Method for electrically contacting stranded wire winding with carrier plate and stranded wire winding

Abstract

The invention relates to a method for contacting a winding with a carrier plate, in which the winding has a first axial end and an opposite second axial end, and in which the winding comprises at least two stranded wire ends for electrical connection with the carrier plate, and in which the stranded wire ends have a single wire and project beyond the axial ends of the winding, the carrier plate is substantially parallel to the axis of the winding and is distributed at least on part of the circumference of the winding, the carrier plate is provided with a first end side facing the tail end of the stranded wire, a second end side deviating from the tail end of the stranded wire and a side surface, the first end side is provided with a notch for accommodating the tail end of the stranded wire, and the second end side is provided with a notch for accommodating the tail end of the stranded wire. The method comprises the following method steps:-folding the stranded wire end with a sleeve in such a way that the sleeve at least partially surrounds the stranded wire end over at least a portion of the length of the stranded wire end,-bringing the stranded wire end into electrical contact with the sleeve,-introducing the stranded wire end fitted with the sleeve into the recess of the carrier plate, and-inserting the sleeve into the recess of the carrier plate. Wherein according to the invention, the winding is a twisted wire winding having an insulating single wire at the end thereof, the insulating material comprising a high temperature resistant varnish, the end of the twisted wire fitted with the sleeve being substantially parallel to the axis of the winding after the end of the twisted wire fitted with the sleeve is introduced into the recess of the carrier plate, and the end of the twisted wire remains substantially parallel to the axis of the winding after the end of the twisted wire fitted with the sleeve is inserted into the recess of the carrier plate. And the sleeve and the carrier plate are electrically contacted with each other.

Description

Technical Field

[0001] The invention relates to a method for contacting a winding with a carrier plate according to the preamble of independent claim 1 and to a litz wire winding suitable for said method according to independent claim 12 .

[0002] The same type of method is applied to the manufacture of electric motors, especially small power electric motors. Background Art

[0003] In order to bundle the strands of the winding wire together, it is known to hold the ends of the winding wire exposed in a solder pool and then tin them. However, depending on the specific embodiment of the insulating varnish, there is a risk that this insulating varnish will not be completely melted off and the strands will not be bundled optimally, which further increases the difficulty of electrical contact. Insulating varnishes used for sterilizable windings are particularly heat-resistant, so that errors can easily occur when making contact with the help of the solder pool.

[0004] Therefore, to ensure a good and reliable connection with the carrier, the strands are inserted into a sleeve which is then brought into electrical contact with the carrier.

[0005] Since the radial construction space is extremely limited in small power motors, especially in small power motors with a diameter of less than 100 mm, and mainly in small power motors with a diameter of less than 60 mm, the ends of the litz wires together with the sleeves should advantageously be kept aligned axially relative to the winding.

[0006] A method for contacting a winding with a carrier is known from the preamble of claim 1 of DE 10 2017 206 187. This document shows that the winding is contacted with the carrier by inserting the ends of the winding into crimping terminals mounted on the carrier and crimping them together with these crimping terminals. Subsequently, the crimping terminals together with the winding ends are deformed in the recesses so that the ends of the winding wires are no longer aligned axially with the windings, but are bent radially inwards or radially outwards and are substantially parallel to the surface of the carrier.

[0007] However, this method requires a large radial installation space and is not suitable for litz wire windings because there is a risk that bending of the wire ends may lead to the individual wires of the litz wire breaking.

[0008] Another document known from the prior art is US2011012468. This document discloses a radial gap motor with a hollow cylindrical winding. The winding is in contact with a carrier plate via winding ends, which may consist of one or more metal wires, wherein for this purpose the winding ends are inserted into through holes in the carrier plate. However, the crimping of the winding ends is not described, nor is it described how the winding ends are in contact with the carrier plate.

[0009] Especially in low-power electric motors, the structural space for the contact between the winding and the carrier plate is extremely limited. Among them, the reliable contact of the winding ends composed of a large number of single wires is more complicated. Summary of the invention

[0010] In view of this, the object of the present invention is to provide a simple method for contacting a litz wire winding with a carrier plate in a compact and reliable manner, and a litz wire winding produced according to said method.

