Method and device for producing at least one wire blank which is bent into a stent shape
By straightening and moving the wire during the drawing process and forming a curved transition section on the offset plane, combined with an annular storage device and clamping device, the problems of large space requirements and inconvenient handling of wire blanks bent into bracket shapes are solved, achieving efficient production and easy-to-handle wire blanks.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- SCHAEFFLER TECHNOLOGIES AG & CO KG
- Filing Date
- 2022-01-25
- Publication Date
- 2026-07-14
AI Technical Summary
Existing technologies make it difficult to efficiently produce wire blanks bent into bracket shapes, resulting in large space requirements and inconvenient handling, especially in the low production efficiency of coil windings in high-power electric motors.
By straightening the wire during the pulling process and moving it on the offset plane to form a curved transition section, and then bending it around the bending axis while keeping it coiled during the movement and bending, a space-saving bending into a bracket shape is achieved using a ring-shaped storage device and clamping device.
It reduces the space required for wire processing, improves production efficiency, ensures the continuity and ease of handling of wire blanks, and is suitable for the production of coil windings for high-power electric motors.
Smart Images
Figure CN116897497B_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a method and apparatus for producing at least one wire blank bent into a support shape. Background Technology
[0002] For example, wire blanks bent into a support shape are needed to produce rotor or stator windings for electric motors. The wire blanks bent into a support shape are wound into winding pads with winding heads and wire webs. The winding pads produced in this way are drawn into the rotor or stator of the electric motor. At this point, the wire webs are located in rotor or stator recesses, and the winding heads form the transition of individual winding wires from one rotor or stator recess to the next.
[0003] For manufacturing purposes, it is desirable to process wire blanks into a single piece. Therefore, it is necessary to ensure the continuity of individual winding wires and avoid welded joints on parts. High-power electric motors, in particular, have a large number of coil windings, necessitating the provision of long wires and the processing into continuous coil windings to minimize line losses and keep the required installation space to a minimum. By providing wire blanks bent into a support shape, the required wire length for producing coil windings can be halved, as the corresponding wire blanks can be processed into support-shaped coil windings with two wire ends. Simultaneously, the support shape provides a precursor for producing the first winding head of the coil winding. However, considerable space is required to produce wire bent into a support shape, as the entire length of the wire must first be processed to produce the support-shaped wire through one or more bending operations.
[0004] Therefore, the object of the present invention is to provide a method and apparatus for producing wires bent into a support shape that can be performed and operated in a space-saving manner. Summary of the Invention
[0005] This objective is achieved through the following:
[0006] A method for producing at least one wire blank bent into a support shape, the wire blank comprising a first wire segment, a second wire segment parallel to the first wire segment, and a bent transition segment located between the first wire segment and the second wire segment, the method comprising the following steps:
[0007] - Supply wire from the wire supply unit;
[0008] - The wire is pulled at least over the length of the transition section and the second section, wherein the wire is straightened during the pulling process;
[0009] - The second wire section is moved parallel to the pull-out direction on the offset plane, thereby forming a transition section between two bending points located between the first wire section and the second wire section;
[0010] - The second wire section is bent around the bending axis, wherein the bending process is carried out in the transition section and the bending axis is located on the offset plane and perpendicular to the pulling direction;
[0011] According to the present invention, the second wire segment is wound around an axis parallel to the bending axis during the pulling process, and remains wound during the moving step and the bending step.
[0012] The advantage of the method according to the invention is that winding the second wire segment requires less space compared to winding the wire segment in a straight line. This relates, on the one hand, to the space required for the wire before performing the moving step and the bending step. In this case, the wound wire saves a considerable amount of space required for unwinding and pulling the wire length. Furthermore, the wound second wire segment is easier to handle in the bending step compared to the unwound second wire segment. This also applies to the handling and space requirements during the bending step. The order of the method steps is not determined by the order reproduced above. For example, it is also conceivable to perform the moving step after the bending step to produce a wire blank bent into a support shape.
[0013] According to another embodiment of the method, a wire including a first wire segment is drawn from a wire feeder in a pull-out direction. As the first wire segment is drawn from the wire feeder in the pull-out direction, it can be straightened during the drawing process. In the pull-out direction, the first wire segment is then straightened between a wire reservoir and a transition segment. To produce a wire blank bent into a support shape according to this method, the first wire segment thus provided needs to be bent into approximately half the length of the support-shaped wire blank, wherein the required length of the transition segment must still be taken into account. This also advantageously contributes to achieving this objective because the space required by the method is generated by the length of the first wire segment, the transition segment, and the space occupied by the coiled second wire segment.
[0014] According to a further improvement to the method, wire cutting is provided after the required length of wire for the wire blank is drawn. For this purpose, a cutting device can be provided between the wire supplier and the first wire segment. In this way, the wire supplier can hold wire for subsequent moving and bending operations to produce bent wire blanks. It is also conceivable that, during the transition period between the moving and bending steps, wire segments (multiple wire segments) for at least one additional wire are drawn from the wire supplier.
