Method for installing stator having wave winding

Abstract

The invention relates to a method for installing a stator (12) having a wave winding (10), which is arranged in slots of the stator and has a winding head that protrudes axially beyond the stator body, between which slots there are provided winding heads that are held in receptacles (16; 116), which tooth section (14) is arranged in the housing (16; 116), which tooth section (14; 116) linearly conveys the pad-shaped wave winding (10) and the receptacle (16; 116) are fed radially outward corresponding to the height of the wire layer during corresponding rotation, and slots for a wire web (26) of the wave winding (10) are formed between the tooth sections. In order to be able to achieve a better method flow, it is proposed that the receptacle (16; 116), only a portion of the tooth section (14) is arranged in the receptacle (16; 116) and is fed radially outward corresponding to the height of the inner conductor layer, and subsequently, in at least one subsequent revolution, a further tooth section (14) is inserted from the inside into the receptacle (16; 116) and is fed radially outward, such that the distance between the receiving portion (16; 116) and after the winding of the entire wave winding (10), all tooth sections (14) are inserted and moved into a radial end position thereof, or finally the last tooth section (14) is inserted and moved radially outward after the winding.

Description

Technical Field

[0001] According to the preamble of claim 1, the invention relates to a method for installing a stator with a wave winding, which is arranged in slots of the stator and has winding heads that protrude axially beyond the stator body, wherein tooth sections are provided between the slots and are held in receptacles, said tooth sections being fed radially outwards in accordance with the height of the wire layers during linear conveyance of the mat-shaped wave winding and corresponding rotation of the receptacles, and wherein slots for the wire of the wave winding are formed between the tooth sections. Background Art

[0002] Methods are known in which the wave winding mat is first transferred into a tool with radially outwardly open slots and then, in a transfer step, is pushed radially outwards into inwardly open slots of a one-piece stator by means of a tool introduced centrally into the stator. In addition to the complex process, in which damage to the sensitive insulation of the wire of the wave winding can occur, disadvantages also exist in the case of internally open slots, such as electrical losses and magnetic field guidance.

[0003] Alternatively, it is known, for example from EP 3 886 303 A1, to roll the winding pads inwardly into radial slots which are open on the outside at the stator circumference. However, due to the reduced circumference of the winding layers, an undesirable increase in the winding head occurs by radially displacing the wire.

[0004] An alternative method based on segmentation of the laminated core is described in DE 10 2011 000 172. The installation objective is achieved there by installing the segmented double teeth into the winding by radial displacement from the outside to the inside. Although no increase in the winding head occurs here, a magnetically preferred laminated core geometry with a pronounced pole shoe or tooth tip cannot be installed. Design features of the slot and tooth geometry similar to those used for the above-mentioned application apply.

[0005] EP 3 731 379 B1 already describes a solution in which the winding layers are each wound onto their final radius. For this purpose, a segmented stator is used, in which all tooth segments are first displaced radially inwards into a subsequent central recess of the stator by winding the first winding layer into the receptacle, and then radially outwards in the subsequent layers, respectively corresponding to the height of the winding layer. Due to the narrow space in the middle, the tooth segments are spaced relatively far apart in the stator, so that the actual slots are only formed later by introducing further stator segments radially from the outside to the inside between the tooth segments. The stator also acquires its final structure only by introducing the stator segments. The number of slots and also their size are limited by the described method, which in turn can lead to disadvantages in efficiency. Summary of the invention

[0006] The object of the present invention is to provide a method which allows improved production of stators and is suitable, for example, for inner rotors of radial flux machines or radially slotted stators.

[0007] According to the invention, the object is achieved by a method of the type mentioned at the outset, wherein during a first rotation of the receptacle, only a portion of the tooth segment is arranged in the receptacle and fed radially outward corresponding to the height of the internal wire layer, and then in at least one subsequent rotation, another tooth segment is inserted into the receptacle from the inside and fed radially outward, so that after the last rotation of the receptacle and the winding of the entire wave winding, all tooth segments are inserted and moved into the radial end position of the tooth segments, or finally the last tooth segment is inserted and moved radially outward.

