Device for bending the ends of rod-shaped conductors arranged in annular layers of a stator of an electric machine

Abstract

In summary, the present invention relates to a device (1) for bending the end (2a) of a rod-shaped conductor (2) arranged in a stator matrix (3a) for an electric motor and arranged in an annular layer (L1-L4), the device comprising a plurality of coaxially arranged coupling bodies (6), the coupling bodies having coupling recesses (7), by means of which the ends (2a) of the rod-shaped conductor (2) can be embedded layer by layer and plastically deformed. A drive platform (10) is provided for each coupling body (6), and the drive platform can be moved along the axial direction (AR) together with the coupling body (6). The coupling body (6) belonging to the drive platform (10) can rotate on the drive platform (10). All drive platforms (10) move axially on a common climbing rod mechanism (11). Each drive platform (10) has its own first drive (8) for axially moving the drive platform (10) and its own second drive (9) for rotating the coupling body (6) on the drive platform (10), and these two drives (8, 9) can be moved axially together with the drive platform (10). The device (1) has a simple structure and requires a small construction space.

Description

Technical Field

[0001] The invention relates to a device for bending the ends of straight or bent rod-shaped conductors arranged in at least four annular layers of a stator of an electrical machine, in particular an electric motor or a generator,

[0002] The device comprises a holder for a stator, in particular a clamping holder,

[0003] The device comprises at least four coupling bodies arranged concentrically about the central axis, each of which has a plurality of annularly arranged coupling recesses at the front end for engaging the ends of the rod-shaped conductors of each annular layer.

[0004] The device has a first drive for moving the connecting body along the axial direction of the central axis and a second drive for rotating the connecting body around the central axis for each connecting body, so that all connecting bodies can move and rotate axially independently of each other. Background Art

[0005] Such a device is known from US Pat. No. 8,327,677 B2.

[0006] Electrical machines, in particular electric motors, are becoming increasingly important, particularly in the field of transportation, since they can be used to convert electrical energy into power, for example driving power, in an emission-free manner.

[0007] Electric motors are generally based on electromagnetic interaction and induction. A common electric motor has a rotor in which permanent magnets are arranged, which rotates relative to a stator, in which electromagnetic coils are arranged, which coils can act as electromagnets. In an electric motor, an electric current is usually conducted through the coils of the stator, and the rotor is thereby subjected to a force which causes the rotor to rotate. In a generator, the rotating rotor generates an electric current in the coils.

[0008] The coils of the stator can be wound with a continuous wire; but high-performance stators can be completed with so-called rod conductors. Here, a common type of rod conductor is a U-shaped bent rod conductor (also called a "hairpin"), which has an electrical connection established between its legs on one side; but unbent rod conductors with free ends on both sides are also widely used.

[0009] A plurality of initially individual (unbent or bent) bar conductors are usually inserted into the stator and are then to be electrically connected to one another at their free ends according to a predetermined wiring diagram, usually by welding. To this end, the ends (end segments) of the bar conductors to be connected are preliminarily mechanically bent in the circumferential direction (plastic deformation) so that the ends of the bar conductors from adjacent radial layers, which were initially spaced apart in the circumferential direction, come closer to one another in the circumferential direction. The name "twisting machine" is also widely used for corresponding machines for bending the ends of the bar conductors.

[0010] US 8,327,677 B2 describes a wire twisting machine in which four concentric radial layers of rod-shaped conductor ends can be bent in the circumferential direction. Each layer is provided with its own coupling device, which can engage the rod-shaped conductor ends of a layer, i.e. the rod-shaped conductor ends on the same radius, with an annularly arranged recess. Here, each coupling device rotates with its own machine axis and moves axially with its own machine axis. For this purpose, a total of 8 servomotors are fixed to the frame. The rotation and movement operations of the individual coupling devices are in turn realized by their own radially extending arms, and it is not described in more detail here how the rotation operation is decoupled from the movement operation on the drive side.

[0011] The wire twisting machine described requires a large amount of installation space and has a complex and inflexible structure due to the lever mechanism. Summary of the invention

[0012] The object of the present invention is to provide a device for bending the ends of rod-shaped conductors which has a simpler and more compact construction.

[0013] This object is achieved by a device of the type mentioned above, characterized in that

[0014] Each coupling body has its own drive platform, which is supported on the corresponding drive platform so that it can rotate about the central axis but is fixed in the axial direction.

[0015] The driving platform is arranged to be able to move independently along the central axis on a climbing rod mechanism fixed at a common position, wherein the climbing rod mechanism comprises at least two climbing rods arranged parallel to the central axis,

[0016] And the corresponding drive platform has:

[0017] - a first drive and a second drive belonging to the coupling body of the drive platform;

[0018] at least two climbing members for axially moving the drive platform, said climbing members being axially fixed to the drive platform and respectively coupled to one of the climbing rods, and driven by a first drive, and

[0019] - a transmission device for rotating the coupling body relative to the drive platform, the transmission device being coupled to the coupling body and driven by the second drive.

[0020] In the device (twisting machine) according to the invention, a plurality of drive platforms are provided, which can be individually moved axially on a common climbing rod mechanism and thus on a corresponding frame. Each coupling body is provided with its own drive platform, on which the coupling body is supported.

[0021] A first (local) driver, such as a first servo motor, for moving the driving platform axially and a second (local) driver, such as a second servo motor, for rotating the coupling body on the driving platform are installed on the corresponding driving platform. When the driving platform is moved axially by the first driver, the related coupling body fixedly supported axially on the driving platform (at least with respect to the force input direction of the bending process) is driven, that is, the coupling body is also moved axially. The related coupling body can be rotated relative to its driving platform by the second driver, and here, the driving platform is particularly held on the frame in a non-rotatable manner by a climbing rod mechanism. Thus, the coupling body can rotate relative to the frame and particularly relative to the stator.