[0011] The solution of the invention for achieving the above mentioned objects lies in the features of independent claims 1 and 12. Therefore, in the method according to the preamble of independent claim 1, the solution of the invention for achieving the above mentioned objects is that the winding is a litz wire winding, the litz wire ends have insulated single wires, the insulating material comprises a high temperature resistant varnish, wherein after the litz wire ends equipped with the sleeves are introduced into the recesses of the carrier plate, the litz wire ends are kept substantially parallel to the axis of the winding, and the sleeves and the carrier plate are brought into electrical contact with each other.

[0012] According to the invention, the ends of the litz wires are substantially parallel to the axis of the litz wire winding both before and after the sleeve is inserted into the recess. Substantially parallel means that the orientation angle of the individual litz wire ends deviates from the axis of the litz wire winding by a maximum of 15°, preferably a maximum of 10°, particularly preferably a maximum of 5°. This has the advantage that almost no radial construction space is required and the litz wire ends are not bent significantly.

[0013] The winding is a stranded wire winding consisting of single wires over the entire length. The single wires are electrically insulated with varnish over the entire length so that the single wires are insulated from each other. The ends of the stranded wires also have insulated single wires equipped with sleeves. Compared with metal wires with the same conductor cross-sectional area, the stranded wires are more flexible and can also avoid or reduce eddy currents. The winding can be used to generate an electromagnetic field in a slotless or ironless motor.

[0014] Advantageous embodiments of the invention are the subject matter of the dependent claims.

[0015] Preferably, the litz wire winding is implemented as a hollow cylinder. However, the method of the present invention can also be applied to litz wire windings of other embodiments known to those skilled in the art.

[0016] According to an advantageous embodiment of the method, the sleeve is implemented as a closed sleeve, and in order to close the sleeve with the stranded wire end, the sleeve is put on the stranded wire end in a certain way so that the stranded wire end is completely surrounded by the sleeve in the radial direction over at least a part of its length range. The sleeve can be completely put on the stranded wire end so that the top end of the stranded wire end protrudes out of the sleeve. However, the sleeve can also be only partially put on the stranded wire end so that the top end of the stranded wire end is inside the sleeve. Preferably, at least half of the length of the sleeve is put on the stranded wire end, and more preferably at least three quarters of the length. The sleeve can be funnel-shaped on at least one side, so that the strands of the stranded wire end are easier to insert into the sleeve.

[0017] According to another advantageous embodiment of the method, when the sleeve is closed with the stranded wire end, the sleeve is implemented as a sleeve blank, which is deformed into the shape of the sleeve so that the stranded wire end is completely surrounded in the radial direction over at least a part of the length range. The sleeve blank is preferably implemented as a strip, wherein the strip has a width and a length, and wherein the strip length is at least twice the strip width, preferably the length is at least three times the width. The strip is orthogonal to the orientation of the stranded wire end along its length direction, so that the strip and the stranded wire end are in contact with each other. Subsequently, the strip is bent inwardly, that is, towards the stranded wire end, several times until the strip completely or almost completely surrounds the stranded wire end. Advantageously, the strip is bent three times so that the stranded wire end is completely surrounded. The strip can also be bent four times so that two of the strip surfaces produced by the bending overlap. By subsequent electrical contact, a reliable electrical connection is established between the bent strip and the stranded wire end. This connection can be implemented by welding, crimping or other methods known to those skilled in the art. The advantage compared to closed and slotted sleeves is that it is not necessary to guide the sleeve blank over the sensitive tips of the individual wires at the end of the stranded conductors, which significantly reduces the risk of bending or breaking and thus improper contact.

[0018] Preferably, the sleeve is exposed on both sides along the axial direction, so that when the end of the stranded wire is in electrical contact with the sleeve, the insulating varnish can be exposed from both sides of the sleeve. This enables the stranded wire end to be in particularly good electrical contact with the sleeve. The closed sleeve and the sleeve blank that becomes the sleeve by deformation are exposed on both sides along the axial direction, so that they have two openings in the axial direction respectively. As a result, when the end of the stranded wire is in electrical contact with the sleeve, the insulating varnish or, for example, tin or other substances that reduce the electrical conductivity of the contact can be exposed from both sides of the sleeve. Since the substance is exposed from both sides of the sleeve, for example, insulating varnish bubbles that deteriorate the electrical contact between the end of the stranded wire and the sleeve will not be formed on the closed side of the sleeve. During the connection process between the sleeve and the end of the stranded wire, the sleeve can be pressed to one side, which will only slightly affect the outflow of the varnish during the connection process between the end of the stranded wire and the sleeve, and will not cause the generation of insulating varnish bubbles and poor contact between the end of the stranded wire and the sleeve. The sleeve can be a core wire end sleeve, and has a funnel at least on one side in the axial direction, which makes it easier for the stranded wire to be introduced into the sleeve.