[0008] Due to the fact that not all tooth segments are already arranged in the inner space of the subsequent stator at the beginning of the method, there is more space available there so that the tooth segments are successively introduced into the process with narrower circumferential spacing. Because the tooth segments are still relatively far radially inwardly displaced in the first winding layer, not all tooth segments are initially introduced during the first revolution, whereby the tooth segments do not collide at their radially inner ends. Subsequently, with further radial outward displacement, the available space expands, so that additional tooth segments are conveyed during the second revolution of the receiving part. If necessary, additional tooth segments can also be conveyed during other revolutions of the receiving part. The tooth segments conveyed subsequently can, but do not have to, be directly displaced to the radial level of the winding layer currently to be wound. The tooth segments conveyed subsequently find their way between the wire webs of the winding pad that connect the winding heads and place the wire webs in their desired positions.

[0009] Preferably, all tooth segments are moved in the axial direction into the stator interior before being inserted radially outwards into the receptacles and then displaced radially outwards stepwise. When mounted on an internally slotted stator for a radial flux machine, no radial inward displacement takes place during the entire method.

[0010] The solution according to the invention offers the following further advantages: No additional steps are required in which further sections have to be displaced radially inwards from the outside, thereby significantly simplifying the process sequence. In the new layer, the level of the delivered wave winding can be adjusted, which can also be done in a manner known per se by storing the winding mats in correspondingly stepped linear silos that deliver the winding mats.

[0011] Since the winding mat is always conveyed to its final position in the stator at its final radius, there is no risk of the winding head being increased during the process.

[0012] Another advantage of radially mounting the teeth into the partially or fully conveyed wave winding mat is that, apart from the stator inner diameter, there are no geometrical restrictions in the radial direction with regard to the number of layers of the winding or the corresponding tooth length.

[0013] In a preferred development of the method, it is provided that before the first rotation of the receptacle, only each second tooth segment is inserted into the receptacle, or only each second tooth segment or third tooth segment is inserted into the receptacle in a discontinuous sequence.

[0014] In order to simplify the insertion of a tooth segment which is added only subsequently, in a particularly preferred development of the method it is provided that a rounded or beveled engagement aid is applied to the radially outer tip of the tooth segment before the tooth segment is inserted into the receptacle.

[0015] The joining aid can also be implemented in a way that it slightly overlaps or covers the tooth profile with the axial end. If necessary, the joining aid can also be removed again after installation.

[0016] In an advantageous development of the method, it is further provided that the receptacle is formed by two half shells with axial projections, wherein a radial guide for the toothed segment is formed between the projections facing each other by means of the projections in that the two half shells are moved axially toward each other.

[0017] This solution offers the advantage that the half shells can be easily introduced into the stator interior to form the receptacle. They can also be easily removed again after the method is completed.

[0018] Outside the stator interior, the half shells can have a larger diameter than the stator interior, since the half shells can be inserted axially into the interior with the region of their guide tooth sections from the opposite side.

[0019] If other shapes for the tooth flanks are desired, the method can be designed in such a way that the spacing between the axial projections in the region of their axial ends is designed differently, so that the width of the guide groove can be set by adjusting the axial position of the half shells relative to one another, so that, for example, tooth segments with a conical longitudinal cross section can be used. Flexible adaptation to different tooth widths can be used, for example, to install different product geometries on the device.

[0020] A particularly expedient and structurally simple measure for improving the method provides that a mounting device with an adjustable guideway is provided in the receptacle, by means of which the tooth segments are displaced radially outward. The guideway can be designed, for example, in the form of a rotating cam, which rotates further into a position with a larger effective radius after each rotation of the receptacle, so that the tooth segments passing by are also correspondingly pressed further radially outward in the guide of the receptacle. The tooth segments subsequently added can be displaced by a correspondingly larger distance to the same radial level as the tooth segments that have been previously conveyed, by means of a corresponding design of the stop surface, so that all tooth segments are arranged at the level of the cushion layer currently to be wound.

[0021] Although it is possible to first convey all tooth segments used during the rotation of the receptacle before the rotation begins and insert them into the guide of the receptacle, it is preferably provided that the tooth segments are conveyed continuously from a magazine of the receptacle. This can be done, for example, by means of a handling robot, which, for example, takes the tooth segments from a magazine outside the stator interior and inserts them radially outward from the interior into the provided guide.

