Method for manufacturing a pressed stranded wire, method for manufacturing an electric motor, use of a pressed stranded wire, and pressed stranded wire

Abstract

The present invention relates to a method for manufacturing a pressed stranded wire (F) from an insulating wire (1) fed linearly or substantially linearly, characterized by the following method steps: a) using a forming device (2), forming the insulating wire (1) into at least one semi-circular shape, circular shape or spiral shape; b) using a twisting device (4), twisting at least one semi-circular shape, circular shape or spiral shape into a wire bundle (D); c) using a pressing device (5), pressing the wire bundle (D), and relates to a method for manufacturing an electric motor, wherein according to the method of the present invention, at least a part of the pressed stranded wire for the electric motor is manufactured, and relates to the application of the pressed stranded wire in the stator (S) of the electric motor, wherein the pressed stranded wire is at least sectionally the pressed stranded wire manufactured according to the present invention.

Description

Field of the Invention

[0001] The present invention relates to a method for manufacturing a pressed stranded wire (or formed stranded wire), a method for manufacturing an electric motor, an application of a pressed stranded wire, and a pressed stranded wire. Background Art

[0002] A pressed stranded wire is a stranded wire that is pressed and thereby obtains a specific cross-sectional shape (mostly a rectangular cross-sectional shape), that is, a cluster of twisted or non-twisted wire rods.

[0003] The pressed stranded wire can be used as a segmented conductor in an electric machine (especially a stator). A segmented conductor is a conductor segment that is inserted or pulled into, for example, a stator slot. The protruding ends of two pressed stranded wires can then be directly connected to form a half coil. The half coils are also connected by corresponding connections on the opposite sides of the stator. Here, various different winding patterns can be realized, such as concentrated winding or, particularly interestingly, a wave winding. A wave winding means that ultimately (three) continuous conductor bars wind around the stator slots. In a three-phase electric machine, this is known, for example, from US9035526B2 or DE10113831B4.

[0004] Preferably, insulated wire rods, especially enameled wire, can be considered as the wire rods for the pressed stranded wire.

[0005] In the end section (pressed stranded wire head), for further contact connection, the individual wire rods are electrically and mechanically connected to each other. This is achieved, for example, by ultrasonic welding or electrode welding, and for this purpose, sleeves are mostly used. The insulating paint of the wire rods present in the pressed stranded wire head will always be partially burned and partially extruded.

[0006] The connection of two pressed stranded wires can be directly realized, for example, by welding two pressed stranded wire heads. For this purpose, the pressed stranded wire heads are particularly sleeved with sleeves and then compressed or welded. There are two reasons for this. One is to create a defined connection surface for welding, and the other is to electrically and mechanically connect the wire ends in the pressed stranded wire heads to each other. An example is given, for example, in EP3051669A1.

[0007] The disadvantage is the high complexity of the production equipment (such as a stranding device) for manufacturing the pressed stranded wire or the pressed stranded wire blank. Summary of the Invention

[0008] Based on this, the present invention aims to provide an improved method for manufacturing a pressed stranded wire, particularly a method that overcomes the aforementioned disadvantages, preferably a method for manufacturing a pressed stranded wire that enables a safe, electrical, and mechanical connection between the individual wire rods in the pressed stranded wire head and, if necessary, with a sleeve.

[0009] The above object is achieved by a method for manufacturing a pressed stranded wire according to the present application. Here, the features and details described in connection with the method of course also apply to the described device, and vice versa, so that with respect to the present disclosure, there is always mutual reference or reference can be made to a single inventive aspect.

[0010] The insulating wire usually supplied by a spool is first formed into at least one semi-ring, ring or spiral in a forming device. It is possible to use only a single wire. Synchronization of a large number of wires is omitted. Further, expensive stranding equipment can be dispensed with. In principle, the working step of cutting or severing the ends of the pressed stranded wire can also be omitted. Since in any case the wire sections in the ends should be electrically connected to each other, the sling-like structure in the head is not obstructive but even advantageous. After forming, the spiral or at least one ring or semi-ring can be twisted and correspondingly pressed. Preferably, the pressing is carried out in a pressing device, in which during the pressing process, the twisted wire bundle is compressed into a pressed stranded wire with a defined outer contour. Subsequently, the electrical and mechanical connection of the individual wires of the pressed stranded wire in the head region can be achieved by methods known from the prior art, if necessary with the use of sleeves.