[0022] This structure makes it possible to achieve an axial displacement and rotation of the coupling bodies in a simple manner by means of the drive platforms independently of one another and also independently of the remaining coupling bodies on the other drive platforms. No radially extending arms that take up a lot of structural space are required. In particular, all drive platforms can be axially displaced on the same climbing rod mechanism, which can be designed to be particularly compact and very economical.

[0023] Preferred implementation forms

[0024] The following embodiment is preferred, which provides:

[0025] At least the outer coupling body has a substantially cylindrical shell-shaped front part and a substantially cylindrical shell-shaped rear part, the front part having a first diameter ED corresponding to the diameter of the annular arrangement of the coupling recess, and the rear part having a second diameter ZD, wherein ZD>ED,

[0026] The innermost coupling body also has a front part and a rear part, in particular the front part is also substantially cylindrical shell-shaped, the front part has a first diameter EDI corresponding to the diameter of the annular arrangement of the coupling recess of the innermost coupling body, and the rear part is also substantially cylindrical shell-shaped, the rear part has a second diameter ZDI, wherein ZDI>EDI is preferably satisfied,

[0027] The front parts and the rear parts of the coupling body are respectively plugged into each other.

[0028] And each transmission device is connected to the rear part of the coupling body for each coupling body. The front part of the coupling body can be compactly plugged into each other corresponding to the annular layer of the column elements on the stator. With the help of the rear part, the coupling body can be optimized so that it is hinged or supported on the drive platform, especially by a larger diameter to obtain better mechanical stability. In order to achieve a compact construction, the rear parts can also be plugged into each other. The cylindrical shell parts of the coupling bodies that are (coaxially) plugged into each other make it possible to guide each other axially and allow the coupling bodies to rotate relative to each other and move axially relative to each other at the same time. It should be noted that the innermost coupling body can also be made of solid material, for example; but in order to achieve a lightweight and material-saving structure, cylindrical shell parts are also preferably used here.

[0029] An embodiment is particularly preferred in which at least the drive platforms of the outer coupling bodies each have a through hole for guiding one or more coupling bodies arranged further inwards through, thereby achieving a particularly compact structure.

[0030] In an advantageous embodiment, the climbing rod is designed as a threaded rod and the climbing element is designed as a nut. This enables the drive platform to be moved precisely and in particular with little play. The threaded rod is usually fixed in a stationary and non-rotatable manner in the frame, and the climbing element (axially fixed to the respective drive platform) is rotated on the respective drive platform by the first drive in order to move the drive platform axially.

[0031] In an alternative, equally preferred embodiment, the climbing rod is configured as a rack and the climbing element is configured as a gear or a worm wheel. This allows the drive platform to be moved particularly simply and stably. The rack is usually fixed in position in the frame, and the gear or worm wheel (axially fixed to the corresponding drive platform) is rotated on the corresponding drive platform by the first drive to move the drive platform axially.

[0032] An embodiment is particularly preferred in which the climbing rods are arranged symmetrically about the central axis, in particular there are exactly two climbing rods lying opposite one another. This symmetrical arrangement ensures that forces are input laterally to the climbing rods equally, which prevents the drive platform from tilting and thus ensures a precise movement of the drive platform, thereby achieving a precise conversion of the axial compensating movement when bending the rod-shaped conductor ends and correspondingly a precise bending of the rod-shaped conductor ends.

[0033] In a preferred embodiment, a first intermediate ring is rotatably supported around a central axis on a corresponding driving platform, the first intermediate ring is driven by a first driver, and each climbing member is connected to the first intermediate ring at different positions, in particular, each climbing member is symmetrically arranged on the first intermediate ring about the central axis. With the help of the first intermediate ring, the force of the first driver can be evenly distributed to each climbing member, and the tilting of the driving platform due to uneven force input is avoided. If more than two climbing rods and climbing members are provided, all climbing members are preferably connected to the first intermediate ring at different positions. The first intermediate ring can be configured as a partially toothed or fully toothed gear ring.

[0034] The following embodiment is also preferred, in which the corresponding transmission device driven by the second drive comprises a gear or a rack and meshes with a toothing on the coupling body or a toothing on a second intermediate ring rigidly connected to the coupling body. The transmission of force for rotating it to the coupling body by the teeth of the gear or the rack and a suitable corresponding toothing on the coupling body or on the second intermediate ring are particularly simple and stable in structure. The second intermediate ring can be designed as a partially toothed or fully toothed gear ring. When using a rack, the rotation of the coupling body can be adjusted by a linear motor.

[0035] Another embodiment is advantageous in which the respective coupling recesses of the coupling body are formed on an end piece which is replaceably fastened to the rest of the coupling body. By replacing the end piece of the coupling body, adaptation to other types of stators can be achieved in a simple manner. Preferably, the front end piece completely comprises the cylindrical shell-shaped front part of the coupling body and preferably also comprises an intermediate flange for connecting the cylindrical shell-shaped rear part of the coupling body.

[0036] Furthermore, an embodiment is advantageous in which the connection recess is designed in a crown-shaped manner at the front end of the respective connection body. The crown-shaped structure requires little material and also allows the ends of the rod-shaped conductors which are arranged relatively close together in the radial direction to be bent. In the case of a crown-shaped design, the connection recess is limited only in the circumferential direction, but not in the radial direction. Alternatively, the connection recess can also be designed as a completely closed depression (in the radial direction and in the circumferential direction); this ensures a particularly secure engagement of the ends of the rod-shaped conductors.