[0015] The method can be further improved by unwinding and straightening the second wire segment after the moving and bending steps, such that the second wire segment extends parallel to the first wire segment in its length. This advantageously facilitates the production of straightened wire blanks bent into a support shape, whose space requirements during storage and further processing—e.g., the production of coil windings—do not exceed the space requirements during production. Furthermore, another advantage is that the bent-support-shaped wire segment with the second wire segment extending parallel to the first wire segment in its length is relatively easy to handle and store as a straight material. According to another embodiment, after unwinding, the second wire segment can be re-straightened perpendicular to the axis from which the second wire segment was wound. This facilitates the release of any stress that may be present in the wire after unwinding.
[0016] To improve the efficiency of this method, it can be performed on two or more wires that are guided in parallel to each other. In particular, the method can be performed on six parallel wires or multiple sets of three parallel wires.
[0017] According to another aspect of the invention, an apparatus is provided for producing at least one wire blank bent into a support shape, the apparatus comprising:
[0018] - A wire supplier for supplying at least one wire in the pull-out direction.
[0019] - A first straightening device, arranged downstream of the wire supplier along the pulling direction, is used to straighten the supplied wire.
[0020] - A first wire storage device, wherein a first wire segment is received.
[0021] -A moving and bending device, in which the transition section of the wire is located.
[0022] - A second wire storage device, wherein the second wire storage device receives a second wire segment, wherein...
[0023] The second wire storage device is a ring-shaped storage device, in which the second wire section can be wound.
[0024] Providing a ring-shaped reservoir results in a reduction of the space required after the moving and bending device. A second wire reservoir is wound within the ring-shaped reservoir. The ring-shaped reservoir can be designed such that the second wire segment is inserted into the ring-shaped reservoir in a single winding layer, or in a spiral shape in several layers. It is also conceivable that the second wire segment is spirally inserted into the ring-shaped reservoir and thus has an extension within the ring-shaped reservoir perpendicular to the wire's pull-out direction. In another structurally advantageous embodiment of the invention, the wire can be supplied from a reel constituting a wire feeder.
[0025] According to another embodiment of the device, the moving and bending device is configured with a first clamping member for fixing a first wire segment and a second clamping member for fixing a second wire segment. The second clamping member is arranged on a support leg, wherein the support leg is pivotable about a pivot axis perpendicular to the pull-out direction and located between the clamping members, and the support leg is movable parallel to the pivot axis. A second wire reservoir is pivotable together with the support leg about the pivot axis. In this way, bending of the wire in the transition section is advantageously achieved without fixing the wire again or at another point. The fact that the support leg can pivot together with the moving and bending device also reduces the installation space required for the device. Furthermore, the first support leg can be movable during the moving step or move along the direction of the second support leg to prevent the wire from elongating in the transition section.
[0026] A further improvement to the device involves equipping the moving and bending mechanism with bending blades that can move perpendicular to the pull-out direction, and whose legs can pivot about these blades. The bending blades advantageously bend the wire at the bending edge, thus creating a defined bend and maintaining a defined length for the corresponding legs of the bent wire blank. In this way, bending can be ensured to be performed precisely and repeatably at the correct point relative to the length of the wire. Furthermore, it can be ensured that the legs of the bent wire blank have the same length, thus avoiding wire waste.
[0027] According to another embodiment of the device, a second wire reservoir is enabled to move linearly against the pull-out direction for removing a second wire segment stored in the second wire reservoir. A second straightening device is provided for the second wire reservoir to straighten the second wire segment removed from the second wire reservoir. In this manner, the second wire segment can be removed from the second wire reservoir in which it is stored, and is simultaneously bent and straightened such that the second wire segment of the wire in the bent-in-support wire blank is parallel to the first wire segment of the bent-in-support wire blank. The pulling or linear movement of the second wire reservoir occurs substantially along the length of the first wire segment, so that no additional space is required relative to the length of the device. Therefore, a further improvement of the invention results in the second wire reservoir being transferable to a slider capable of linear movement parallel to the pull-out direction, and the second straightening device being arranged on the linearly movable slider. Attached Figure Description
[0028] Other features, details, and advantages of the invention will become apparent from the wording of the claims and the following description of exemplary embodiments based on the accompanying drawings.
[0029] In the attached diagram:
[0030] Figure 1A , Figure 1B The diagram shows a configuration of multiple wires extending parallel to each other in the device after being pulled from the wire supplier, in side view and plan view.
