Method and device for producing winding pad for stator or rotor of electric motor

Abstract

The invention relates to a method for producing a winding pad (5) for a stator or a rotor of an electric motor, in which two conductor strands (1) are provided and are each fed along the x-direction of the Cartesian coordinate system to receiving devices (2), one conductor strand (1) being each received by each receiving device (2). Subsequently, the oppositely arranged winding ends (11) are formed by means of a forming tool (4), and the cross-layer sections (3) are punched in the winding ends (11) in the opposite direction in the y direction. According to the invention, the connecting strand (12) extending in the z-direction is shaped by means of a movement of the receiving device (2) along a bending path, and a lifting movement of the receiving device (2) is carried out, in which the conductor strand (1) is transferred to a conveying device (6) and is transported in the x-direction with a conveying cycle. The above steps are repeated until a winding pad (5) having a defined number of windings is produced, each winding being formed from two conductor strands (1) and each comprising two winding ends (11) and four connecting strips (12). The invention also relates to a device for producing a winding pad (5) for a stator or rotor of an electric motor.

Description

Technical Field

[0001] The present invention relates to a method and an apparatus for manufacturing winding pads for a stator or rotor of an electric motor. Background Art

[0002] The importance of electric motors has increased significantly due to the energy transition and transport transformation, as the demand for drives that do not require fossil fuels continues to increase. Conventional electric motors consist of a stator and a rotor. When current flows through the conductor wound around the rotor, north and south poles are formed and the rotor begins to rotate due to the external magnetic field of the stator. The winding type of the stator and rotor plays an important role in the efficiency of the electric motor.

[0003] When the conductor is wound into a winding mat which is fixed around or at the stator or rotor, the conductor is subjected to mechanical stress. In order to be able to ensure high efficiency, very smooth running, low noise levels and high robustness of the electric motor, the winding process must be reproducible and the conductor be subjected to as little mechanical stress as possible. In addition, high stresses of the conductor material during winding are also disadvantageous, since this leads to increased material costs during production.

[0004] There are different methods for manufacturing winding mats for stators or rotors. Usually, one or more winding wires or conductors, which can be round wires or flat wires, are fed to a winding plate or terminal block via a feeding device and wound thereon.

[0005] Patent document WO 2019 / 130232 A1 discloses winding around a terminal block. For this purpose, a conductor and a terminal block are provided. The latter has a slot for accommodating the conductor. The conductor is provided with the aid of one or more wire guides. The conductor is introduced into the slot of the terminal block so that some parts of the conductor are located in the slot and other parts of the conductor protrude from the slot. A connection (winding end) connected to a part of the conductor to be placed in the nearest slot (connecting strip) is formed from the part of the conductor that protrudes from the slot.

[0006] Patent document DE 10 2004 035 084 A1 describes a winding method for multiple windings around a winding plate. The winding method requires a template on which, in a first process step, connecting strips located on the template and winding ends projecting beyond the template are produced from n parallel wires. The winding ends are produced preferably in a V-shape or pointed shape by means of shaped bodies placed on the template. After the connecting strips and winding ends have been produced, in a second process step, they are displaced along the axis of rotation of the template by n times the spacing. The aforementioned process steps are repeated until the number of windings produced corresponds to the number of rotor slots or stator slots.

[0007] Patent document DE 197 39 353 A1 discloses a method and a device for producing a wave-shaped distributed winding for an electric motor, in particular an electric motor with a large number of poles. In the disclosed method, a coil group consisting of several wires or conductors and assigned to a first phase is produced in a wave-shaped manner on a rotatable template and transferred to an axially aligned coil former. For this purpose, the coil group is pulled out. Then, another coil group of the same phase that is wired to the previous coil group is wound and transferred to the same coil former. The method can process multiple wires in parallel without the wires crossing each other.

[0008] Patent document US 7 281 312 B2 describes another winding method using a winding plate. This method is similar to the previously described method, but additionally includes transferring the resulting winding mat into a transfer tool, a rotor or a stator.

[0009] An important problem with the method described is that, in particular when the length of the winding mat is large, an adaptation of the dimensions and (removal) transfer is not possible or is possible only at considerable expense, since the length of the template (terminal plate, winding plate, etc.) on which the wire or conductor is wound essentially corresponds to the length of the winding mat to be manufactured.

