Method for manufacturing a stator assembly

Abstract

A method for manufacturing a stator assembly having a stator core and a winding assembly, the stator core having stator slots and defining a stator axis, the winding assembly having winding elements having conductors with insulating layers and being configured such that the winding element has two interconnected winding element legs, the winding element legs having two winding element end sections assigned to the winding element legs having winding element ends; the method comprising the steps of: A) positioning the winding elements relative to the stator core such that the winding element legs extend through one of the stator slots and the winding element end sections extend out on a first axial side of the stator core; B) after step A), removing the insulating layer at least partially on the first and second winding element end sections of the first and second winding elements by means of a first laser assembly; C) pressing the first and second winding element end sections together and welding them together by means of a second laser assembly.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing stator assemblies. Background Technology

[0002] WO 2019 / 115 059 A1 discloses a method for stripping an electrical conductor with insulating elements from the stator of an electric machine, the conductor being a flat wire, and the method includes stripping the insulating elements at the stripping area using a laser.

[0003] DE 10 2018 200 035 A1 illustrates a method for electrically connecting hairpin ends during the manufacture of a rotor or stator, wherein the connection is achieved using a 3D printing method.

[0004] US 2019 / 0 280 577 A1 discloses a method for manufacturing a stator, wherein winding elements are formed by bending conductors, the winding elements are placed into stator slots, and wherein a laser beam is used to strip the winding elements.

[0005] CN 205 355 698 U illustrates a stripping device for multilayer wires. Different laser beams are used to strip multilayer wires of different materials.

[0006] EP 1 128 530 B1 illustrates a method for manufacturing a stator for a generator, wherein coil components are formed by cutting and bending wire material, and wherein the ends of the wire are connected into a winding by welding end sections together. Summary of the Invention

[0007] Therefore, the object of the present invention is to provide a novel method for manufacturing stator assemblies.

[0008] This objective is achieved through the following methods used to manufacture stator assemblies.

[0009] A method for manufacturing a stator assembly—the stator assembly having a stator core and a winding assembly, the stator core having stator slots and defining a stator axis, the winding assembly having winding elements having conductors with insulating layers and being formed such that the winding element has two interconnected winding element legs, the winding element legs having two winding element end sections assigned to the winding element legs, the winding element end sections having winding element ends—comprising the following steps:

[0010] A) The winding element is positioned relative to the stator core in such a way that the legs of the winding element extend through one of the stator slots and the end section of the winding element extends out on the first axial side of the stator core.

[0011] B) After step A), the insulating layer is removed at least partially by the first laser assembly on the first winding element end section of the first winding element and the second winding element end section of the second winding element.

[0012] C) The end sections of the first winding element and the end sections of the second winding element are pressed together and welded together by the second laser assembly.

[0013] The stripping performed according to step A) can improve the process reliability during welding. The first and second welding components are preferably different welding components to enable the implementation of optimized wavelengths.

[0014] According to a preferred embodiment, steps B) and C) are performed for the end sections of other winding elements that need to be welded to each other. Thus, the entire interconnect can be performed using this method.

[0015] According to a preferred embodiment, during step B), at least one device for dispersing the particles generated during the removal of the insulating layer is at least temporarily activated, and the at least one device comes from a first group of devices consisting of the following:

[0016] - Suction device, and

[0017] - Blower unit.

[0018] This reduces the risk of particulate contamination in the area surrounding the stator assembly and improves process reliability.

[0019] According to the preferred embodiment:

[0020] -The end section of the first winding element, or

[0021] -The end section of the second winding element, or

[0022] - First winding element section and second winding element section

[0023] In step A), after the winding elements are pushed into the stator core, they are deformed in such a way that they are offset, at least in the circumferential direction, relative to their exit positions from the stator core. This deformation allows the end sections of the winding elements to be connected to be brought closer together.