[0019] According to a particularly advantageous embodiment of the method, the sleeve is brought into contact with the single wires at the end of the stranded wire resting on the inner circumference by crimping, preferably by hot crimping. The single wires at the end of the stranded wire are preferably electrically insulated with an insulating varnish. The sleeve is squeezed with a crimping tool so that the copper of the single wire is electrically connected to the crimped sleeve. The advantage of hot crimping is that the insulating varnish of the single wires at the end of the stranded wire is melted by heating the area surrounded by the sleeve at the end of the stranded wire. The heating is performed at least at 200° C. and preferably at 250° C. At this temperature, the insulating varnish surrounding the single wires will be melted. Depending on the specific type of insulating varnish, a higher temperature is required. Among them, the insulating varnish suitable for sterilizable parts requires a higher temperature in order to completely melt, thereby achieving good contact between the single wires at the end of the stranded wire and the sleeve. High temperature resistant insulating varnish (for example VT220) can be used for sterilizable parts, such as windings. A high temperature resistant insulating varnish is a varnish having a softening temperature of more than 300°C according to IEC 60851-6 4. It can preferably be a polyamide-imide varnish which is also suitable for sterilizable components. In the case of using a high temperature resistant or sterilizable varnish for windings, the ends of the stranded wires should be heated to 500°C to 900°C, preferably 750°C. At this temperature, the high temperature resistant varnish has a low viscosity and partially evaporates. The insulating varnish is pressed out of the connection between the stranded wire and the crimping piece by the pressure of the crimping tool, thereby forming a somewhat pure metal connection. The metal connection has excellent contact properties, including high electrical and thermal conductivity. The sleeve or crimping sleeve can be made of tinned copper. The tin on the surface of the crimping piece will also liquefy due to the high temperature and be pressed out of the connection by the contact pressure of the crimping tool. As a result, a particularly pure copper connection with particularly good electrical conductivity is formed between the stranded wire and the sleeve. The insulating varnish pressed out of the crimped connection and the tin also partially pressed out of the crimped connection partially solidify in the exit area of ​​the crimp sleeve, thereby forming a protective layer which protects the underlying stranded conductor from contact with the sleeve from corrosion.

[0020] Preferably, the heating is performed by applying an electric current with a current strength of 100 A to 200 A and preferably 140 A to 160 A. In addition to good electrical contact, the advantage of the thermocompression connection is also its robustness against vibrations.

[0021] By applying a high current to the sleeve, heat can be generated locally in the crimp sleeve. As a result, the area in the immediate vicinity of the sleeve heats up less, which is advantageous in particular in the case of smaller or shorter motors. The method is particularly suitable for contacting motors that operate at high temperatures or that have to withstand high temperatures, for example due to sterilization processes.

[0022] According to a particularly preferred embodiment of the method, the sleeve has a first width and a second width, wherein the first and second widths are orthogonal to the longitudinal axis of the stranded wire end. The first and second widths can be at right angles to each other. After electrical contact, the spatial extension of the first width of the sleeve is twice as large as the second width. Preferably, the first width is four times as large as the second width. Thus, the sleeve has a flat shape after crimping.

[0023] According to another preferred embodiment of the method, for contacting, the stranded wire end is immersed in a tin bath together with the sleeve until the insulation material of the individual wires of the stranded wire end melts. The time for the insulation material to melt can be from 2 seconds to 8 seconds, preferably 5 seconds. The time for the insulation material to melt depends on the type of insulation material used. In particular, the insulating varnish used for sterilizable windings is very heat-resistant, so that the melting time is relatively long.