[0010] Patent document EP 3 182 568 B2 also describes a method for manufacturing a winding mat using a winding plate. In the described method, a single or multiple wires are wound several times around a winding plate. For this purpose, a holding mechanism may be provided, which holds a portion of the wire during winding, while another portion of the wire moves relative to it. However, winding is not performed until the number of windings reaches a value that corresponds to the number of rotor slots or stator slots, and the wound wire is transported away directly after winding via a transport device that rotates with the winding device, the transport device being configured as a belt conveyor or a toothed belt conveyor. This has the advantage that the length of the winding mat to be manufactured can be flexibly adapted to the stator or rotor.

[0011] In the described winding method, the conductor is removed from the winding plate or terminal block after winding and is subsequently pressed together flat. The squeezing of the winding mat or conductor causes great stresses on the insulation of the conductor. When using rotating terminal blocks or winding plates, the step width can also only be changed to a limited extent. As a result, the conductors wound in parallel are not symmetrical to each other and circular currents can form. This leads to losses in the conductor during operation and does not contribute to the formation of torque. Summary of the invention

[0012] The object of the present invention is to provide a winding method for manufacturing a winding mat for a stator or rotor of an electric motor, which method produces less mechanical load on the conductor without using a winding plate and allows a higher design flexibility of the winding mat.

[0013] According to the present invention, the object is achieved by a method for manufacturing a winding pad for a stator or rotor of an electric motor, in which: two conductor strands are provided, each having at least one conductor; the conductor strands are respectively conveyed to a receiving device along the x direction of a Cartesian coordinate system, the receiving device being connected to a guide and being movable in the x direction, the y direction and the z direction of the Cartesian coordinate system, wherein each receiving device respectively receives one conductor strand; and winding ends arranged opposite to each other are formed, wherein a first part of a forming tool pushes (extrudes) each conductor strand in opposite directions in the z direction, wherein a first side of the winding end is respectively formed, and then a second part of the forming tool pushes, wherein a second side of the winding end is respectively formed. side, and the winding ends are respectively fixed in the forming tool; cross-layer portions are respectively punched in opposite directions in the y direction in the transition portion from the first side to the second side of the winding end; a connecting strip extending along the z direction is formed, wherein the connecting strip is formed by moving the accommodating device along a curved path; a lifting movement of the accommodating device along the y direction is performed, wherein the conductor strands are transferred to the conveying device and the conductor strands are respectively conveyed along the x direction at a conveying rhythm; and the conveying of the conductor strands, the forming of the winding ends, the punching of the cross-layer portions, the forming of the connecting strips, the lifting movement and the conveying of the conductor strands are repeated until a winding pad with a defined number of windings is produced, wherein each winding is formed by two conductor strands and respectively includes two winding ends and four connecting strips.

[0014] A first side edge of the winding end and a second side edge of the winding end are formed for each conductor of the conductor strand.

[0015] In order to protect the conductor material, it is reasonable not to use terminal strips or winding strips. This has the advantage that winding mats of almost any length and shape can be produced, while the mat width and mat height are relatively small, and the conductors can be inserted and removed flexibly in the method.

[0016] The conductor strands advantageously have the same number of conductors and in each case a plurality of conductors, and conveying the conductor strands, shaping the winding ends, punching out the layer spans, shaping the connecting strips, performing the lifting movement and transporting the conductor strands are in each case carried out simultaneously for all conductors of the conductor strands.

[0017] During the method, the forming tool can be replaced in order to change the step width of the windings in the produced winding mat. The step width represents the distance between two adjacent connecting bars of the conductor.

[0018] Advantageously, the cross-layer portion is punched out by moving the first and second parts of the forming tool relative to each other in the y direction. It is also advantageous if the cross-layer portion is punched out during the forming of the winding head. This can speed up the method. The winding head is advantageously pointed.

[0019] In order to simplify and accelerate the shaping of the terminal strip, during the shaping of the terminal strip, the conductor strands can each be deformed in the z direction by means of a third component, wherein the third component is displaced in the z direction.

[0020] According to the present invention, the object is achieved by a device for manufacturing a winding pad for a stator or rotor of an electric motor, the device comprising: two accommodating devices, which are respectively connected to a guide and can be moved in the x-direction, y-direction and z-direction of a Cartesian coordinate system; two forming tools, which respectively have a first part and a second part, and the first part and the second part can be moved relative to each other in the y-direction of the Cartesian coordinate system; and a conveying device, which is designed to transport conductor strands along the x-direction at a conveying rhythm.

[0021] The device is designed to carry out a method for producing a winding mat for a stator or a rotor of an electric motor.

[0022] Advantageously, the guide elements can each comprise a slide and a rail on which the slide is guided, wherein one of the guide elements is arranged above the conductor strands and the other guide element is arranged below the conductor strands.

[0023] The receiving device may have a bending head with a wire retaining portion and a bending arm.