[0024] According to a preferred embodiment, the end section of the mentioned winding element also has at least partially a radial distance from the stator axis that is altered compared to the radial distance from the exit position of the stator core. This design allows the winding elements to be guided past each other more closely.

[0025] According to a preferred embodiment, steps B) and C) are performed at a pre-defined workstation. This saves on transportation to additional workstations and reduces time.

[0026] According to a preferred embodiment, in step B), at least one laser beam is directed at an assigned incident position on the end section of the first winding element or the end section of the second winding element with an incident angle that is the angle between the laser beam at the incident position and the extension direction of the end section of the winding element toward the end of the winding element. The incident angle is correspondingly greater than 0° and less than 90° with respect to the rotor axis, and preferably at least two laser beams are directed at the assigned incident positions at least temporarily and simultaneously.

[0027] An incident angle within this range has proven advantageous for stripping in a partially assembled state, since stripping is almost impossible at an angle of 0°, while some sections of the winding element end section are difficult to access at an angle of 90° or greater.

[0028] According to a preferred embodiment, the angle of incidence is between 30° and 60°, preferably between 40° and 50°. In experiments, this angle of incidence yielded particularly advantageous heat introduction when it was sufficiently accessible.

[0029] According to a preferred embodiment, in step B), the laser beam incident on the corresponding winding element end section extends in a straight line from a first position of the laser assembly to the winding element end section, the first position being located on the side of the winding element end section opposite to the stator core. This arrangement of the first position allows the laser beam to advantageously extend to the winding element section.

[0030] According to a preferred embodiment, in step B), the laser beam incident on the end section of the second winding element traverses at least one predetermined first space, which is obtained by displacing the surface of the winding element end section of the first winding element away from the stator core in the direction of the stator axis. Therefore, it is possible to reach the end section of the first winding element beyond the end of the second winding element, and this can increase energy input at a specific incident position or enable stripping over a larger area.

[0031] According to a preferred embodiment, in step B), at least two laser beams are incident on the stator assembly at least temporarily and simultaneously, preferably exactly two laser beams at least temporarily and simultaneously. This allows for faster stripping.

[0032] According to a preferred embodiment, a positioning device is used, which has two positioning elements that are movable back and forth relative to each other between a first state and a second state, the positioning elements being designed to:

[0033] - In this first state, the movement of the end sections of the two winding elements to be contacted is restricted at least in a predetermined direction, while simultaneously achieving a certain distance between the end sections of the winding elements to be contacted; and

[0034] - In this second state, the end sections of the winding elements to be contacted are pressed together to enable welding.

[0035] The positioning device is at least partially in the first state in step B) and at least partially in the second state in step C). This positioning device makes it possible, on the one hand, to remove the area between the end segments of the winding element, and on the other hand, to make welding possible.

[0036] According to a preferred embodiment, the positioning device is not removed from the end sections of the first and second winding elements between steps B) and C). In other words, the positioning device remains on the end sections of the winding elements between steps B) and C). Therefore, preferably, the positioning device can be placed in the second state immediately after step B) and can be soldered. This reduces the risk of contamination when the positioning device is moved again.

[0037] According to a preferred embodiment, the first laser assembly is moved at least partially during step B) to direct the laser beam to different incident positions, wherein the movement is at least partially linear. This facilitates stripping at different locations.

[0038] According to a preferred embodiment, the laser assembly has a mirror that is movable in a controllable manner so as to enable controllable deflection of the laser beam.

[0039] According to a preferred embodiment, the first winding element end section and the second winding element end section are at least temporarily spaced apart from each other in step B). This enables stripping to be performed in the area between the winding element sections. The outer portion of the winding element section after welding can be stripped either with the winding element end sections spaced apart (first state) or with the winding element end sections pressed together (second state of the positioning device). Attached Figure Description

[0040] Further details and advantageous improvements of the invention derive from the embodiments described below and shown in the accompanying drawings, as well as from the dependent claims, which should not be construed as limiting the invention in any way. It goes without saying that the features mentioned above, and those still described below, can be used not only in the corresponding combinations given, but also in other combinations or alone, without departing from the scope of the invention. In the drawings:

[0041] Figure 1 A top view of a winding element with conductors is shown.