[0031] Figure 2 A schematic diagram of the moving and bending device after the moving step is shown in plan view;
[0032] Figure 3A , Figure 3B A schematic diagram of the movement and bending device after the bending step is shown in side view and plan view; and
[0033] Figure 4A , Figure 4B The diagram shows a schematic of the apparatus following the production of multiple support-shaped wire blanks that extend parallel to each other, presented in side and plan views. Detailed Implementation
[0034] Figure 1A A side view shows a schematic diagram of the configuration of multiple wires 10a extending parallel to each other in the device 1 after being pulled from the wire supplier 2. It can be seen that the wires 10 are pulled from the wire supplier 2 and straightened by the first straightening device 3. For example, the wire supplier 2 can be represented by a spool. The first straightening device 3 straightens the wires 10 so that the wires extend in a straight line along the pull-out direction A. The wires 10 can be pulled by means of a feeding unit 70, which can be arranged downstream of the first straightening device 3 along the pull-out direction A. The straightened wires 10 are conveyed by the feeding unit 70 through the first wire storage 20 and the moving and bending device 40 to the second wire storage 30, in which the second wire segment 12 exists in a wound state. When the second wire storage 30 is full, the wire feeding or pulling of the wires 10 from the wire supplier 2 is then interrupted. The transition section 13 is located in the moving and bending device 40 and between the wire supply 2 and the moving and bending device 40. The first wire section 11 is located in the first wire storage 20, which in this embodiment is configured as a linear storage.
[0035] Figure 1B A plan view shows a schematic diagram of the configuration of multiple parallel wires 10a extending parallel to each other in the device 1 after being drawn from the wire supplier 2. The multiple parallel wires 10a are sequentially fed to the first wire storage 20, the moving and bending device 40, and the second wire storage 30. After a corresponding wire 10 is drawn to the required wire length from the wire blank 100, the corresponding wire 10 is cut between the wire supplier 2 and the first wire storage 20 by means of scissors 60, and another wire 10 is drawn into the device 1 until multiple parallel wires 10a, in this embodiment 4x3 wires, are located in the device 1.
[0036] The wires 10, having corresponding wire segments 11 and 12, are inserted into the first wire storage 20 and the second wire storage 30 at approximately the same length.
[0037] Figure 2 A schematic diagram of the moving and bending device 40 after the moving step is shown in plan view. It can be seen that the moving and bending device 40 has a first clamping member 41 for clamping the first wire segment 11 and a second clamping member 42 for clamping the second wire segment 12. The first wire segment 11 and the second wire segment 12 are offset from each other in a direction perpendicular to the pull-out direction A. At this point, the second wire segment 12 exists in a wound state in the second wire reservoir 30, which moves perpendicular to the pull-out direction A together with the clamping member 41 of the moving and bending device 40. In this way, a bending point 14 is formed in the transition segment 13 before or after the clamping members 41, 42. An inclined offset is formed in the corresponding wire 10a by the moving step. In this embodiment, the movement is perpendicular to the pull-out direction A with an offset amount equal to 1.5 times the distance between the parallel-pulled wires. The clamping member 41 of the moving and bending device 40, which moves perpendicular to the pulling direction A, can also move in the opposite direction of the pulling direction A at the same time to prevent the wire 10a from elongating due to the moving step.
[0038] Figure 3A A side view shows a schematic diagram of the moving and bending device 40 after the bending step. It can be seen that one leg 43 of the moving and bending device 40 has been folded 180° in the opposite pulling direction A, while the clamps 41 and 42 respectively secure the first wire segment 11 and the second wire segment 12. At this point, the second wire storage 30 pivots simultaneously with the leg 43 of the moving and bending device 40. The folding of the leg 43 of the moving and bending device 40 or the pivoting of the second wire storage 30 occurs about the pivot axis 44.
[0039] Figure 3B A schematic diagram of the moving and bending device 40 after the bending step is shown in plan view, wherein clamps 41, 42 are positioned one on top of the other. It can be seen that the wire blank 100 bent into a support shape forms a roof-shaped winding head 110.
[0040] Figure 4AA side view shows a schematic diagram of the apparatus 1 after the production of multiple support-shaped wire blanks 100 extending parallel to each other. A second wire reservoir 30 is transferred to a linearly movable slider 50, on which a second straightening device 51 is also arranged. By means of the linearly movable slider 50 moving the second wire reservoir 30 in the opposite direction of pull-out, a second wire segment 12 wound in the second wire reservoir 30 is pulled out of the second wire reservoir 30 and straightened by the second straightening device 51. The first wire segment 11 and the second wire segment 12 are thus parallel to each other. In another step, the clamps 41, 42 of the moving and bending device 40 are released, allowing the wire blanks (multiple wire blanks) 100 bent into support shapes to be removed from the apparatus 1. Figure 4B A schematic diagram of the apparatus 1 is shown in plan view after the production of multiple wire blanks 100 extending parallel to each other in the shape of a bracket and before the release of the clamps 41, 42.