[0037] In a preferred embodiment, the device further comprises a rail system having at least two fixed rails extending parallel to the central axis and at least two counterparts are fixed or formed on each drive platform, each of which is axially movable on one of the rails. The rails fixed on the frame can achieve a particularly good stabilization effect (in addition to the climbing rod mechanism) on the drive platform to prevent tilting. Usually, the counterparts surround the rails and / or engage in the rails.

[0038] There is another embodiment which is also preferred, and this embodiment is configured as follows:

[0039] The stator holder is arranged on the auxiliary platform, and the auxiliary platform is also movably arranged on the climbing rod mechanism in the axial direction of the central axis.

[0040] And the auxiliary platform comprises an additional drive and at least two additional climbing members for making the auxiliary platform move axially, the additional climbing members are axially fixed on the auxiliary platform and are respectively connected to one of the climbing rods, and the additional climbing members are driven by the additional drive. By the additional platform that can move axially, the amount of axial movement of the coupling body is reduced when bending the layer of the rod-shaped conductor. At this time, the retaining member performs the main movement for the bending process, and the coupling body only completes a small differential movement. The fixing of the retaining member on the additional platform (and the stator in the retaining member) is usually anti-rotation. Alternatively, the additional platform for the retaining member can also be fixed on the climbing rod mechanism in a fixed position (axially and in rotation).

[0041] In a further development of the embodiment of the device with a rail system and an axially displaceable additional platform for the holder, at least two additional counterparts are also fastened or formed on the additional platform, each of which is arranged axially displaceably on one of the rails. This also makes it possible to mechanically stabilize the additional platform better, in particular to stabilize it against tilting.

[0042] The invention also includes the use of the above-described device according to the invention for bending the ends of straight or bent rod-shaped conductors arranged in at least four annular layers of a stator of an electrical machine, in particular an electric motor or a generator,

[0043] The stator is arranged in a holder,

[0044] The ends of the rod-shaped conductors of the corresponding annular layers arranged in the stator are respectively overlapped with the connection recesses of the corresponding connection bodies.

[0045] and independently controlling the axial movement and the rotational movement of the coupling body,

[0046] In particular, the rotation directions of the coupling bodies arranged radially one after the other are changed alternately. By rotating the coupling body and moving it axially, the ends of the rod-shaped conductors can be bent in a desired manner. The rotation adjusts the degree of bending of the ends of the rod-shaped conductors in the circumferential direction. The effective axial shortening of the ends of the rod-shaped conductors is compensated by the axial movement during circumferential bending, so that the ends of the rod-shaped conductors do not disengage at the coupling recesses during the bending process. Preferably, the rod-shaped conductors have different axial lengths at the beginning of the bending process, and the bending process includes supplementary axial guidance of the coupling body in such a way that the ends of the rod-shaped conductors are at the same axial height at the end of the bending process. Within the scope of the present invention, all machine axes (rotation and axial movement of each drive platform) can be individually controlled to achieve an optimal bending process.

[0047] A variant of the application is preferred here, which provides that:

[0048] When the ends of the stator's rod-shaped conductors are bent, the axial movement of the coupling increases from the inside to the outside.

[0049] In particular, the rotational angle interval of the rotational movement of each coupling increases from the inside to the outside. By increasing the axial stroke outward, it is possible to take into account a greater change in the effective length of the bent rod-shaped conductor further outward in the radial direction; when the angular offset is (approximately) the same, the rod-shaped conductors that are closer to the outside are shortened by bending more strongly in the circumferential direction than the rod-shaped conductors that are closer to the inside, since the absolute bending path in the circumferential direction is larger when it is closer to the outside. Within the scope of the present invention, the rotational angle interval of the actual manipulation of the rotational movement may include an overbending of the ends of the rod-shaped conductors beyond the desired end position in order to take into account the elastic rebound of the ends after the bending process. By increasing the rotational angle interval achieved by the actual manipulation radially outward, especially after the rebound, it is possible to maintain the same rotational angle interval in all layers, thereby achieving particularly precise manufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Further advantages of the present invention will be apparent from the description and the drawings. Likewise, the features described above and to be described further can also be used according to the present invention individually or in combination. The embodiments shown and described are not to be understood as an exhaustive enumeration, but rather have an exemplary character for the purpose of illustrating the present invention.

[0051] in:

[0052] Figure 1 A schematic perspective view showing an exemplary embodiment of the device according to the invention;

[0053] Figure 2A Show Figure 1A schematic perspective view of a stator having a rod-shaped conductor used in the present invention disposed therein;

[0054] Figure 2B A schematic diagram showing the Figure 2A stator;

[0055] Figure 2C An alternative selector for use with the present invention is shown in schematic perspective view, wherein the post element is configured to bend into a "hairpin";

[0056] Figure 3A Use longitudinal section view for Figure 1 A schematic exploded view of the front end components of the coupling body of the device;

[0057] Figure 3B Shown for Figure 1 A schematic longitudinal sectional view of the coupling bodies of the device connected to each other;

[0058] Figure 4 Shown for use according to Figure 1 A schematic longitudinal cross-sectional view of a drive platform of a device together with associated couplings;

[0059] Figure 5A Show Figure 4 A schematic top view of a driving platform;

[0060] Figure 5B Show Figure 4 A schematic bottom view of a driving platform;

[0061] Fig. 6A Schematically showing the application according to the present invention Figure 1 Axial shortening of the rod-shaped conductor when bending in the case of a device and the selection of the axial stroke of the coupling body according to the invention;

[0062] Figure 6B Schematically showing the application according to the present invention Figure 1 The elastic rebound of the rod-shaped conductor during bending under the condition of the device and the selection of the overbending angle interval of the connecting body according to the present invention. DETAILED DESCRIPTION

[0063] The figures show, by way of example, embodiments of a device according to the invention for bending the ends of rod-shaped conductors of a stator of an electrical machine, such as an electric motor or a generator.