[0042] Figure 2 Showing has Figure 1 The cross-section of the stator assembly of the winding elements.

[0043] Figure 3 Show Figure 1 The cross-section of the conductor,

[0044] Figure 4 Shown after the first manufacturing step Figure 2 Spatial diagram of the stator assembly.

[0045] Figure 5 Shown after the second manufacturing step Figure 4 Spatial diagram of the stator assembly.

[0046] Figure 6 Shown after the third manufacturing step Figure 4 Spatial diagram of the stator assembly.

[0047] Figure 7 A workstation with a positioning device in a first state and two spaced-apart winding element end sections is schematically illustrated.

[0048] Figure 8 The schematic illustration shows the stripping of the end section of the winding element disposed in the positioning device.

[0049] Figure 9 The schematic diagram illustrates how the positioning device in the second state pre-tightens the end sections of the winding elements together and achieves contact through welding.

[0050] Figure 10 The schematic diagram illustrates the contacted winding element end section and the positioning device.

[0051] Figure 11 The schematic diagram illustrates the contacted winding element end section after the positioning device has been removed.

[0052] Figure 12 A top view showing another embodiment of the positioning device with clamping elements, and

[0053] Figure 13 Two laser components are shown schematically. Detailed Implementation

[0054] In the following text, parts that are identical or have the same function are given the same reference numerals and are generally described only once. This description is conceived to be consistent throughout the arrangement of the drawings to avoid unnecessary repetition.

[0055] When relative concepts such as left, right, up, and down that depend on the orientation of the accompanying drawings are used below, the concepts are referred to with respect to the corresponding drawings.

[0056] Figure 1 A winding element 40 is shown, which can be used to manufacture a stator assembly (see [link]). Figure 4 The winding element 40 has a conductor 81, which can be designed as a single wire conductor (e.g., a flat wire conductor) or as a stranded wire conductor. The winding element 40 is configured to have a first leg 47, a second leg 48, a connecting section 43, a first winding element end section 41 having a first winding element end 141, and a second winding element end section 42 having a second winding element end 142. The first winding element end section 41 is connected to the first leg 47, and the second winding element end section 42 is connected to the second leg 48. The connecting section 43 connects the first leg 47 and the second leg 48.

[0057] This type of winding element 40 is also known as a hairpin.

[0058] Figure 2 A schematic cross-section through stator assembly 20 is shown. Stator assembly 20 has a stator core 22, which is designed, for example, as a laminated group. Winding elements 40 along... Figure 1 The stator core 22 is cut along section II-II. The stator core 22 has slots 25 through which conductors 81 extend. In one embodiment, five conductors 81 extend through the slots 25, but the number can vary depending on the size of the stator assembly 20 and the desired power.

[0059] An insulating paper 71 is preferably provided around the conductor 81 to reduce the risk of short circuit to the stator core 22. Alternatively or additionally, it can be impregnated with an insulating material, such as plastic.

[0060] In this embodiment, conductor 81 has a basic rectangular shape, at least in sections. This facilitates achieving a high fill of the stator slot 25. However, the basic shape can also be, for example, circular or generally square.

[0061] Figure 3Conductor 81 is shown in cross-section. An insulating layer 82, such as varnish or wire varnish, is provided on the outer surface of conductor 81. This prevents conductive connections between conductors 81 or to the stator core 22. Insulation between conductors 81 is not absolutely necessary due to the potential difference, as the individual wires 81 of the winding element 40 are interconnected with the same winding interface in many cases at the end sections 41, 42 of the winding element. In higher frequency applications, insulation can increase the outer surface area of ​​conductor 81, which is particularly relevant to current flow due to the skin effect. Alternatively, the insulating layer 82 may be provided only on a portion of conductor 81.