[0041] All features and advantages arising from the claims, specification, and drawings, including construction details, spatial arrangements, and method steps, whether individually or in various combinations, may be necessary for the present invention. Therefore, the bending step can be performed before the moving step. Furthermore, the first wire segment can also be inserted into the space-saving annular reservoir while performing the moving and bending steps, and can be removed from the reservoir and straightened similarly to the second wire segment after the moving and bending steps.
[0042] List of reference numerals
[0043] 1 device
[0044] 2 Wire supply
[0045] 3 First straightening device
[0046] 10 wires
[0047] 10a Parallel Wire
[0048] 11 First Wire Section
[0049] 12 Second Wire Section
[0050] 13 Transition Section
[0051] 14. Bending point
[0052] 20 First wire storage device
[0053] 30 Second wire storage device
[0054] 40 Moving and bending device
[0055] 41 First clamping component
[0056] 42 Second clamping component
[0057] 43 legs
[0058] 44. Pivot axis, bending axis
[0059] 50 Slider
[0060] 51 Second Straightening Device
[0061] 60 scissors
[0062] 70 Delivery Unit
[0063] A. Pull out direction
[0064] 100 wire blanks
[0065] 110 Winding Head
Claims
1. A method for producing at least one wire blank (100) bent into a support shape, the wire blank comprising a first wire segment (11), a second wire segment (12) parallel to the first wire segment, and a bent transition segment (13) located between the first wire segment (11) and the second wire segment (12), the method comprising the following steps: - Supply wire (10) from wire supply (2); -The wire is pulled at least along the lengths of the transition section (13) and the second wire section (12), wherein, The wire (10) is straightened during the pulling process; - The second wire segment (12) is moved parallel to the pull-out direction (A) on the offset plane, thereby forming the transition segment (13) between two bending points (14) located between the first wire segment (11) and the second wire segment (12); - The second wire segment (12) is bent around the bending axis (44), wherein the bending process is carried out in the transition segment (13), and the bending axis (44) is located on the offset plane and perpendicular to the pull-out direction (A); Its features are, The second wire segment (12) is wound around an axis parallel to the bending axis (44) during the pulling process and remains wound during the moving and bending steps.
2. The method according to claim 1, comprising the following steps: - The wire (10), including the first wire section (11), is pulled from the wire supplier (2) along the pull-out direction (A).
3. The method according to claim 2, comprising the following steps: - Cut the wire (10) after it has been drawn out to the required length of the wire blank (100).
4. The method according to any one of the preceding claims, wherein, After the moving step and the bending step, the wire (10) of the second wire segment (12) is unwound and straightened, such that the second wire segment (12) extends parallel to the first wire segment (11) along the length of the second wire segment.
5. The method according to any one of the preceding claims, wherein, The method is performed for two or more wires (10a) that are guided in parallel to each other.
6. An apparatus (1) for producing at least one wire blank (100) bent into a support shape, the apparatus comprising: - Wire supplier (2), the wire supplier being used to supply at least one wire (10) in the pull-out direction (A), - A first straightening device (3), arranged downstream of the wire supplier (2) along the pulling direction (A), is used to straighten the supplied wire (10). - First wire storage (20), the first wire storage receiving a first wire segment (11), - A moving and bending device (40), wherein the transition section (13) of the wire (10) is located in the moving and bending device. - A second wire storage unit (30), wherein the second wire storage unit receives a second wire segment (12), wherein, The second wire storage unit (30) is a ring-shaped storage unit, and the second wire segment (12) can be wound in the ring-shaped storage unit.
7. The apparatus (1) according to claim 6, characterized in that, The moving and bending device (40) has a first clamp (41) for fixing the first wire segment (11) and a second clamp (42) for fixing the second wire segment (12), wherein the second clamp (42) is arranged on a leg (43) and the leg (43) is pivotable about a pivot axis perpendicular to the pull-out direction (A) and located between the clamps (41, 42), and the leg is movable parallel to the pivot axis, wherein the second wire reservoir (30) is pivotable together with the leg (43) about the pivot axis.
8. The apparatus (1) according to claim 7, characterized in that, The moving and bending device (40) has a bending blade that is movable perpendicular to the pull-out direction (A) and the leg (43) of the moving and bending device (40) is pivotable about the bending blade.
9. The apparatus (1) according to any one of claims 6 to 8, characterized in that, The second wire storage (30) is capable of linear movement against the pull-out direction (A) for removing the second wire segment (12) stored in the second wire storage, wherein a second straightening device (51) is provided for the second wire storage (30) for straightening the second wire segment (12) removed from the second wire storage (30).
10. The apparatus according to claim 9, characterized in that, The second wire storage (30) can be transferred to the slider (50), which is capable of linear movement parallel to the pull-out direction (A), and the second straightening device (51) is arranged on the linearly movable slider (50).