[0064] Figure 1 1 shows a schematic perspective view of a device 1. The device 1 is used to bend the ends of a rod-shaped conductor 2 which has been inserted into a stator 3 having a substantially cylindrical shell-shaped stator base body 3a. Figure 1In the figure, the upper free end 2b of the rod-shaped conductor 2 is visible; however, the device is used to bend the Figure 1 The hidden lower free ends of the rod-shaped conductors 2 (it should be noted, however, that the stator 3 can also be inserted into the device 1 in reverse, so that the previous upper ends 2b of the rod-shaped conductors 2 now become the lower ends, which can also be bent by the device 1).

[0065] Figure 2A The stator 3 and the rod-shaped conductor 2 held therein are shown in addition, the lower end (end section) 2a of which protrudes downward from the stator base body 3a of the stator 3 and which can be used as a Figure 1 The device is bent. Figure 2B This is a view of the stator 3 as seen from below.

[0066] The lower ends 2a of the rod-shaped conductors 2 to be bent are arranged in rows 38 distributed in the radial direction RR in the unbent state and inserted into corresponding grooves elongated in the radial direction RR in the stator base body 3a for each row 38. Here, four ends 2a of the rod-shaped conductors 2 are arranged in each row 38, which corresponds to four annular layers L1, L2, L3, L4 of the ends 2a of the rod-shaped conductors 2.

[0067] The lower end 2a of the rod-shaped conductor 2 can be bent in the circumferential direction UR (also called the azimuthal direction) by the device according to the invention. In a conventional bending process, for example, the end 2a of the layer L1 is bent counterclockwise by half the middle angle of the row, and the end 2a of the adjacent layer L2 is bent clockwise by half the middle angle of the row; similarly, the end 2a of the layer L3 is also bent counterclockwise by half the middle angle of the row, and the end 2a of the adjacent layer L4 is bent clockwise by half the middle angle of the row. It is preferred within the scope of the invention that the bending direction alternates between the layers L1-L4. At this time, the overlapping ends 2a of the layers L1 and L2 and also the layers L3 and L4 can be welded to each other in the position (not shown) reached by permanent deformation.

[0068] Reference again Figure 1 , the stator 3 is fixed in a holder 4, here a clamping holder. The holder 4 is arranged on an additional platform 33, which is described in further detail below.

[0069] In the embodiment shown, the device 1 comprises four so-called drive platforms 10 ; in other embodiments, more drive platforms (for a correspondingly greater number of radial layers of bending the ends of the rod-shaped conductors) may also be provided.

[0070] The drive platform 10 can move along the central axis 5, which passes through the stator 3 in the center and extends vertically here. Here, each drive platform 10 moves on a common climbing rod mechanism 11, which is configured here to have two climbing rods 12. Here, the climbing rod 12 is configured as a screw (for the sake of simplicity, the external thread of the climbing rod 12 is not shown in detail). The climbing rod 12 runs parallel to the central axis 5, and the central axis 12a of the central axis 5 and the climbing rod 12 are located in a common plane (see Figure 4 The lower longitudinal section plane / drawing plane) is arranged in a fixed position in the machine frame 37.

[0071] The drive platform 10 is additionally guided by a rail system 30, which here comprises a total of four rails 31, which are formed in a fixed position on a frame 37 (a large part of one of the rails 31 is connected to the frame 37). Figure 1 is hidden in the middle).

[0072] The driving platforms 10 are configured to respectively have a first drive for moving the corresponding driving platform 10 axially along the climbing rod mechanism 11 and also have a coupling body 6 (in Figure 1 Mostly hidden but visible below) the second drive rotates.

[0073] The additional platform 33 has an additional drive 34, here a servomotor, which is coupled to two additional climbing members 35 in a manner not described in detail (e.g., via an additional intermediate ring supported coaxially to the central axis 5). On the additional platform 33, the additional climbing members 35 are fixed to the additional platform 33 in the axial direction AR (i.e., cannot move relative to the additional platform 33 in the axial direction AR), but can be rotated by the additional drive 34. The additional climbing members 35 are each configured as a nut (with an internal thread) and are screwed onto the climbing rod 12. Therefore, by rotating the additional climbing member 35 by means of the additional drive 34, the additional platform 33 can be moved in the axial direction, and the holder 4 and the stator 3 together with its rod-shaped conductor 2 can be moved in the axial direction together with the additional platform.

[0074] Here, the additional platform 33 also has an additional counterpart 36 which here encompasses the two rails 31 of the rail system 30 and thereby guides the additional platform 33 and additionally secures it against tilting.

[0075] Figure 2C The invention is shown in particular for Figure 1Here, the rod-shaped conductor 2 is designed to be bent into an approximately U-shape ("hairpin"), with the legs 42 of the rod-shaped conductor 2 protruding downward and protruding from the stator base body 3a with the lower end 2a to be bent. A bracket 43 of the rod-shaped conductor 2 is formed on the stator 3, which respectively connects the two legs 42 of the rod-shaped conductor 2. In this type of rod-shaped conductor 2, the bending process and welding only need to be carried out in the region of the free lower end 2a of the rod-shaped conductor 2, but not in the region of the upper end.

[0076] Figure 3A Exploded diagram showing the Figure 1 The front (here upper) end piece 29 of the coupling body 6 of the device. The end piece 29 here respectively comprises a front piece 16 and an intermediate flange 41, and the front piece is designed to be essentially cylindrical shell-shaped.