[0024] Advantageously, the forming tools each have a third part which is displaceable in the z direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention will be described in more detail below by way of embodiments with reference to the accompanying drawings.

[0026] Figure 1 A view showing an embodiment of a device for producing a winding mat,

[0027] Figure 2a to Figure 2f The method steps for producing a winding mat are shown in a top view,

[0028] Figure 3 A view showing an advantageous embodiment of a receiving device,

[0029] Figure 4 A view showing an advantageous embodiment of a forming tool,

[0030] Figure 5 A view showing the punching of the cross-layer portion using a forming tool. DETAILED DESCRIPTION

[0031] Figure 1A view of an embodiment of an apparatus for manufacturing a winding mat 5 is shown. The apparatus has two accommodating devices 2, which are respectively connected to guides 21 and can move in the x-direction, y-direction and z-direction of a Cartesian coordinate system. The guides 21 respectively include a slide 23 and a track 22, on which the slide is guided. One of the guides 21 is arranged above the conductor strand 1, whereby one of the slides 23 can move above the conductor strand 1 in a first plane parallel to the xz plane. The other guide 21 is arranged below the conductor strand 1, whereby the other slide 23 can move below the conductor strand 1 in a second plane parallel to the xz plane. The conductor strand 1 is wound on a bobbin before being provided for use. The conductor strand 1 is respectively transported to one of the two accommodating devices 2 along the x-direction of a Cartesian coordinate system, and the conductor strand 1 is accommodated in the accommodating device. The conductor strand 1 respectively contains at least one conductor, and the accommodating devices 2 respectively accommodate all the conductors of the conductor strand 1. From the bobbin, as viewed in the x-direction, the conveying device 6 is arranged after the accommodating device 2. The conveying device 6 is designed to transport the conductor strand 1 in the x-direction with a conveying cycle.

[0032] Figure 2a to Figure 2f The individual method steps for producing a winding mat 5 for one conductor strand 1 are shown in each case. Another conductor strand 1 is wound similarly at the same time, with the winding ends 11 being arranged opposite one another. Figure 2a In the method step shown, the conductor strand 1 is already received by the receiving device 2. The first part 41 of the shaping tool 4 is pushed against the conductor strand 1, which is shown simplified as a single conductor. The first part 41 is shown simplified as an equilateral triangle. By pushing, the first side 111 of the winding end 11 is shaped. Then, as shown in FIG. Figure 2b As shown, the second part 42 of the shaping tool 4 is pushed against the conductor strand 1 . Figure 2c The winding end 11 is shown fixed in the forming tool 4. The winding end 11 is advantageously held by a plate which is pressed from above (against the y direction) onto the first part 41, the second part 42 and the winding end 11, as shown in FIG. Figure 2c As shown. After fixing, the receiving device 2 performs a curved movement, whereby the conductor strand 1 is bent and the connecting strips 12 are formed. After the winding ends 11 and the connecting strips 12 are formed, the receiving device 2 performs a lifting movement in the y direction in order to transfer the conductor strand 1 to the conveying device 6. Subsequently, the conductor strand 1 is transported by the conveying device 6 along the x direction at a conveying rhythm that is advantageously consistent with the slot width of the stator or rotor and the aforementioned method steps are repeated until a winding mat 5 with a defined number of windings is produced, each of which is formed by two conductor strands 1 and includes two winding ends 11 and four connecting strips 12. With the exception of the first and last connecting strips 12 of the winding mat 5, each connecting strip 12 is assigned to two windings. Figure 2d to Figure 2fThe next winding end 11 and the next connecting strip 12 are formed in parallel with the method steps shown, respectively another conductor strand 1 (not shown) is formed opposite one another.

[0033] Like the shape of the winding ends 11, the step width SW of the resulting winding depends on the forming tool 4 used in the winding method. The forming tool can be replaced during the method, so that the winding mat 5 produced can have windings with different step widths SW.

[0034] Figure 3 An advantageous embodiment of the receiving device 2 is shown. The receiving device 2 has a bending head 23 with a wire holder 231 and a bending arm 232. One or more conductors of the conductor strand 1 can be received between the wire holder 231 and the bending arm 232. When received in the receiving device 2, the conductor strand 1 should be subjected to the least possible mechanical stress.

[0035] Figure 4 An advantageous embodiment of a forming tool 4 is shown. The forming tool 4 advantageously has a first component 41 and a second component 42. The first component 41 and the second component 42 can each have a linear drive and can be moved relative to each other in the y direction. It is also possible that only the first component 41 or the second component 42 can be moved in the y direction.