[0062] Figure 4 A stator assembly 20 having a stator core 22 and a winding assembly 30 is shown. The stator core 22 has slots 25 and defines a stator axis 12, also referred to as a longitudinal axis 12, a first axial side 23, and a second axial side 24 opposite to the first axial side 23. A winding element 40 is pushed into the lamination group 22 from the second axial side 24, such that a first winding element end section 41 and a second winding element end section 42 are respectively arranged on the first axial side 23. A connecting section 43 is arranged on the second axial side 24 and forms a winding head (also referred to as a winding head) 32 therein, i.e., the area where the axial extension of the winding assembly 30 extends beyond the lamination group 22. Legs 47 and 48 are respectively arranged at least partially in their assigned slots 25.

[0063] After the winding element 40 is pushed in, additional steps must be performed to form a properly interconnected winding assembly 30 and to set up the winding interface.

[0064] Figure 5 The schematic diagram illustrates a working step known as extension, in which the end sections 41A, 41B, 41C, 41D, and 41E of the five winding elements of slot 25 (as shown on the left) are further radially spaced side-by-side, at least partially, from each other after the winding element 40 is pushed in. Lines 26 and 27 respectively show the distance... Figure 4 The stator axes 12 have equal radial distances, with the radial distance of line 26 being less than that of line 27. This is the unfolded diagram, but in reality, lines 26 and 27 are circular.

[0065] As can be seen on the right, the end sections 41B, 41C, 41D, and 41E of the winding elements have been radially offset outward due to deformation. This step facilitates providing space for the interconnection of the end sections 41A, 41B, 41C, 41D, and 41E of the winding elements. It is also possible to offset them at least partially radially inward, or partially inward and partially outward.

[0066] Figure 6The diagram schematically illustrates a working step known as torsion, in which the end sections 41, 42 of the winding elements are at least partially offset in the circumferential direction to enable interconnection with other end sections 41, 42 of the winding elements. Lines 26, 27 again show the distance... Figure 4 The constant distance between the stator axes 12, wherein the radial distance of line 26 is less than the radial distance of line 27. Figure 5 Similarly, this is the unfolded diagram, but in reality, lines 26 and 27 are circular.

[0067] The left side shows the situation according to Figure 5 The winding element end sections 41A, 41B, 41C, 41D, and 41E are shown in their extended state. The right side shows the twisted state, with winding element end sections 41B, 41C, 41D, and 41E offset to the left in the circumferential direction. For winding element end section 41C, the initial position is indicated by a dashed line, while the twisted position is indicated by a solid line. Alternatively or additionally, the winding element end sections may be (partially) offset to the right or may remain partially unchanged in the circumferential direction.

[0068] For example, winding element end sections 42A and 41B are arranged adjacent to each other, and thus the two winding element end sections 42A and 41B can be interconnected, for example, by welding. In this way, winding elements 40 can be interconnected into winding assemblies 30. In this embodiment, the winding element end sections 41B and 42A to be connected are arranged radially relative to each other, but they can also be arranged side by side in the circumferential direction, or inclined relative to the circumferential direction and relative to the radial direction.

[0069] During torsion, for example by using a robot, the region of the winding element protruding from the stator slot 25 is bent. The orientation during torsion is preferably in the circumferential direction, but a deviated orientation is also possible.

[0070] Figure 7 A workstation 118 with a positioning device 120 is shown, which may also be referred to as a clamping device 120. In this embodiment, the positioning device 120 has a first positioning element 121 with a first notch 131 and a second positioning element 122 with a second notch 132.

[0071] The two winding element end sections 42A and 41B pass through two notches 131 and 132. The positioning device 120 is in a first state Z1, in which the two winding element end sections 42A and 41B can be spaced apart from each other. Therefore, in this embodiment, the two notches 131 and 132 overlap in a first region that allows for an intermediate space between the winding element end sections 42A and 41B. Here, either the winding element end sections 42A and 41B can be kept at a distance from each other due to their inherent elasticity, or they can be moved apart by the positioning device 120, for example by a third positioning element (not shown), which can move into the region between the winding element end sections 42A and 41B.