[0077] The upper part 16 is here each formed at its front end, the upper end in FIG. 3a, with a so-called crown structure 7a, which in each case forms an axial recess as a coupling recess 7 between two tines. Overall, each crown structure 7a has the same number of radial rows of the (initially undeformed) rod-shaped conductor ends on the stator below (see Figure 2B ) The same coupling recesses 7. The corresponding crown structures 7a engage with the aid of the tines in the intermediate spaces between the radial rows of the ends of the rod-shaped conductors, the ends of the rod-shaped conductors being located in the coupling recesses 7 accordingly (not shown in detail).

[0078] The diameter of the corresponding crown structure 7a or the diameter of the front part 16 of the coupling body 6, here referred to as the first diameter ED (or EDI for the innermost coupling body 20), is equal to the diameter of the respectively corresponding annular layer of the rod-shaped conductor ends. By twisting the coupling bodies 6 or the crown structures 7a relative to each other, the engaged ends of the rod-shaped conductors can be bent individually in the circumferential direction in all layers, whereby the coupling bodies 6 can be subsequently guided individually in the axial direction in all layers.

[0079] The upper part 16 transitions into the intermediate flange 41 at the bottom. The rear part of the coupling body 6, which is also in the form of a cylindrical shell, is replaceably fixed, for example screwed, to the corresponding intermediate flange 41 (at Figure 3A Not shown, but for this see Figure 3B or Figure 4 ); This rear member has the same outer diameter as the intermediate flange 41, Figure 3A The second diameter ZD is marked in the middle (or ZDI for the innermost coupling body 20).

[0080] Here, in each connecting body 6, the corresponding first diameter ED is smaller than the corresponding second diameter ZD, that is, ED<ZD (or EDI<ZDI), thereby, the connecting body 6 can be firmly and reliably supported on the drive platform, but at the same time, a small rod-shaped conductor structure can also be accurately manufactured or bent on the stator.

[0081] It should be noted that in the coupling body 6 the (radial) first diameter ED and the (radial) second diameter ZD decrease from top to bottom in the exploded view, so that in the assembled state the coupling bodies 6 can be radially nested in one another (see below).

[0082] The front part 16 and the rear part 18 of the coupling body 6 in the assembled state are Figure 3B (the uppermost / outermost coupling body 6 is marked as an example, and see also Figure 4 ). In order to achieve a compact structure of the device, the coupling bodies 6 are plugged into each other ("nested"). Here, the front (upper) parts 16 of different coupling bodies 6 are plugged into each other, and the rear (lower) parts 18 of the coupling bodies 6 are also plugged into each other (the rear parts also extend downward and separately from each other). At this time, a total of four coupling bodies 6 can rotate relative to each other and can move axially relative to each other (over a correspondingly determined distance). For this purpose, the corresponding front parts 16 are configured to be basically cylindrical shell-shaped, and the corresponding rear parts 18 are also configured to be basically cylindrical shell-shaped. The rear parts 18 are respectively supported on the drive platform 10 (only partially shown, see Figure 4 , 5A , 5B below). The wall portions of the front parts 16 of the adjacent coupling bodies 6 are close to each other (with a certain gap), and the wall portions of the rear parts 18 of the adjacent coupling bodies 6 are also close to each other (with a certain gap); thus, mutual support is achieved. Here, all parts 16, 18 of the four coupling bodies 6 are coaxially arranged relative to each other about the central axis 5.

[0083] It should be noted that, in the illustrated embodiment, the cylindrical shell shape of the front part 16 and the rear part 18, i.e. the shape with through hole 26 is necessary only for the outer coupling body 15, so that one or more radially more inner coupling bodies 6 can be passed. For the innermost coupling body 20, the coupling body 20 in the front part 21 and / or the rear part 22, for example, can also be made of solid material or be manufactured to have a radially stable strut (not shown in detail). However, in order to keep the material cost and weight of the equipment lower, the cylindrical shell shape (as shown in the figure) with through hole 26 is also preferred here.

[0084] Figure 4 A schematic longitudinal section through the central axis 5 and the central axis 12a of the climbing rod 12 and Figure 5A The schematic diagram of the above side 40, and Figure 5B The schematic diagram of the lower side 39 shows Figure 1 An exemplary driving platform 10 of the device. It should be noted that Figure 1 The device here has a total of four essentially identical drive platforms 10 for four coupling bodies 6 (each with its own diameter), which are here each arranged on the machine frame in an alternating orientation in order to achieve a compact design.

[0085] The drive platform 10 has its own first drive 8, which is arranged here on the underside 39 of the drive platform 10. The first drive 8 drives a first intermediate ring 27, which is mounted rotatably about the center axis 5. The first intermediate ring 27 is designed here as a toothed ring with an external toothing (not shown in detail) and is also arranged here on the underside 39 of the drive platform 10.

[0086] The two climbing elements 13 are in turn connected to the first intermediate ring 27. For this purpose, the climbing elements 13 are each rigidly fixed to a transmission ring 13a with an external toothing. Here, the transmission ring 13a with an external toothing engages in the first intermediate ring 27 at positions opposite to each other, where the center axis 5 is located exactly between said positions.

[0087] The climbing member 13 is configured with an internal thread (not shown in detail), by means of which the climbing member is screwed onto the climbing rod 12 configured as a screw. The climbing member 13 is axially fixed to the drive platform 1 by radial overlap on the climbing member support 13b. However, the climbing member 13 together with the transmission ring 13a with external teeth can be supported rotatably around the central axis 12a of the climbing rod 12.

[0088] Thus, the two climbing elements 13 can be rotated around the central axis 12a by the first drive 8 and here move helically around the climbing rod 12, thereby driving the drive platform 10 and moving it in the axial direction AR.