[0036] Figure 5 The punching of the cross-layer section 3 is shown. The winding end 11 is fixed in a forming tool 4 (not shown in its entirety). By moving the first part 41 and the second part 42 relative to each other in the y direction, the cross-layer section 3 can be punched in the transition 113 from the first side 111 to the second side 112. Punching can advantageously ensure that the thickness of the conductor strand 1 or the individual conductors of the conductor strand 1 is also reduced. By punching, a plurality of conductor strands 1 or windings can be interwoven with each other to form a winding mat 5.

[0037] Figure 5 The third removable part 43 of the shaping tool 4 is shown. The third part 43 can be moved in order to shape the connecting strip 12.

[0038] List of reference numerals:

[0039] 1 conductor strand

[0040] 11 Winding end

[0041] 111 First side

[0042] 112 Second side

[0043] 113 Transition

[0044] 12 Connecting strips

[0045] 2. Accommodation device

[0046] 21 Guides

[0047] 22 tracks

[0048] 23 Bend Head

[0049] 231 Wire holding part

[0050] 232 Bend Arm

[0051] 24 Slides

[0052] 3 Cross-layer department

[0053] 4 Forming tools

[0054] 41 First Part

[0055] 42 Second Part

[0056] 43 Third Part

[0057] 5 Winding pads

[0058] 6 Conveying device

[0059] SW step width.

Claims

1. A method for manufacturing a winding pad (5) for a stator or rotor of an electric motor, the method comprising the following steps: A. providing two conductor strands (1), each of which has at least one conductor, B. conveying the conductor strands (1) to respective receiving devices (2) along the x direction of the Cartesian coordinate system, wherein the receiving devices are respectively connected to guide members (21) and are movable along the x direction, y direction and z direction of the Cartesian coordinate system, wherein each receiving device (2) receives one conductor strand (1), C. forming winding ends (11) arranged opposite to each other, wherein a first part (41) of a forming tool (4) pushes each conductor strand (1) in opposite directions in the z direction, wherein a first side edge (111) of the winding end (11) is formed respectively, and then a second part (42) of the forming tool (4) is pushed, wherein a second side edge (112) of the winding end (11) is formed respectively, and the winding end (11) is fixed in the forming tool (4) respectively, D. punching cross-layer portions (3) in opposite directions in the y direction in the first side (111) or the second side (112) of the winding end (11) or in the transition portion (113) from the first side (111) to the second side (112), respectively; E. forming a connecting strip (12) extending in the z-direction, wherein the connecting strip (12) is formed by moving the receiving device (2) on a curved path, F. performing a lifting movement of the receiving device (2) along the y direction, wherein the conductor strand (1) is transferred to a conveying device (6) and the conductor strand (1) is transported along the x direction with a conveying cycle, and G. Steps B to F are repeated until a winding mat (5) having a defined number of windings is produced, the windings being formed from two conductor strands (1) and each comprising two winding ends (11) and four connecting bars (12).

2. The method according to claim 1, characterized in that: The two conductor strands (1) have the same number of conductors and each have a plurality of conductors, and steps B to F are respectively performed simultaneously for all conductors of a conductor strand (1).

3. The method according to claim 1 or 2, characterized in that: The forming tool (4) is replaced during the method in order to change the step width (SW) of the winding.

4. The method according to any one of the preceding claims, characterized in that The cross-layer portion (3) is punched by moving the first part (41) and the second part (42) of the forming tool (4) relative to each other in the y-direction.

5. The method according to any one of the preceding claims, characterized in that When the connecting strip (12) is formed, the third component (43) deforms the conductor strand (1) in the z-direction, wherein the third component (43) moves in the z-direction.

6. A device for manufacturing winding pads (5) for a stator or rotor of an electric motor, the device comprising: - two receiving devices (2), each of which is connected to a guide (21) and is movable in the x-direction, the y-direction and the z-direction of a Cartesian coordinate system, - two forming tools (4), each having a first part (41) and a second part (42), the first part and the second part being movable relative to each other in the y direction of a Cartesian coordinate system, and A conveying device (6) which is designed to transport the conductor strand (1) in an x-direction with a conveying cycle.

7. The device according to claim 6, characterized in that The guides (21) respectively comprise a slide (23) and a track (22), the slide (23) being guided on the track, wherein one of the guides (21) is located above the conductor strand (1) and the other guide (21) is located below the conductor strand (1).

8. The device according to claim 6 or 7, characterized in that The receiving devices (2) each have a bending head (23) with a wire holding portion (231) and a bending arm (232).

9. The device according to any one of claims 6 to 8, characterized in that The forming tools (4) each have a third component (43) which is movable in the z-direction.

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