[0024] According to a particularly preferred embodiment of the method, the recess at the first end side of the carrier plate has a depth, which extends orthogonally from the first end side in the direction of the second end side, and the recess has a first width and a second width, wherein the first and second widths are at right angles to each other, and wherein the sleeve contacts the stranded wire end in such a way that at least one width of the sleeve can be closed with at least one width of the recess at the first end side, thereby creating a gap of at least 0.1 mm, preferably at least 1 mm, more preferably at least 2 mm. Thus, the difference between the first width of the sleeve and the first width of the recess is at least 0.1 mm, preferably at least 1 mm, more preferably at least 2 mm. Furthermore, the difference between the second width of the sleeve and the second width of the recess is at least 0.1 mm, preferably at least 1 mm, more preferably at least 2 mm.

[0025] Preferably, the sleeve and the recess match each other so that the sleeve can be introduced into the recess without getting stuck and the gap must not be larger than necessary for the easiest installation. With this spacing, the solder can also flow from one end side of the carrier through the recess to the opposite end side, so that a good electrical contact is achieved between the sleeve and the carrier support.

[0026] The litz wire winding and the carrier plate are aligned coaxially with each other to allow the sleeve to be introduced into the recess. The litz wire winding and the carrier plate are aligned with each other by rotation about a common axis so that the sleeve can be introduced into the recess by axially moving the litz wire winding and / or the carrier plate.

[0027] Preferably, the recess and / or the sleeve has a profile that is defined by the first and second widths of the sleeve and recess, respectively, that tapers at one end, whereby such guidance further simplifies installation.

[0028] According to a particularly preferred embodiment of the method, the recess on the first end side of the carrier plate extends to the second end side and the side surface, wherein the carrier plate and the litz wire winding are aligned with each other so that the axis of the litz wire winding is parallel to a longitudinal axis of the carrier plate orthogonal to the first end side of the carrier plate, and wherein the carrier plate and the litz wire winding are axially matched to each other so that the sleeve is inserted into the recess by a radial inward movement. Alternatively, the litz wire winding is moved as a whole in the direction of the recess to introduce the sleeve. The carrier plate can also be moved together with the recess in the direction of the sleeve, or the sleeve and the recess can be moved towards each other, whereby the sleeve is introduced into the recess.

[0029] According to a particularly preferred embodiment of the method, the recesses are designed as elongated holes, which are open to the side of the carrier plate, wherein the longitudinal axis of the elongated hole is oriented radially at an angle to the center of the end face, wherein this angle is 30°-60°, preferably 40°-50°, and wherein the sleeve is introduced into the elongated hole of the carrier plate by a radial displacement, and this displacement is superimposed on an additional rotational movement of the carrier plate about the center point of the end face. For this embodiment of the method according to the invention, the sleeve is advantageously aligned with the position of the elongated hole. For this purpose, the width of the sleeve and the recess are matched to each other not only in size but also in orientation. For this purpose, a first width of the sleeve extends in the direction of the longitudinal axis of the elongated hole.

[0030] The sleeve can be brought into electrical contact with the carrier immediately after the sleeve is introduced into the recess of the carrier. When making the electrical contact, a reliable electrical contact is established between the two components by welding, crimping or other methods known to those skilled in the art. According to a preferred embodiment of the present invention, the sleeve is brought into electrical contact with the carrier by means of welding.

[0031] Particularly preferably, the invention provides a litz wire winding which is preferably produced according to one of the above-described embodiments of the claimed method.

[0032] According to a particularly preferred embodiment of the litz wire winding of the present invention, one litz wire end includes at least five individual wires, preferably at least fifteen individual wires. The litz wire winding may also include 20 to 60 individual wires.

[0033] According to another preferred embodiment of the litz wire winding of the present invention, the insulating material of the single wires of the litz wire winding comprises a sterilizable varnish. The sterilizable varnish is characterized by its heat resistance, and therefore, it is preferred to implement hot crimping so that the ends of the stranded wires are in contact with the sleeve. Alternatively, the contact of the sleeve with the ends of the stranded wires can also be achieved with the aid of a tin bath. The time for which the sleeve and the ends of the stranded wires are exposed to the tin bath together must be correspondingly extended compared to the case where a non-sterilizable varnish is used. As an alternative or supplement, the tin bath can be heated to a higher temperature. The temperature of the tin bath can, for example, exceed 300°C and be as high as 400°C.