[0011] In particular, according to the features of the dependent claims, other advantageous designs of the proposed invention are obtained. The subject matter or features of the different claims can in principle be combined with each other arbitrarily.

[0012] In an advantageous design of the present invention, it can be preset that the forming is carried out in a forming device configured as a winding support. The winding support usually has two or four parallel pins and is optionally configured with a rotating shaft or without a rotating shaft. Depending on the type of winch, the wire can be wound or unwound here and shaped. This design is particularly suitable for forming the wire into at least one ring or spiral, where the shape mainly depends on the spacing and design of the pins, but in principle should approximate a rectangle with preferably rounded corners, especially since this formation should be twisted into an elongated pressed stranded wire in the subsequent process step. In this regard, for both the spiral and the ring, two long sides and two short sides are basically produced. A design with only one pin can also be considered, which is mainly suitable for forming the wire into a semi-ring here. In this case, two long sides and one short side connecting the two long sides are correspondingly produced.

[0013] It is also considered disadvantageous that the insulating layer arranged around a single wire impedes the connection process of the single wires in the pressed stranded wire ends and, due to the lacquer residue, also impedes the mutual connection process of two pressed stranded wire ends, especially due to the generation of smoke, the overflow of insulating lacquer residue from the pressed stranded wire ends, and the insecure connection caused by the unclear quantity and distribution of the insulating lacquer residue in the pressed stranded wire ends, etc.

[0014] In particular, it is proposed to limit the evaporation of the insulating lacquer of the single wires to a local area for individual production (batch production) and continuous production (as endless wires). Here, it is difficult to solve the synchronization of multiple single wires so that the segments of the local wire stripping of multiple single wires are placed flatly one above the other in an overlapping manner.

[0015] In an advantageous design of the present invention, a wire stripping device is used to achieve partial wire stripping of wires or semi - rings, rings or spirals, wherein the partial wire stripping is carried out, in particular, on the long side or the short side between the pins of the winding support after forming and before twisting, or before forming, in particular, on a straight - fed or substantially straight - fed insulated wire. Within the framework of the first variant, the partial wire stripping is carried out when the shape of at least one semi - ring, ring or spiral to be twisted has been fixed. In this regard, it is possible to ensure in a simple way that the stripped area is in the correct position, i.e., the position where the single wires should be electrically connected to each other and, if necessary, to the sleeve. However, alternatively, the partial wire stripping can also be carried out before forming, in particular, on a straight - fed or substantially straight - fed insulated wire.

[0016] Preferably, the partial wire stripping is achieved mechanically and / or abrasively, in particular by grinding and / or sandblasting, and / or chemically and / or thermally, in particular by using cold embrittlement, laser sublimation, induction heating. This choice is not decisive. However, the aforementioned methods are particularly advantageously suitable for industrial use.

[0017] In another advantageous design of the present invention, it can be preset that a twisting device is used to achieve the twisting of at least one semi - ring, ring or spiral, wherein the twisting device includes a first clamp for the first distal end of at least one semi - ring, ring or spiral, and a second clamp for the second distal end of at least one semi - ring, ring or spiral, and the clamps rotate around or approximately around the longitudinal axis of at least one semi - ring, ring or spiral.

[0018] In a further advantageous design of the present invention, it can be presupposed that the first clamp is formed by a first pin and the second clamp is formed by a second pin or a clamping tool. This design of the twisting device is preferably suitable for twisting semi-rings. In particular, the open part of the semi-ring can be grasped by the clamping tool, while the closed part can be grasped by the pin.

[0019] In a further advantageous design of the present invention, it can be presupposed that the twisting device is integrated in the forming device, specifically, the twisting is carried out in the forming device. This measure is conducive to process optimization, so that it is possible to avoid transferring at least one semi-ring, ring or spiral. In this regard, for example, it can be presupposed that the forming device (in particular the winding support) is equipped with corresponding mechanical means so that the pin can be deflected, and thus at least one semi-ring, ring or spiral received on the pin can be twisted.

[0020] In a further advantageous design of the present invention, it can be presupposed that the insulating wire and / or the wire bundle is at least partially applied with a bonding varnish. The bonding varnish can mechanically fix the individual wires relative to each other. This particularly relates to the vibrations that occur when alternating current passes through.