[0022] In a particularly preferred embodiment of the invention, it is proposed that a plurality of rollers are used to guide the wire, with the aid of which the wave winding is deformed to the desired radius of the current winding layer of the stator. After the wave winding has been removed from its linear magazine, the rollers ensure that the winding pad follows the radius of the stator winding without blocking the necessary installation space for the teeth.

[0023] One expedient embodiment can provide that the roller, which can also be mounted elastically, is set at a certain distance from the rotation axis of the receptacle in accordance with the respective winding layer.

[0024] A further measure preceding the actual method may provide that the tooth segment is coated and / or insulated by a forming method.

[0025] In a preferred development of the method, it is provided that after the wave winding has been wound between the tooth segments, a stator yoke is pressed in axially, which gives the stator its final shape and mechanically stabilizes the stator.

[0026] It is possible here that the receptacle is not a component of the subsequent stator, but may possibly be. The receptacle can be removed in particular if, after the wave winding has been wound between the tooth segments, the stator yoke is completed, for example by the aforementioned axial pressing.

[0027] The multi-part stator produced by the method has the following special properties: the spacing of the teeth and their length are selected so that, in the event of a hypothetical radial displacement of the teeth, adjacent teeth collide before the teeth leave the slots, and the multi-part stator has: a plurality of individual teeth with parallel tooth flanks, between which a winding with winding heads is held; and a stator yoke.

[0028] The special geometrical properties allow a particularly efficient design of the stator, which can be manufactured by the method according to the invention as described above. For a wave-wound stator with parallel tooth flanks, the ratio of the number of slots / number of teeth, the stator inner diameter and / or the slot depth of the stator segmented in this way is better than is possible in the prior art, and the dimensions of the winding heads, which do not contribute to the performance, can also be kept smaller. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Further features, details and advantages of the invention are apparent from the wording of the claims and from the exemplary embodiments described below with reference to the accompanying drawings. The accompanying drawings show:

[0030] Figure 1 a schematic side view showing the start of the method;

[0031] Figure 2 An expanded partial view showing two receptacles forming a receptacle for a tooth segment;

[0032] Figure 3 Shows a similar Figure 1 Side view of

[0033] Figure 4 The expanded partial view shows a receptacle with an inclined guide edge. DETAILED DESCRIPTION

[0034] To illustrate the installation method, Figure 1 1 shows schematically the initial state of transferring a wave winding 10 present as an elongated mat into a stator 12 to be constructed: tooth segments 14, between which the subsequent stator slots of the stator are formed. In the early stage of the method, in which the first wire web 16 has just reached the first tooth segment 14 and the wave winding still has a purely linear mat-shaped extension, the first few tooth segments 14 are inserted into the stator 12 with radial guides 18 (see Figure 2), wherein a rounded engagement aid 20 is placed at the radially outer tip of the tooth segment. In this initial phase, the tooth segments 14 also do not occupy the radial guides 18 that follow one another directly, but only each second or third guide, so that enough space remains in the central space, so that the tooth segments 14 that follow one another do not collide with one another, and there is also space for a robot gripper 22, which can remove the tooth segment 14 from a magazine outside the central space and insert it into the provided radial guide.

[0035] The tooth segment 14 has a lateral projection 24 at the radially inner end, which then partially closes the stator slot radially on the inside and prevents the conductor wire from leaving the slot.

[0036] Only some of the double-layer wire webs 26 are shown from the winding mat, which are to lie in the subsequent axial slots of the stator. The schematic diagram shows only approximately every fourth wire web, wherein - as already mentioned - even in the first winding layer, not all tooth segments 14 have yet been inserted into the receptacles by a rotation of the receptacles. In the illustrated embodiment, a tooth segment is inserted at every second radial guide 18, and if a tooth segment 14 has already been displaced radially outwards by a certain distance from the first revolution, so that the tip of the tooth segment is between the wire webs 26, the remaining radial guides 18 are inserted in the second revolution of the receptacle 16.