[0072] An insulating layer 82 is still provided on the end sections 42A and 41B of the winding element, which are also referred to as pins.

[0073] Figure 8 Preferred subsequent manufacturing steps are shown, wherein the insulation layer 82 on the winding element end sections 42A and 41B is at least partially removed in order to enable process-reliable welding of the winding element end sections 42A and 41B to each other.

[0074] The positioning device 120 remains in the first state Z1, and the winding element end sections 42A and 41B are spaced apart from each other. The winding element end sections 42A and 41B are preferably stripped using a laser. For this purpose, lasers 91A and 91B are provided in this embodiment. Laser 91A generates a laser beam 191A, and laser 91B generates a laser beam 191B.

[0075] Laser beams 191A and 191B preferably have wavelengths that are well absorbed by insulating layer 82 and cause insulating layer 82 to heat up and evaporate.

[0076] Preferably, a suction device 97 and / or a blower device 95 are provided to transport the particles 100 generated during evaporation away from the stator assembly 20. For this purpose, the suction device 97 and / or the blower device 95 generate a fluid flow 99 that at least partially carries away the particles 100. In this embodiment, the blower device 95 has a hose 96, and the suction device 97 has a suction opening 98.

[0077] In this embodiment, laser beams 191A and 191B are preferably incident obliquely from above onto the winding element end sections 42A and 41B, with the end sections 42A and 41B pointing upwards. A vertical angle of incidence on the insulating layer 82 at the surface of the winding element end sections 42A and 41B enables maximum absorption. However, since there may be a large number of winding element end sections 41 and 42 in the twisted stator assembly 20, and even in the case of two winding element end sections 42A and 41B, at least one side is correspondingly blocked by other winding element end sections, it is not possible, or at least not in all cases, for the laser beam to be perpendicular to the surface to be irradiated. This differs from the case where the conductor 81 is stripped before being formed into the winding element 40, at which time the straight conductor 81 can be irradiated perpendicularly.

[0078] The upward tilting orientation of the laser beams can depend on the specific pattern of the stripped areas of the winding element end sections 42A and 41B caused by the movement of lasers 91A and 91B, where the trajectories of laser beams 191A and 191B do not extend transversely to the extending direction of the winding element end sections 42A and 41B, but rather extend obliquely to the extending direction. This is the case, for example, when the incident angle of lasers 91A and 91B is tilted and they move in a straight line (which does not extend parallel to one of the sides of the winding element end sections 42A and 41B). Using each of lasers 91A and 91B, two sides of the winding element end sections 42A and 41B can be processed from a predetermined laser position. When lasers 91A and 91B are arranged on opposite sides of the winding element end sections 42A and 41B, all four sides of the square cross-section can be stripped.

[0079] The directions of laser beams 191A and 191B can be changed either by moving all lasers 91A and 91B, or by influencing laser beams 191A and 191B through movable mirrors (see [link]). Figure 13 And change.

[0080] As schematically shown, the first laser assembly 91A or 91B preferably moves at least partially during stripping to direct the laser beams 191A, 191B toward different incident positions 183A, 183B, wherein, more preferably, the movement is at least partially linear. However, the movement may also be curved or can be performed freely.

[0081] Figure 9The positioning device 120 is shown in a second state Z2, in which the end sections 42A and 41B of the winding elements are close to each other and preferably pressed against each other. This can be achieved by displacing the positioning elements 121 and 122 relative to each other, wherein either both positioning elements 121 and 122 are displaced or only one of them is displaced.

[0082] Preferably, the winding element end sections 42A and 41B are pressed together, and the positioning device 120 may also be referred to as a clamping device. The stripped areas of the winding element end sections 42A and 41B are pressed together and can be welded together by the laser 92. The laser 92 preferably emits a laser beam 192 with a wavelength very well suited to be absorbed by the material of the conductor 81, thereby achieving heating of the winding element end sections 42A and 41B and achieving the welded connection. Either the laser 92 is different from the first laser 91, or the same laser may be used.