[0089] Furthermore, the drive platform 1 also has its own second drive 9, which is also designed as a servo motor and is also arranged here on the lower side 39 of the drive platform 1. The second drive 9 here directly drives the transmission gear 14a, which is arranged in a groove on the upper side 40 of the drive platform 1. The transmission gear 14a meshes with a second intermediate ring 28 with an external toothing, which is rigidly connected to the coupling body 6 in the region of the lower part 18 via a connecting flange 28a. The second intermediate ring 28 is supported rotatably about the center axis 5. The second intermediate ring 28 can introduce axial forces from the coupling body 6 downward into the drive platform 10 where the coupling body is located; accordingly, the coupling body 6 is supported axially fixedly on this drive platform 10 (for the bending process). Preferably, the second intermediate ring 28 or the coupling body 6 is also fixed against axial upward movement relative to the drive platform 10 (for example, by overlapping in the radial direction, not shown in detail).

[0090] The transmission gear 14 a and the second intermediate ring 28 here form a transmission 14 , with which the second drive 9 can rotate the coupling body 6 on the drive platform 10 about the central axis 5 .

[0091] Each drive platform 10 here has two counterparts 32 rigidly fixed thereto. Each counterpart 32 surrounds one of the rails 31 in order to additionally guide the drive platform 10 and in particular additionally secure the drive platform 10 against tilting (in particular a tilting of the surface normal of the upper side 40 of the drive platform 10 relative to the central axis 5).

[0092] The coupling body 6 is rigidly fixed to the coupling flange 28a with its rear part 18. The front (upper) end part 29 of the coupling body 6 is replaceably fixed to the upper end of the rear part 18 (for example, by a threaded structure, not shown in detail). Here, the end part 29 comprises the front part 16 of the coupling body 6 and the intermediate flange 41 (threaded holes can be arranged radially on the outside in the intermediate flange, not shown in detail), into which the front part 16 enters and transitions. On the front part 16, the coupling recess 7 or the crown structure 7a is formed at the upper end.

[0093] With the device according to the invention, the radial layers of the ends of the rod-shaped conductors can be bent independently of one another, whereby the coupling body can be operated independently of one another in the axial and radial directions. As schematically shown by way of example in FIGS. 6a and 6b, this can be used, in particular, to intentionally select different strokes of the axial movement and the rotation angle intervals when bending the rod-shaped conductors in different layers L1 (radially inward), L2, L3 and L4 (radially outward). It should be noted that in Fig. 6A and Figure 6BIn the drawings, the degree of curvature, length and shortening are partially exaggerated and partially reduced in order to illustrate the effects and features of the present invention.

[0094] The starting state is the first undeformed (not yet plastically deformed) rod-shaped conductor 2 or undeformed free end (end section) 2a in the layers L1 to L4, see the left side of FIG. 6a. The upper end 2b of the rod-shaped conductor 2 (if necessary, it can also be a bracket of the hairpin-shaped rod-shaped conductor, not shown in detail) is at the same (axial) height 44. Here, the length of the rod-shaped conductor 2 is the longest in the radially outermost layer L4 and decreases radially inward from layer to layer, so that the shortest rod-shaped conductor 2 appears in the innermost layer L1, see the left side of FIG. 6a. Using the method according to Figure 1 The device now bends the lower end 2a of the rod-shaped conductor 2 together with the coupling body, which is initially connected to the end 2a of the rod-shaped conductor 2 at different heights in different layers L1-L4. During the bending process, the rod-shaped conductor 2 is bent in the circumferential direction (at this time, the layers are bent with alternating turns), and after the bending, a radial row of rod-shaped conductors 2 protrude as shown on the right in Figure 6a (for simplicity, they are shown side by side here). The lower end 2a of the rod-shaped conductor 2 is now at the same (axial) height 45. For this purpose, the coupling body has traveled through different axial strokes H1-H4 in different layers L1-L4, and the device according to the present invention can easily predetermine the strokes. The axial strokes H1 to H4 increase radially outward layer by layer from the innermost layer L1 of H1 to the radially outermost layer L4 of H4.

[0095] However, if an overbending occurs in the circumferential direction during the bending process, so that the elastic spring travel ("rebound") after the coupling is released is to be taken into account, in some applications, only the final position of the rod-shaped conductor 2 shown in FIG. 6a can be achieved. In this case, the rod-shaped conductor 2 must first be bent to the position shown in FIG. 6b with a dashed line, so that after the rebound, the desired position of the rod-shaped conductor 2 shown in a solid line or a corresponding residual (plastic) deformation is obtained. In this case, for the application shown, the spring travel or the necessary bending angle interval is For the radially innermost layer L1 It is the smallest at the radially outermost layer L4 and increases radially outward. The place is the biggest.

[0096] For the application shown, the basic rotation angle interval BDW corresponding to the angle difference between the starting state and the desired end state of the rod-shaped conductor 2 is the same for all layers L1-L4. However, since this requires increasingly larger overbending angle intervals from the inside to the outside, Therefore, the actual manipulated rotation angle range DWI of the joint must increase from the inside to the outside, as follows:

[0097]

[0098]

[0099] as well as

[0100]

[0101] The device according to the invention can easily adjust the rotation angle interval DWI actually to be manipulated in the respective layer L1-L4. Thus, in the application shown, after the bending process, the permanent rotation angle interval obtained in all layers L1-L4 is equal to the desired basic rotation angle interval BDW.

[0102] It should be noted that in other applications, other distributions of the layers at the overbending angle intervals may also be used, for example radially decreasing overbending angle intervals from the inside to the outside. The overbending angle intervals to be used may depend in particular on the rod-shaped conductor cross section and the rod-shaped conductor material or also on the bending geometry of the respective layers.