[0021] In a further advantageous design of the present invention, the mechanical and electrical connection of the wire section in the end is achieved without a sleeve.

[0022] Another object of the present invention is to provide an improved method for manufacturing an electric motor.

[0023] This object is achieved by the method for manufacturing an electric motor according to the present application. Since the pressed stranded wire used here is manufactured according to the method of the present invention, the advantages achieved here can also be used for constructing an electric motor.

[0024] Another object of the present invention is to indicate an advantageous application of the pressed stranded wire manufactured according to the present invention.

[0025] This object is achieved by the application of the pressed stranded wire according to the present application in the stator of an electric motor.

[0026] Another object of the present invention is to provide an improved pressed stranded wire.

[0027] This object is achieved by the pressed stranded wire provided by the present application. Description of the Drawings

[0028] Other features and advantages of the present invention will become clear from the following description of the preferred embodiments with reference to the accompanying drawings. In the drawings:

[0029] Figure 1Shows a pressed stranded wire manufactured according to the method of the present invention;

[0030] Figure 2 Shows in a side view a stator of an electric motor (in particular an electric traction motor) for a motor vehicle, which includes a pressed stranded wire manufactured according to the method of the present invention;

[0031] Figure 3 Shows in a front view a stator of an electric motor (in particular an electric traction motor) for a motor vehicle, which includes a pressed stranded wire manufactured according to the method of the present invention;

[0032] Figure 4.1 Shows the shaping of an insulating wire into a helix on a winding support including two pins;

[0033] Figure 4.1a Shows according to Figure 4.1 the top view of the winding support;

[0034] Figure 4.2 Shows in according to Figure 4.1 / 4.1a the partial stripping of the wire on the winding support;

[0035] Figure 4.3 Shows the twisting of the wire on the winding support / twisting device;

[0036] Figure 5.1 Shows the shaping of an insulating wire into a helix on a winding support including four pins;

[0037] Figure 5.1a Shows according to Figure 5.1 the top view of the winding support;

[0038] Figure 5.2 Shows in according to Figure 5.1 / 5.1a the partial stripping of the helix on the winding support;

[0039] Figure 5.3 / 5.4 shows the transfer of the helix from the four-pin winding support to the two-pin winding support;

[0040] Figure 5.5 Shows the twisting of the helix on the winding support / twisting device;

[0041] Figure 6.1 Shows the partial stripping of the insulating wire, which occurs before shaping on the winding support, i.e., shaping the partially stripped wire into a helix on a winding support including two pins;

[0042] Figure 6.1a Shows according to Figure 6.1 the top view of the winding support;

[0043] Figure 6.2 Shows the spirals being twisted on a winding support / twisting device;

[0044] Figure 7 Shows a winding support (top view / side view) including a pin and a semi - ring;

[0045] Figure 8 Shows a winding support (top view / side view) including two pins and a ring;

[0046] Figure 9 Shows a twisting device including a pin, a clamping tool, and a semi - ring;

[0047] Figures 10.1 to 10.5 Shows the twisted wire bundle being pressed in a press;

[0048] Figure 11 Shows the electrode welding of the end of the stranded wire for electrically and mechanically connecting the wire segments located here. Detailed Description

[0049] The starting point of the method for manufacturing a pressed stranded wire according to the invention is an insulated wire 1, preferably an enamelled insulated wire. Here, it refers to a conductive wire, which is preferably made of copper, aluminum, or a copper alloy and / or an aluminum alloy. The insulated wire may also include another coating, for example, in the form of a bonding varnish. The insulated wire is usually located on a spool, and the wire is unwound from the spool and supplied to the manufacturing process as a straight or substantially straight wire. This means that the wire is unwound from the spool and only formed into the predetermined shape of a semi - ring, a ring, or a spiral during the forming process.

[0050] The result of the manufacturing process is a pressed stranded wire F. The pressed stranded wire includes a first end and a second end. The ends of the pressed stranded wire (more precisely, the wire segments located here) are electrically and mechanically connected to each other, which can be achieved by means of sleeves H1 or H2. A wire bundle D is arranged between the ends. The wire bundle is composed of multiple wires, which are usually twisted with each other and, as a wire bundle, are preferably surrounded by a main insulation layer. Additionally, the pressed stranded wire is pressed, which preferably has a rectangular or trapezoidal cross - section.