[0037] The radial displacement of the toothed segment 14 is carried out by means of a mounting device 28 which is essentially formed with an adjustable guide in the form of a rotatable cam 30. Figure 1 and Figure 3 3 shows the cam in a first position, wherein the cam presses the tooth segment 14 passing by radially outwards into the first radial position by means of the stop bevel 32. The displacement takes place in the region in which the winding mat is tangential to the receptacle 16, so that the next tooth segment 14 behind is still pulled back radially and does not collide with the wire web 26 of the winding mat 10.

[0038] In the subsequent rotation, the cam 30 rotates clockwise, so that the stop ramp 32 further extends radially outwards accordingly. Then, the beginning of the stop ramp 32 is still at Figure 1 The tooth segments 14 shown in FIG. 1 are in the radially inner region, so that the tooth segments 14 that are subsequently inserted can be displaced radially outwards by a correspondingly greater total distance.

[0039] Figure 2In the expanded top view, a part of the receptacle 16 with the radial guide 18 is shown. The receptacle 18 is formed by two annular half shells 34, 36. The half shells have axial projections 38, 40 pointing toward each other and oriented in alignment with the projections 38, 40 of the respective other half shell 34, 36, so that a radial guide is formed between them.

[0040] The half shells 34 , 36 can be removed after the stator has been installed by pulling them apart axially, provided that they are not designed as components of the stator.

[0041] In order to be able to wind the delivered winding mat 10 on a predetermined circumference, a plurality of reforming rollers 42 are provided which are arranged one behind the other and which describe a radius corresponding to the outer diameter of the current winding layer of the winding mat 10. The rollers 42 are usually arranged directly next to the tooth section 14 and act on the winding head of the winding mat. The position of the rollers 42 can be set so that it can be adapted to the radius of the current layer of the winding mat 10 to be wound. The rollers 42 can be supported elastically.

[0042] based on Figure 1 ,exist Figure 3 , a state at a later stage of the installation method is shown, in which the first tooth segment 14 with the wire web 26 located therebetween has arrived in the area of ​​the reforming roller 42. As already mentioned, not all wire webs 26 are shown, and some of the tooth segments 14 are also installed first, i.e. free spaces still remain between the tooth segments, which are not filled until the second revolution, and if necessary also in subsequent revolutions, if more than two layers of winding mats are wound or there is not enough space initially. It is also possible to complete the winding first and, if the spatial conditions in the interior are to be particularly limited, then finally also to supplement the missing tooth segments.

[0043] exist Figure 3 It can also be clearly seen that the toothed section 14 protrudes radially beyond the reforming roller.

[0044] Although in Figure 1 , Figure 2 and Figure 3 The device shown in FIG. 1 is suitable for forming conically widening stator slots, but it is also possible to form stator slots with parallel slot walls by means of tooth segments 14 which are conically formed in longitudinal section. Since the tooth segments can then no longer be guided in guide slots with a constant cross section, Figure 41 shows an embodiment of a receptacle 116 in which the half shells 134, 136 are designed such that the axial projections 138, 140 have a greater spacing between them in the region of their ends, which tapers conically toward the base of the half shells 134, 136. Due to the greater axial spacing of the half shells 134, 136 at the beginning of the method, a radial guide 138 of a greater cross section for the conical tooth segment 14 can be achieved. The effective width of the radial guide 118 can then be adapted to the cross section of the tooth segment 14 which tapers radially inwardly by axially advancing the two half shells.

[0045] After the winding mat 10 has been completely wound up and all tooth segments 14 have been introduced, the stator yoke, which gives the stator mechanical stability, can be axially inserted to complete the stator. The half shells 34 , 36 of the receptacle 16 can be removed if necessary and used when installing a further stator.

[0046] The present invention is not limited to any one of the above-described embodiments but can be modified in various ways.

[0047] All features and advantages arising from the claims and the description, including structural details, spatial arrangements and method steps, may be essential to the invention both individually and in various combinations.