[0103] If the necessary overbending is taken into account and the alignment is precisely adjusted during the bending process according to the invention, the ends of the rod-shaped conductors can be welded in the next production step with almost no mechanical stress, which simplifies the welding process and makes it possible to manufacture the entire stator for the electric machine including its rod-shaped conductors 2 more accurately.

[0104] During the bending process, the individual rotational manipulation (rotation) of the coupling body can also be used to set the azimuthal connection widths differently between the rod-shaped conductor ends on different layer pairs. For example, in one layer pair, an electrical connection can be provided between rod-shaped conductors that are immediately adjacent in the azimuthal direction, while in another layer pair, an electrical connection can be provided to the rod-shaped conductor that is next in the azimuthal direction. This can be achieved very well with the device according to the invention.

[0105] In summary, the present invention relates to a device (1) for bending the ends (2a) of a rod-shaped conductor (2) arranged in a stator matrix (3a) for an electric motor and arranged in an annular layer (L1-L4), the device comprising a plurality of coaxially arranged coupling bodies (6), the coupling bodies having coupling recesses (7), the coupling recesses being able to engage the ends (2a) of the rod-shaped conductor (2) layer by layer and plastically deform them. A drive platform (10) is provided for each coupling body (6), the drive platform being able to move along an axial direction (AR) together with the coupling body (6). The coupling body (6) belonging to the drive platform (10) can rotate on the drive platform (10). All drive platforms (10) move axially on a common climbing rod mechanism (11). Each drive platform (10) has its own first drive (8) for axially moving the drive platform (10) and its own second drive (9) for rotating the coupling body (6) on the drive platform (10), and these two drives (8, 9) can move axially together with the drive platform (10). The above device (1) has a simple structure and requires a small construction space.

[0106] Reference numerals list

[0107] 1 Equipment (also called twisting machine)

[0108] 2 Rod-shaped conductor

[0109] 2a Lower end (rod-shaped conductor)

[0110] 2b Upper end (rod-shaped conductor)

[0111] 3. Stator

[0112] 3a Stator base

[0113] 4. Retaining parts

[0114] 5 Central Axis

[0115] 6 Connector

[0116] 7 Connection recess

[0117] 7a Crown structure

[0118] 8 First Drive

[0119] 9 Second Drive

[0120] 10. Drive Platform

[0121] 11 Climbing rod mechanism

[0122] 12 Climbing rod (here is a screw)

[0123] 12a Central axis (climbing pole)

[0124] 13 Climbing parts (here: nuts)

[0125] 13a Transmission ring

[0126] 13b Support

[0127] 14 Transmission

[0128] 14a Transmission gear

[0129] 15 Outer (not innermost) connector

[0130] 16 Front part

[0131] 18 Rear parts

[0132] 20 Innermost connector

[0133] 21 Front part (innermost connector)

[0134] 22 Rear part (innermost connector)

[0135] 26 Through Holes

[0136] 27 First intermediate ring

[0137] 28 Second intermediate ring

[0138] 28a Connecting flange

[0139] 29 End piece

[0140] 30 Track System

[0141] 31 Track

[0142] 32 corresponding parts

[0143] 33 Additional Platforms

[0144] 34 Additional Drivers

[0145] 35 Additional climbing parts

[0146] 36 Additional counterparts

[0147] 37 Rack

[0148] 38 radial rows (rod conductor ends)

[0149] 39 Lower side

[0150] 40 upper side

[0151] 41 Intermediate flange

[0152] 42 Legs

[0153] 43 Bow Stand

[0154] 44 Same height (upper end)

[0155] 45 Same height (lower end)

[0156] AR Axial direction (also called axial direction)

[0157] BDW (desired) base rotation angle interval

[0158] DWI (actually controlled) rotation angle interval

[0159] ED First diameter (upper part / outer coupling)

[0160] EDI First Diameter (Upper Part / Innermost Coupling)

[0161] RR Radial direction

[0162] UR Circumferential

[0163] Excessive bending rotation angle interval

[0164] ZD Second diameter (rear part / outer coupling)

[0165] ZDI Second diameter (rear component / innermost coupling)

Claims

1. A device (1) for bending the ends (2a) of straight or bent rod-shaped conductors (2) of a stator (3) of an electric machine, arranged in at least four annular layers (L1-L4), The device (1) comprises a holder (4) for a stator (3), The device (1) comprises at least four coupling bodies (6) arranged concentrically about a central axis (5), and each of the coupling bodies has a plurality of annularly arranged coupling recesses (7) at the front end for engaging the ends (2a) of the rod-shaped conductors (2) of each annular layer (L1-L4). The device (1) comprises, for each coupling body (6), a first drive (8) for moving the coupling body (6) in an axial direction (AR) of the central axis (5) and a second drive (9) for rotating the coupling body (6) around the central axis (5), so that all coupling bodies (6) can move and rotate in the axial direction independently of each other. It is characterized in that Each coupling body (6) has its own drive platform (10), and the coupling body (6) is supported on the corresponding drive platform (10) so as to be rotatable about the central axis (5) but fixed in the axial direction. The driving platform (10) is arranged to be able to move independently along the central axis (5) on a climbing rod mechanism (11) fixed at a common position, wherein the climbing rod mechanism (11) comprises at least two climbing rods (12) arranged parallel to the central axis (5). And each driving platform (10) has: - a first driver (8) and a second driver (9) of the coupling body (6) matched with the driving platform (10); - at least two climbing members (13) for axially moving the driving platform (10), the climbing members (13) being axially fixed to the driving platform (10) and respectively connected to one of the climbing rods (12), and the climbing members (13) being driven by the first drive (8), and - a transmission device (14) for rotating the coupling body (6) relative to the driving platform (10), the transmission device (14) being coupled to the coupling body (6) and driven by the second drive (9).