[0051] The method for manufacturing a pressed stranded wire according to the invention at least includes the following process steps:

[0052] - On a forming device 2, forming the insulated wire into at least one semi - ring, ring, or spiral;

[0053] - Optionally, a wire stripping device 3 is used to partially strip at least one semi - ring, ring or spiral.

[0054] - A twisting device 4 is used to twist the at least one semi - ring, ring or spiral that has been partially stripped into a wire bundle.

[0055] - A pressing device 5 is used to press the wire bundle.

[0056] A spiral should be understood as a helical structure having a plurality of turns. The ends are generally not interconnected. However, in principle, the ends of the spiral can be connected. The spiral does not necessarily have to be configured as circular. Rather, the shape of the spiral approximates a rectangle with rounded corners. In this regard, two long sides 2a and two short sides 2b of the spiral can be mentioned.

[0057] A ring should be understood as a closed wire structure with one turn, i.e., the ends are interconnected. The ring does not necessarily have to be configured as circular. Rather, the shape of the ring approximates a rectangle with rounded corners. In this regard, two long sides 2a and two short sides 2b of the ring can be mentioned.

[0058] A semi - ring refers to a U - shaped structure that is open on one side. The wire does not form a complete turn and the ends are not interconnected. In this regard, two long sides 2a and one short side 2b of the semi - ring can be mentioned.

[0059] The following explains the individual method steps:

[0060] Forming

[0061] Forming is achieved in the forming device 2. A so - called winding support can be considered as the forming device.

[0062] In the simplest embodiment, the winding support includes a pin 2.1 on which the insulating wire is placed to some extent and formed into a semi - ring. Multiple wires can be placed on the pin in sequence and correspondingly formed into multiple semi - rings. The resulting semi - rings can be placed side - by - side and / or one above the other on the pin.

[0063] In another embodiment, the winding support can include two pins 2.1, 2.2. The two pins are oriented parallel or substantially parallel to each other and spaced apart. One or more rings of the insulating wire can be pushed onto the winding support. The rings can be placed side - by - side and / or one above the other on the pins.

[0064] In another embodiment, the winding support may include two pins 2.1, 2.2 and a rotating shaft R. The rotating shaft is preferably arranged between the pins and parallel to the pins. Here, it mainly refers to a type of winch around which an insulating wire can be wound into a spiral. The wires of the spiral can be arranged side by side and / or one above the other in an overlapping manner.

[0065] In another embodiment, the winding support may include four pins 2.1 to 2.4. The four pins are oriented parallel to each other or substantially parallel to each other and spaced apart from each other. In a top view, the four pins preferably form the corners of a quadrilateral or a square. One or more loops of the insulating wire can be pushed onto the winding support. The loops can be placed side by side and / or one above the other in an overlapping manner on the pins.

[0066] In another embodiment, the winding support may include four pins 2.1 to 2.4 and a rotating shaft R. The four pins are oriented parallel to each other or substantially parallel to each other and spaced apart from each other. In a top view, the four pins preferably form the corners of a quadrilateral or a square. The rotating shaft is preferably arranged between the pins, to a certain extent at the center of a rectangle or a square and parallel to the pins. Here, it mainly refers to a type of winch around which an insulating wire can be wound into a spiral. The wires of the spiral can be arranged side by side and / or one above the other in an overlapping manner.

[0067] In principle, variants including three or more pins can also be considered.

[0068] As a result of the forming process, the insulating wire is formed into at least one semi-loop, loop or spiral.

[0069] Wire stripping

[0070] Using the wire stripping device 3, partial wire stripping of at least one semi-loop, loop or spiral is achieved. The partial wire stripping of the insulating at least one semi-loop, loop or spiral can be achieved mechanically and / or abrasively, in particular by grinding and / or sandblasting. Chemical and / or thermal methods, in particular by using cold embrittlement, laser sublimation, induction heating, etc., can also be considered. In principle, any method capable of removing the insulator of the wire can be considered here. The term "partial wire stripping" means that the insulating material on a section of the insulating wire extending in the longitudinal direction is removed, where "removing" should refer to the technical relevant scope. If the insulating wire is also coated with other components such as bonding paint, these components are also removed. Basically, the key lies in exposing the conductive surface of the wire.