[0083] The motion of positioning elements 121 and 122 between the first state Z1 and the second state Z2 can be characterized as follows:

[0084] In the first state Z1, the positioning elements 121 and 122 restrict the movement of the two winding element end sections 41B and 42A to be contacted, at least in a predetermined direction, and simultaneously enable the positioning elements to maintain a certain distance between the winding element end sections 41B and 42A to be contacted. Therefore, it is not necessary to firmly hold the winding element end sections 41B and 42A, but their movement should be restricted at least to a degree that allows for precise positioning sufficient for stripping.

[0085] - In the second state Z2, the positioning elements 121 and 122 press the end sections 41B and 42A of the winding elements to be contacted against each other so that welding can be achieved.

[0086] The positioning device 120 is preferably used in the peeling ( Figure 8 ) and welding ( Figure 9 The winding elements are not removed from the end sections 41B and 42A between them to shorten the process time.

[0087] Figure 10 The illustration shows Figure 9 The result of the welding process. Through Figure 9 The energy input achieved by the laser beam 192 has caused the end sections 42A and 41B of the winding elements to be heated and melted, and subsequently joined together, with the welded joint 44 forming an electrical contact between the end sections 42A and 41B. In practice, the welded joint 44 can also have rounded edges, provided that the entire free end of the end sections 42A and 41B of the winding elements is heated accordingly.

[0088] Figures 7 to 10 The method steps are preferably all implemented in workstation 118, so that stator assembly 20 does not need to be transported to other workstations during this period.

[0089] Figure 11 The completed welded connection 44 of the winding element end sections 42A and 41B is shown after the positioning device 120 is removed. For this purpose, it is preferable to return the positioning device 120 to the first state Z1 and then move the positioning device upward or away from the stator core 22 relative to the stator core.

[0090] Figure 12 A schematic top view illustrates another embodiment of the two winding element end sections 42A, 41B and the positioning device 120. The stator core 22 is not shown. The positioning device 120 has two positioning elements 121, 122, wherein positioning element 121 contacts three sides of the winding element end section 42A, and positioning element 123 contacts three sides of the winding element end section 41B. Positioning elements 121, 122 are movable relative to each other. In the first state Z1 shown, the winding element end sections 41B, 42A are spaced apart from each other, and the winding element end sections 41B, 42A can make contact by relative movement toward each other.

[0091] Positioning elements 121 and 122 may have grippers for holding the end sections 41B and 42A of the winding elements, or the positioning elements may simply limit upward, downward, and lateral outward movement in the figures by means of their stop function. Positioning elements 121 and 122 may also contact or form stops only on both sides of the respective end sections 41B or 42A of the winding elements.

[0092] During stripping, the laser beam 191B incident on the end section 42A of the winding element preferably traverses at least one pre-defined first space 143, which extends by displacing the surface of the winding element end 141 of the end section 41B away from the stator core 22 in the direction of the stator axis 12. Figuratively, the laser beam 191B extends through the adjacent end section 41B of the winding element. In the same manner, the laser beam 191A preferably extends through the adjacent end section 42A of the winding element when stripping the end section 41B of the winding element. Although the end regions 41B and 42A are spatially close, this geometry still allows for good and large-area stripping.

[0093] Laser beams 191A and 191B are preferably generated simultaneously, at least temporarily, during stripping.

[0094] Figure 13A stator assembly 20 having a stator core 22 and an enlarged view of the winding element end sections 41 is schematically illustrated. Other winding element end sections 41, 42 are not shown. Two laser assemblies 91A and 91B are schematically indicated.