[0048] Reference numerals list

[0049] 10 Wave winding / winding pad

[0050] 12 Stator

[0051] 14 tooth segment

[0052] 16 Accommodation

[0053] 18 Radial guide

[0054] 20 Joining aid

[0055] 22 Robotic Gripper

[0056] 24 Lateral protrusion

[0057] 26 Wire web

[0058] 28 Installing the equipment

[0059] 30 Rotatable cam

[0060] 32 stop slope

[0061] 34, 36 Half Shell

[0062] 38, 40 Axial protrusion

[0063] 42 Modified Roller

[0064] 116 Accommodation

[0065] 118 Radial guide

[0066] 134, 136 Half Shell

[0067] 138, 140 Axial protrusion

Claims

1. A method for installing a stator (12) having a wave winding (10) arranged in slots of the stator and having winding heads protruding axially beyond the stator body, wherein tooth segments (14) held in receptacles (16; 116) are provided between the slots, the tooth segments being fed radially outwards in accordance with the height of the wire layer during linear transport of the mat-shaped wave winding (10) and corresponding rotation of the receptacles (16; 116), and the slots for the wire webs (26) of the wave winding (10) being formed between the tooth segments, characterized in that During a first rotation of the receiving portion (16; 116), only a portion of the tooth segment (14) is arranged in the receiving portion (16; 116) and fed radially outward corresponding to the height of the wire layer inside, and then in at least one subsequent rotation, another tooth segment (14) is inserted into the receiving portion (16; 116) from the inside and fed radially outward, so that after the last rotation of the receiving portion (16; 116) and the winding of the entire wave winding (10), all tooth segments (14) are inserted and moved into the radial end position of the tooth segments, or finally after winding, the last tooth segment (14) is inserted and moved radially outward.

2. The method according to claim 1, characterized in that: Before the first rotation of the receiving portion (16; 116), only each second tooth segment (14) is inserted into the receiving portion (16; 116), or only each second tooth segment or third tooth segment (14) is inserted into the receiving portion (16; 116) in a discontinuous order.

3. The method according to claim 1 or 2, characterized in that: Before the tooth segment (14) is inserted into the receptacle (16; 116), a rounded or beveled engagement aid (20) is mounted on the radially outer tip of the tooth segment (14).

4. The method according to any one of the preceding claims, characterized in that The receptacle (16; 116) is formed by two half shells (34, 36; 134, 136) having axial projections (38, 40; 138, 140), wherein a radial guide (38; 138) for the tooth segment (14) is formed between the projections (38, 40; 138, 140) by means of the projections (38, 40; 138, 140) facing each other, in that the two half shells (34, 36; 134, 136) are moved axially toward each other.

5. The method according to claim 4, characterized in that The spacing between the axial projections (138, 140) is larger in the region of the axial ends of the axial projections, so that the width of the guide groove (138) can be set by adjusting the axial position of the half shells (134, 136) relative to each other, so that a tooth segment (14) with a conical longitudinal cross-section can be used to produce a groove with parallel groove side edges.

6. The method according to any one of the preceding claims, characterized in that A mounting device (38) having an adjustable guide groove (40) is arranged in the receptacle, by means of which the toothed segment (14) is displaced radially outward.

7. The method according to any one of the preceding claims, characterized in that The tooth segments (14) are continuously fed from a silo of the receiving portion (16; 116).

8. The method according to any one of the preceding claims, characterized in that A plurality of rollers (42) are used to guide the wire, by means of which the wave winding (10) is deformed to the desired radius of the current winding layer of the stator.

9. The method according to claim 8, characterized in that The roller (42) is set at a specific distance from the rotation axis of the receiving portion (16; 116) corresponding to the respective winding layer.

10. The method according to any one of the preceding claims, characterized in that The tooth segment (14) is coated and / or insulated by a forming method.

11. The method according to any one of the preceding claims, characterized in that After the wave winding (10) has been wound between the tooth segments (14), it is axially pressed into the stator yoke.

12. The method according to claim 11, characterized in that After the stator yoke has been pressed in, the receptacle is removed.

13. A multi-part stator having: a plurality of individual teeth with parallel tooth flanks, between which a winding with a winding head is held; and a stator yoke, characterized in that In, The spacing of the teeth and their length are selected so that, in the case of an imaginary radial displacement of the teeth, Adjacent teeth may collide before the teeth leave the slot.

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