[0071] The insulating wire 1 is also kept in the corresponding forming device 2 in principle, so that in principle, stripping can be considered on those sections of at least one semi-ring, ring or spiral that are bare (or in other words, not in contact with the pin). Here, depending on the forming device, the preferred sections where stripping should or can be carried out are obtained.

[0072] In the case where the winding support includes a pin, the area of the semi-ring that is directly adjacent to the pin and is on the end side of the semi-ring can be considered.

[0073] In the case where the winding support includes two pins, the area of the spiral or ring that is directly adjacent to the pins can be considered. To some extent, the ends of the long side 2a are stripped.

[0074] In the case where the winding support includes four pins, the area of the spiral or ring that is between two pins can be considered. When the pins form the corners of a rectangle, this area is preferably located on the shorter section of the spiral or ring. To some extent, the short side is stripped.

[0075] The result of the stripping process is that the spiral or ring or semi-ring includes a partially stripped wire.

[0076] Twisting

[0077] By means of the twisting device 4, the twisting of the spiral or ring or semi-ring is achieved. The twisting device mainly includes a first clamp 4.1 for the first distal end of the spiral or ring or semi-ring, and a second clamp 4.2 for the second distal end of the spiral or ring or semi-ring. The clamps rotate approximately around the longitudinal axis of the spiral or spiral or ring or semi-ring, thereby twisting the wire.

[0078] In the first embodiment of the twisting device, the first clamp is formed by a pin, and the second clamp is formed by a pliers tool. This twisting device is preferably suitable for twisting semi-rings. The pliers tool grasps the free end of the semi-ring, and the pin grasps the short side of the semi-ring. In this regard, the first pin of the twisting device can also be the first pin of the forming device. In this case, the forming device can be equipped with additional mechanical means that enable the relative rotation of the pin and the pliers tool with respect to each other.

[0079] In a preferred embodiment of the twisting device, the first clamp is formed by a first pin and the second clamp is formed by a second pin. Such a twisting device is preferably suitable for twisting spirals or rings. These pins grab the corresponding spiral distal end or ring distal end, i.e. the short side. In this regard, the first pin of the twisting device can also be the first pin of the forming device, or the second pin of the twisting device can also be the second pin of the forming device. In this case, the forming device can be equipped with additional mechanical devices, which make it possible for these pins to rotate relative to each other.

[0080] If the forming device is equipped with four pins, the ring or spiral wound thereon can be transferred to a twisting device comprising two pins. Then, preferably, the twisting is achieved by the twisting device. For this, reference can be made to the explanations made above.

[0081] The result of the twisting process is a twisted wire bundle.

[0082] Pressing

[0083] In a pressing device 5 , in particular a press, pressing takes place.

[0084] During the pressing process, the twisted wire bundle is compressed into a pressed strand F. The previous method steps ensure that the respective distal ends of the twisted wire bundle have been stripped. If the ends still contain partially insulated wires, they can be cut off, but this is not necessary.

[0085] The result of the pressing process is a pressed stranded wire F.

[0086] The end sections of the pressed strands can then be electrically and mechanically connected to one another in a further process step. Figure 11 An electrode welding method is shown which comprises two welding electrodes E, wherein the wire sections of the end are electrically and mechanically connected to one another. In the case of already stripped head sections, a sleeve is not absolutely necessary.

[0087] Alternative process

[0088] In the process outlined above, it is preferably provided that the forming is performed before the stripping. In an alternative design of the method, it can be provided that the stripping is performed before the forming (see in particular Figure 6.1 , Figure 6.1a , Figure 6.2 and Figure 7 ). For other aspects, you can basically refer to the features outlined above.

[0089] Here, first, a stripping device is used to partially strip an insulated wire, preferably supplied from a spool, so that it can subsequently be formed into at least one semi-circular, circular, or spiral shape using a forming device. Preferably, a rotatable double-pin winding support can be considered as the forming device. Preferably, synchronization from stripping to the winding support is achieved such that the stripped wire area lies within the range of the pins. If the forming device is also configured as a twisting device, the resulting at least one circular or spiral shape can remain on the pins and be directly twisted.

[0090] The result here is also a twisted wire bundle, which can be supplied to the subsequent method steps, in particular the pressing process.