2. The device (1) according to claim 1, characterized in that At least the outer coupling bodies (6, 15) each have a substantially cylindrical shell-shaped front part (16) and a substantially cylindrical shell-shaped rear part (18), wherein the front part has a first diameter ED equal to the diameter of the annular arrangement of the coupling recesses (7), and the rear part has a second diameter ZD, wherein ZD>ED, The innermost coupling body (6, 20) also has a front part (21) and a rear part (22). The front parts (16, 21) and the rear parts (18, 22) of the connecting bodies (6, 15, 20) are respectively arranged to be plugged into each other. And the corresponding transmission device (14) for a coupling body (6, 15, 20) is respectively connected to the rear parts (18, 22) of the coupling body (6, 15, 20).

3. The device (1) according to claim 1 or 2, characterized in that The drive platform (10) of at least the outer coupling body (6, 15) respectively has a through hole (26) for guiding one or more coupling bodies (6, 20) arranged more inwardly through.

4. The device (1) according to claim 1 or 2, characterized in that The climbing rod (12) is configured as a threaded rod, and the climbing element (13) is configured as a nut.

5. The device (1) according to claim 1 or 2, characterized in that The climbing rod (12) is configured as a rack, and the climbing element (13) is configured as a gear wheel or a worm wheel.

6. The device (1) according to claim 1 or 2, characterized in that The climbing rods (12) are symmetrically arranged around the central axis (5).

7. The device (1) according to claim 1 or 2, characterized in that A first intermediate ring (27) is supported on each drive platform (10) so as to be rotatable around a central axis (5), the first intermediate ring (27) being driven by a first drive (8), and each climbing member (13) being connected to the first intermediate ring (27) at different positions.

8. The device (1) according to claim 1 or 2, characterized in that Each transmission device (14) driven by the second drive (9) comprises a gear (14a) or a rack and meshes with a toothed portion on the coupling body (6) or with a toothed portion on a second intermediate ring (28) rigidly connected to the coupling body (6).

9. The device (1) according to claim 1 or 2, characterized in that The coupling recess (7) of each coupling body (6) is formed on an end piece (29), which is replaceably fixed to the remaining part of the coupling body (6).

10. The device (1) according to claim 1 or 2, characterized in that The coupling recess (7) is configured in a crown-like manner at the front end of the corresponding coupling body (6).

11. The device (1) according to claim 1 or 2, characterized in that The device (1) further comprises a rail system (30) having at least two fixed rails (31) extending parallel to the central axis (5), and furthermore at least two counterparts (32) are fixed or formed on each drive platform (10), each of which is axially movably arranged on one of the rails (31).

12. The device (1) according to claim 1 or 2, characterized in that A retaining member (4) for the stator (3) is arranged on an additional platform (33), and the additional platform (33) is also movably arranged on a climbing rod mechanism (11) along an axial direction (AR) of a central axis (5), and the additional platform (33) comprises an additional drive (34) and at least two additional climbing members (35) for axially moving the additional platform (33), the additional climbing members (35) being axially fixed on the additional platform (33) and respectively connected to one of the climbing rods (12), and the additional climbing members (35) are driven by the additional drive (34).

13. The device (1) according to claim 11, characterized in that A retaining member (4) for the stator (3) is arranged on an additional platform (33), and the additional platform (33) is also movably arranged on a climbing rod mechanism (11) along the axial direction (AR) of the central axis (5), and the additional platform (33) includes an additional drive (34) and at least two additional climbing members (35) for axially moving the additional platform (33), the additional climbing members (35) being axially fixed to the additional platform (33) and respectively connected to one of the climbing rods (12), and the additional climbing members (35) are driven by the additional drive (34), and in addition, at least two additional corresponding members (36) are fixed or formed on the additional platform (33), and the additional corresponding members are respectively movably arranged on one of the rails (31) along the axial direction.

14. The device (1) according to claim 1 or 2, characterized in that The holder for the stator (3) is a clamping holder.

15. The device (1) according to claim 2, characterized in that The front part (21) of the innermost coupling body is also basically cylindrical shell-shaped, and the front part of the innermost coupling body has a first diameter EDI equal to the diameter of the annular arrangement structure of the coupling recess (7) of the innermost coupling body (6, 20), and the rear part (22) of the innermost coupling body is also basically cylindrical shell-shaped, and the rear part of the innermost coupling body has a second diameter ZDI, wherein ZDI>EDI.

16. The device (1) according to claim 7, characterized in that Each of the climbing elements (13) is arranged on the first intermediate ring (27) symmetrically with respect to the central axis (5).

17. Application of the device (1) according to any one of claims 1 to 16, for bending the ends (2a) of the straight or bent rod-shaped conductors (2) of the stator (3) of the motor, which are arranged in at least four annular layers (L1-L4), wherein the stator (3) is arranged in a retaining member (4), the ends (2a) of the rod-shaped conductors (2) of the corresponding annular layers (L1-L4) arranged in the stator (3) are overlapped by the connecting recesses (7) of the corresponding connecting bodies (6), and the axial movement and rotational movement of the connecting bodies (6) are controlled independently of each other.

18. The use according to claim 17, characterized in that When the end (2a) of the rod-shaped conductor (2) of the stator (3) is bent, the stroke (H1-H4) of the axial movement of the coupling body (6) increases from the inside to the outside.

19. The use according to claim 17, characterized in that: The rotation directions of the coupling bodies (6) arranged successively in the radial direction change alternately.

20. The use according to claim 18, characterized in that The rotation angle interval (DWI) of the rotational movement of each coupling body (6) increases from the inside to the outside.

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