[0095] During stripping, laser beam 191A is incident at an incident angle 181A onto the assigned incident position 183A of the winding element end section 41. The incident angle 181A is the angle between the laser beam 191A at incident position 183A and the extension direction 182 or 182A of the winding element end section 41 toward the winding element end 141. The incident angle 181A is preferably greater than 0° and less than 90°, and preferably, at least two laser beams 191A and 191B are at least temporarily and simultaneously pointed onto the assigned incident positions 183A and 183B. Laser beam 191B is incident at incident position 183B in the same manner at an incident angle 181B, and its extension direction at that position is denoted by 182B.

[0096] The incident angles 181A and 181B are preferably at least temporarily between 30° and 60°, and more preferably between 40° and 50°.

[0097] During stripping, laser beams 191A and 191B incident on the winding element end section 41 preferably extend in a straight line from a first position 91A2 or 91B2 of the laser assembly 91A or 91B to the winding element end section 41, the first position 91A2 or 91B2 being arranged on the side 196 of the winding element end section 41 facing away from the stator core 22. A side 195 facing the stator core 22 and a boundary line are drawn. In other words, the first positions 91A2 and 91B2 are located on the first axial side 23 of the stator core 22, and the axial distance of the first position from the stator core 22 is greater than the axial distance of the winding element end 141 of the winding element end section 41 from the stator core. In this embodiment, the first position 91A2 is a reflector illuminated by the base unit 91A1. The reflector 91A2 preferably enables controllable deflection of the laser beam 191A. The first position 91B2 is the exit of the laser assembly 91B.

[0098] Of course, a wide variety of variations and modifications can be implemented within the scope of this invention.

[0099] In addition to interconnecting the end sections 41 and 42 of the winding elements, the end sections 41 and 42 of the winding elements can also be partially used for connection to interconnection devices (not shown). For this purpose, the end sections 41 and 42 of the winding elements involved are preferably stripped in the workstation 118 and subsequently connected to the conductors (not shown) of the interconnection device. A winding interface (not shown) is preferably provided on the stator assembly 20 for connection to the final stage.

[0100] In an embodiment, the positioning device 120 is correspondingly configured for two winding element end sections 41, 42. The positioning device may also be configured for more than two winding element end sections 41, 42, or additional positioning devices 120 may be provided. When the winding element end sections 41, 42 to be connected are arranged relative to each other in the circumferential direction, the positioning device 120 may have two positioning elements 121, 122, which are disc-shaped with open portions and can be twisted relative to each other, so that they can be connected as shown in the figure. Figure 7 The first state Z1 and the second state Z2 are realized in the positioning device 120 as described above.

Claims

1. A method for manufacturing a stator assembly (20), the stator assembly (20) having a stator core (22) and a winding assembly (30). The stator core (22) has stator slots (25) and defines a stator axis (12). The winding assembly (30) has winding elements (40), each winding element (40) having a conductor (81) with an insulating layer (82) and being configured such that the winding element has two interconnected winding element legs (47, 48). Each winding element leg has two winding element end sections (41B, 42A) assigned to the winding element leg (47, 48), and each winding element end section has a winding element end (141; 142). The method comprises the following steps: A) The winding element (40) is positioned relative to the stator core (22) such that the winding element legs (47, 48) extend through one of the stator slots (25) and the winding element end sections (41B, 42A) extend out on the first axial side (23) of the stator core (22). B) After step A), the insulating layer (82) is removed at least partially by the first laser assembly (91A, 91B) on the first winding element end section (41B) of the first winding element (40) and the second winding element end section (42A) of the second winding element (40). C) The first winding element end section (41B) and the second winding element end section (42A) are pressed together and welded together by the second laser assembly (92); in - The end section (41B) of the first winding element, or - The end section (42A) of the second winding element, or - The end section (41B) of the first winding element and the end section (42A) of the second winding element In step A), after the winding elements (40) are pushed into the stator core (22), they are deformed in such a way that they are offset at least in the circumferential direction relative to the exit position away from the stator core (22).

2. The method of claim 1, wherein steps B) and C) are performed for additional winding element end sections (41B, 42A) to be welded together.