[0091] Preferably, the manufacturing process for producing a pressed stranded wire from an insulated wire is carried out in the following manner (see in particular Figure 4.1 , Figure 4.1a , Figure 4.2 , Figure 4.3 and Figures 10.1 to 10.5 ).

[0092] A double-pin winding support including a rotating shaft R is used as the forming device, on which the insulated wire is wound into a spiral shape. The wires of the spiral shape are preferably all placed side by side.

[0093] Using a laser as the stripping device, the insulator on the section of the spiral shape immediately adjacent to the pins is removed.

[0094] The forming device also includes a twisting device, so that the wire wound between the pins, i.e., the spiral shape, can be directly twisted.

[0095] The wire bundle together with the sleeve is placed into the pressing device and compressed.

[0096] The result is a pressed stranded wire, the cross-sectional shape of which is determined by the shape of the press. Subsequently, the end sections of the pressed stranded wire are electrically and mechanically connected to each other by electrode welding. Electrical contact is correspondingly produced between the ends of the wire bundle stripped in this area.

[0097] A more preferred manufacturing process for producing a pressed stranded wire from an insulated wire can be carried out in the following manner (see in particular Figure 5.1 , Figure 5.1a , Figure 5.2 , Figure 5.3 , Figure 5.4 , Figure 5.5 and Figures 10.1 to 10.5 ).

[0098] A four-pin winding support including a rotating shaft R is used as the forming device, on which the insulated wire is wound into a spiral shape. The wires of the spiral shape are preferably all placed side by side.

[0099] The laser as a wire stripping device removes the insulation on the section of the spiral that is directly between the two pins and, to a certain extent, on the short sides.

[0100] The helix is transferred from the four-pin winding support to the two-pin twisting device.

[0101] In a double pin twisting device, the helices are twisted into a wire bundle.

[0102] The wire bundle is placed in a pressing device and compressed. Subsequently, the end sections of the pressed stranded wire are electrically and mechanically connected to each other by electrode welding.

[0103] Additional method steps / other aspects of the invention

[0104] Additional, but not exhaustive, method steps may be, for example, the application of an adhesive varnish or the application of a primary insulation layer around the pressed strands, for example by extrusion.

[0105] The purpose of the bonding lacquer is to mechanically fix the individual wires relative to each other. This is particularly related to the vibrations that can occur when an alternating current flows through them. When heated and / or compressed, the bonding lacquer becomes viscous and bonds the individual wire layers to each other, for this purpose see, for example, DE 10 2015 2017 11 A1. Instead of a double-layer structure (insulator + bonding lacquer), composite materials known to those skilled in the art can also be used. Partial removal of the bonding lacquer should also belong to the production step "partial wire stripping".

[0106] It is also possible to produce a higher-order pressed strand. This means that strands are twisted with strands to form a new (higher-order) strand. This can be done in the method step "twisting".

[0107] Preferably, the forming device, the stripping device and / or the twisting device are combined in one device. Thus, in particular the pin can have different functions (winding, twisting, etc.). Of course, these devices can also be configured separately.

[0108] These embodiments are generally not limited to the manufacture of pressed stranded wires including a sleeve. These embodiments can also be applied to pressed stranded wires without a sleeve.

[0109] As already explained above, the pressed stranded wire produced according to the present invention is advantageously suitable for producing an electric motor, in particular its stator S. Accordingly, for the production of an electric motor, in particular its stator, the advantages of the pressed stranded wire production method according to the present invention can be utilized. Figures 1 to 3 , a stator S of an electric motor is shown by way of example.

[0110] In this regard, the application of the pressed stranded wire manufactured according to the invention in the stator S of an electric motor is obtained.

[0111] A method or application of the above type is used in the production of electric motors, especially in vehicles.

[0112] List of reference signs

[0113] The following reference signs are used in the drawings:

[0114] E Welding electrode

[0115] F Pressed stranded wire

[0116] H1 Sleeve / end

[0117] H2 Sleeve / end

[0118] D Wire harness

[0119] S Stator

[0120] R Rotating shaft

[0121] 1 Insulated wire

[0122] 1' Partially stripped wire

[0123] 2 Shaping device, especially winding support

[0124] 2.1 First pin

[0125] 2.2 Second pin

[0126] 2.3 Third pin

[0127] 2.4 Fourth pin

[0128] 2a Long side

[0129] 2b Short side

[0130] 3 Stripping device, especially laser

[0131] 4 Twisting device

[0132] 4.1 First clamp

[0133] 4.2 Second clamp

[0134] 5 Pressing device, especially press.

