameters are output. The output parameters are output as a numerical value and / or as a graphical representation.

[0040] In at least one further method step 46, the winding nozzle geometry 20 determined in the at least one method step is transferred to a production machine for manufacturing the winding nozzle 10. The winding nozzle geometry 20 is transmitted to the production machine digitally, as a STEP file or as a CAD model. After the winding nozzle geometry 20 has been designed, the winding nozzle 10 is manufactured in a milling and / or eroding process. The winding nozzle geometry 20 is transferred automatically. The winding nozzle 10 is manufactured on one and / or more production machines in a milling and / or eroding process. Other manufacturing processes for manufacturing the winding nozzle 10 that appear appropriate to a person skilled in the art are conceivable. The winding nozzle geometry 20 is transferred from the computing unit to the production machine via a data connection, such as a LAN, Wi-Fi, intranet, or the like.It is conceivable that the data could also be transferred to the production machine via a storage medium, such as a USB stick. Alternatively, the winding nozzle geometry 20 could also be printed out and manually transferred into a production program on the production machine 54.

[0041] In at least one further method step 74, the winding nozzle 10 is manufactured using the production machine 54 based on the previously designed winding nozzle geometry 20. The winding nozzle 10 is manufactured in a milling and / or eroding process.

[0042] The Fig.5 shows a schematic representation of a Pareto diagram 56. The Pareto diagram 56 is configured to graphically represent a relationship between the parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 and / or the output parameters. The Pareto diagram 56 has an ordinate 58. Parameter 30 of the parameter set is plotted on the ordinate 58 as an example. The Pareto diagram 56 has a first abscissa 60. Parameter 28 of the parameter set is plotted on the first abscissa 60 as an example. The Pareto diagram 56 has a second abscissa 62. One of the output parameters is plotted on the second abscissa 62 as an example. The maximum deformation of the winding nozzle 10 is plotted on the second abscissa 62 as an example. It is conceivable that the Pareto diagram 56 depicts three of the nine parameters 22, 24, 26, 28, 30, 32, 34, 36, 38 of the parameter set. The Pareto diagram 56 shows the 353 base models 42.The Pareto diagram 56 has a plurality of calculated winding nozzle geometries 20. The design model calculates 5,000 winding nozzle geometries 20. The calculated winding nozzle geometries 20 are formed by averaging between the base models 42. It is conceivable that a winding nozzle geometry 20 is formed by one of the base models 42. The Pareto diagram 56 has a Pareto front 64. The Pareto front 64 has all base models 42 and all winding nozzle geometries 20 that satisfy the boundary conditions and the parameters. The Pareto front 64 is formed by the base models 42 and the permissible winding nozzle geometries 20.

Claims

[1] Method for producing a winding nozzle (10) by means of a manufacturing device for winding a coil (12), in particular of an electric motor, for example a stator (14) of the electric motor, with a coil wire (16), wherein in at least one method step (44) a winding nozzle geometry (20) is designed by means of a computing unit on the basis of a parameterized design model, characterized by that the winding nozzle geometry (20) is designed in the at least one method step (44) on the basis of at least one parameter (22, 24, 26, 28, 30, 32, 34, 36, 38) from a parameter set, at least partially automatically and in a multi-objective optimised manner, in that the at least one parameter (22, 24, 26, 28, 30, 32, 34, 36, 38) is predetermined at least by a coil geometry (40) to be wound and / or by the coil wire (16), and in that at least one boundary condition, in particular a material characteristic of a winding nozzle material, is taken into account. [2] Method according to claim 1, characterized by that the parameter set has at least 2 parameters (22, 24, 26, 28, 30, 32, 34, 36, 38) and at most 20 parameters (22, 24, 26, 28, 30, 32, 34, 36, 38). [3] Method according to one of the preceding claims, characterized by that the parameter set has 9 parameters (22, 24, 26, 28, 30, 32, 34, 36, 38). [4] Method according to one of the preceding claims, characterized by that the at least one parameter (22, 24, 26, 28, 30, 32, 34, 36, 38) of the parameter set, preferably all parameters (22, 24, 26, 28, 30, 32, 34, 36, 38) of the parameter set, is designed as at least one geometric input parameter which can be specified as a fixed value or as a value range by a user and / or read in as measurement or geometry data. [5] Method according to one of the preceding claims, characterized bythat the at least one boundary condition is designed as a preset fixed value, in particular a maximum value, and / or as a range of values. [6] Method according to one of the preceding claims, characterized by that the design model for multi-objective optimizing winding nozzle design is supported by at least a plurality, in particular between 100 and 1000, preferably between 300 and 400, pre-designed basic models (42). [7] Method according to one of the preceding claims, characterized by that a number of permissible winding nozzle geometries (20) are preselected by means of a Pareto analysis at least on the basis of the basic models (42) taking into account the at least one parameter (22, 24, 26, 28, 30, 32, 34, 36, 38) of the parameter set and the at least one boundary condition. [8] Method according to claim 7, characterized bythat an optimal winding nozzle geometry (20) is approximated at least from an averaging at least between the preselected basic models (42). [9] Method according to one of the preceding claims, characterized by that the at least one boundary condition is designed as at least one, in particular maximum, deformation of the winding nozzle (10). [10] Method according to one of the preceding claims, characterized by that the at least one boundary condition is designed as at least one, in particular maximum, mechanical stress in the winding nozzle (10). [11] Method according to one of the preceding claims, characterized by that a maximum deviation from calculation results of the design model is less than 15% for at least substantially all calculation points. [12] Method according to one of the preceding claims, characterized bythat the maximum deviation of at least substantially 15% is taken into account as a safety factor for the boundary conditions, in particular an allowable mechanical load. [13] Method according to one of the preceding claims, characterized by that in at least one further method step (46) the winding nozzle geometry (20) determined in the at least one method step (44) is transferred, in particular automatically, to a production machine for producing the winding nozzle (10). [14] Winding nozzle (10) manufactured according to the method, in particular according to one of the preceding claims.

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