3. The method according to claim 1 or 2, wherein during step B), at least one device (95, 97) for discharging the particles (100) generated during the removal of the insulating layer (82) is at least temporarily activated, said at least one device being derived from a first group of devices consisting of: - Suction device (97), and - Blower unit (95).

4. The method according to claim 1 or 2, wherein - The end section (41B) of the first winding element, or - The end section (42A) of the second winding element, or - The end section (41B) of the first winding element and the end section (42A) of the second winding element In step A), after the winding elements (40) are pushed into the stator core (22), they are deformed in such a way that they also have a changed radial distance from the stator axis (12) compared to the radial distance from the exit position of the stator core (22).

5. The method according to claim 1 or 2, wherein step B) and step C) are performed in a pre-given workstation (118).

6. The method according to claim 1 or 2, wherein in step B), at least one laser beam (191A; 191B) is directed at an incident angle (181A; 181B) at an assigned incident position (183A, 183B) of the first winding element end section (41B) or the second winding element end section (42A), the incident angle (181A, 181B) being an angle between the laser beam (191A; 191B) at the incident position (183A, 183B) and the extension direction (182; 182A; 182B) of the winding element end section (41B, 42A) toward the winding element end (141; 142), the incident angle (181A; 181B) being greater than 0° and less than 90°.

7. The method of claim 6, wherein at least two laser beams are at least temporarily simultaneously pointed to the assigned incident positions (183A, 183B).

8. The method of claim 6, wherein the incident angle (181A; 181B) is between 30° and 60°.

9. The method of claim 8, wherein the incident angle (181A; 181B) is between 40° and 50°.

10. The method according to claim 1 or 2, wherein in step B), the laser beams (191A; 191B) incident on the respective winding element end sections (41B; 42A) originate from a first position (91A2) of the first laser assembly (91A; 91B); 91B2) extends in a straight line to the end section (41B; 42A) of the winding element, the first position (91A2; 91B2) is arranged on the side (196) away from the stator core (22) of the winding element end (141) in the winding element end section (41B; 42A).

11. The method according to claim 1 or 2, wherein in step B), the laser beam (191A; 191B) incident on the second winding element end section (42A) passes through at least one predetermined first space (143), the predetermined first space (143) being obtained by displacing the surface of the winding element end (141) of the first winding element end section (41B) away from the stator core (22) in the direction of the stator axis (12).

12. The method according to claim 1 or 2, wherein in step B), at least two laser beams (191A, 192B) are incident on the stator assembly (20) at least temporarily and simultaneously.

13. The method according to claim 1 or 2, wherein a positioning device (120) is used, the positioning device (120) having two positioning elements (121, 122) movable relative to each other between a first state (Z1) and a second state (Z2), the positioning elements (121, 122) being designed for: - In the first state (Z1), the movement of the two winding element end sections (41B; 42A) to be contacted is restricted at least in a predetermined direction, while simultaneously achieving a certain distance between the winding element end sections (41B; 42A) to be contacted; and - In the second state (Z2), the end sections (41B; 42A) of the winding elements to be contacted are pressed together to enable welding. The positioning device is at least partially in the first state (Z1) in step B) and at least partially in the second state (Z2) in step C).

14. The method of claim 13, wherein the positioning device is not removed from the first winding element end section (41B) and the second winding element end section (42A) between steps B) and C).

15. The method of claim 1 or 2, wherein the first laser assembly (91A, 91B) is at least partially moved during step B) to direct the laser beam (191A; 191B) to different incident positions (183A; 183B), wherein the movement is at least partially linear.

16. The method of claim 15, wherein the first laser assembly (91A, 91B) has a mirror that is movable in a controllable manner to enable controllable deflection of the laser beam (191A; 191B).

17. The method according to claim 1 or 2, wherein the first winding element end section (41B) and the second winding element end section (42A) are at least temporarily spaced apart from each other in step B).

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