Claims

1. A method for manufacturing a pressed stranded wire (F) from an insulating wire (1) fed linearly or substantially linearly, the method comprising the following method steps: a) Use a forming device (2), configure the forming device (2) as a winding support, and form the insulating wire (1) into at least one semi-circular shape, circular shape, or spiral shape by the winding support, where The winding support includes a pin (2.1), on which the insulating wire is placed and formed into a semi-circular shape having a short side (2b) and two long sides (2a); alternatively, the winding support includes two pins (2.1, 2.2), where the pins are oriented parallel or substantially parallel to each other and spaced apart, and at least one loop of the insulating wire is pushed onto the winding support, the loop having two short sides (2b) abutting against the pins and two long sides (2a); alternatively, the winding support includes two pins (2.1, 2.2) and a rotating shaft (R), where the pins are oriented parallel or substantially parallel to each other and spaced apart, and the insulating wire is wound into a helix on the winding support, the helix having two short sides (2b) abutting against the pins and two long sides (2a); alternatively, the winding support includes four pins (2.1 to 2.4), where the pins are oriented parallel or substantially parallel to each other and spaced apart, and at least one loop of the insulating wire is pushed onto the winding support, the loop having two short sides (2b) arranged between the pins and two long sides (2a) arranged between the pins; alternatively, the winding support includes four pins (2.1 to 2.4) and a rotating shaft (R), where the pins are oriented parallel or substantially parallel to each other and spaced apart, and the insulating wire is wound into a helix on the winding support, the helix having two short sides (2b) arranged between the respective pins and two long sides (2a) arranged between the pins; b) Using a twisting device (4), twisting at least one of the semi-circular shape, loop or helix into a wire bundle (D); c) Using a pressing device (5), pressing the wire bundle (D), wherein, after forming (a) and before twisting (b), a partial stripping of the wire or the semi-circular shape, loop or helix is performed on the long side (2a) or the short side (2b) between the pins of the winding support using a stripping device (3).

2. The method according to claim 1, wherein The partial stripping is achieved by grinding abrasively.

3. The method according to claim 1, characterized in that, The partial stripping is achieved mechanically by sandblasting.

4. The method according to claim 1, wherein The partial stripping is achieved chemically and / or thermally by using cold embrittlement, laser sublimation, induction heating.

5. The method according to claim 1 or 2, characterized in that, Using a twisting device (4), the twisting of at least one of the semi - rings, rings or spirals is achieved, wherein the twisting device comprises a first clamp (4.1) for the first distal end of at least one of the semi - rings, rings or spirals, and a second clamp (4.2) for the second distal end of at least one of the semi - rings, rings or spirals, wherein the first clamp and the second clamp rotate around or substantially around the longitudinal axis of at least one of the semi - rings, rings or spirals.

6. The method according to claim 5, wherein The first clamp is formed by a first pin, and the second clamp is formed by a second pin or a clamping tool.

7. The method according to claim 1 or 2, characterized in that The twisting is implemented in the shaping device.

8. The method according to claim 1 or 2, characterized in that, The insulated wire and / or the wire bundle is / are at least partially coated with a bonding varnish.

9. The method according to claim 1 or 2, characterized in that, After the twisting, the stripped wire segments are mechanically and electrically connected to each other.

10. The method according to claim 9, characterized in that, The connection of the stripped wire segments in the end - pieces is carried out without a sleeve.

11. A method for manufacturing an electric motor, the electric motor comprising a stator (S), wherein the winding in the stator is formed at least in sections by pressed stranded wires, characterized in that, The pressed stranded wire is at least partially obtained by the method according to any one of claims 1 to 10.

12. Application of a pressed stranded wire in a stator (S) of an electric motor, characterized in that, The pressed stranded wire is at least partially a pressed stranded wire (F) manufactured by the method according to any one of claims 1 to 10.

13. A pressed stranded wire obtained by the method according to any one of claims 1 to 10, characterized in that, At least one end - piece has an unbroken sling.

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