[0034] According to another preferred embodiment of the litz wire winding according to the invention, the litz wire ends are arranged on a circumferential section of the litz wire winding of at most 180°, preferably on a circumferential section of at most 150°. The recesses of the first end side of the carrier plate are correspondingly also distributed on a circumferential section of at most 180°, preferably not more than 150°, and are arranged in such a way that when the litz wire winding is coaxially aligned with the carrier plate, it can be positioned by rotating the litz wire winding or the carrier plate, so that the litz wire ends can be introduced into the recesses by axially moving the litz wire winding or the carrier plate. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The method of the present invention will be described below with reference to the accompanying drawings.

[0036] in:

[0037] Figure 1 : Schematic diagram of the twisted wire winding and carrier board of the present invention.

[0038] Figure 2 : Figure 1 Schematic diagram of the ends of twisted wires in .

[0039] Figure 3a : Schematic diagram of the end of a twisted wire with a closed sleeve.

[0040] Figure 3b : Schematic diagram of the end of a twisted wire with a closed sleeve.

[0041] Figure 4 : Schematic diagram of the positioning of the sleeve blank relative to the end of the stranded wire.

[0042] Figure 5 : Schematic diagram of the orientation of the ends of the twisted wires.

[0043] Figure 6 : Schematic diagram of an alternative embodiment of a carrier board.

[0044] Figure 7 : Schematic diagram of the stranded wire winding and the carrier board after the method of the present invention has been implemented. DETAILED DESCRIPTION

[0045] For the following embodiments, the same components are marked with the same reference numerals. If a figure contains reference numerals which are not explained in detail in the corresponding figure description, reference is made to the preceding or following figure description.

[0046] Figure 1A first embodiment of a litz wire winding 1 with four litz wire ends 5 is schematically shown. The litz wire winding 1 has a hollow cylindrical shape and has a first axial end 3, a second axial end 4 opposite the first axial end 3, and an axis 7. An axial direction 18 and a radial direction 19 are defined for the litz wire winding 1. Figure 2 As shown, the litz wire end 5 comprises a plurality of individual wires 6 which are parallel to the axis 7 of the litz wire winding 1 and protrude beyond the second axial end 4. Furthermore, the litz wire ends 5 are distributed over a partial circumference of the litz wire winding 1, approximately over a quarter of the circumference of the litz wire winding 1 in this first embodiment. Figure 1 Also shown is a carrier plate 2, which comprises a first end side 8 facing the litz wire winding 1, a second end side 9 and side faces 10. The carrier plate 2 is circular and has a longitudinal axis 24. The four recesses 11 of the first end side 8 have a depth 15 and extend through to the second end side 9. The litz wire winding 1 and the carrier plate 2 are aligned coaxially with each other and are oriented from the longitudinal axis 24 to the longitudinal axis 24. Figure 1 It can be clearly seen that the strand ends 5 and the grooves 11 are also aligned with each other in the axial direction.

[0047] like Figure 2 As shown, the stranded wire end 5 includes a large number of single wires 6. Preferably, the stranded wire end 5 includes at least fifteen single wires 6. The stranded wire end 5 is in contact with the sleeve 12, wherein the sleeve 12 completely surrounds a portion of the stranded wire end 5. The sleeve 12 with a first width 13 can be implemented as a closed sleeve 12, see FIG. 3, wherein the sleeve 12 is then sleeved on the stranded wire end 5. Alternatively, the sleeve 12 can be implemented as a sleeve blank 22 before contact, see Figure 4 In the embodiment shown, the stranded wire end 5 protrudes beyond the sleeve 12 . However, the connection of the stranded wire end 5 to the sleeve 12 can also be implemented in such a way that the tip of the stranded wire end 5 ends inside the sleeve 12 .

[0048] The sleeve 12 is exposed on both sides in the axial direction, so that when the stranded wire end 5 is in electrical contact with the sleeve 12, the insulating varnish can be exposed from both sides of the sleeve. This enables the stranded wire end 5 to be in particularly good electrical contact with the sleeve 12. The closed sleeve 12 and the sleeve blank 22 that is transformed into the sleeve 12 are exposed on both sides in the axial direction, so that they each have two openings in the axial direction. As a result, when the stranded wire end 5 is in electrical contact with the sleeve 12, the insulating varnish or, for example, tin or other substances that reduce the electrical conductivity of the contact can be exposed from both sides of the sleeve 12 along the stranded wire end 5 in the axial direction. Since the substance is exposed from both sides of the sleeve 12, for example, insulating varnish bubbles that deteriorate the electrical contact between the stranded wire end 5 and the sleeve 12 will not be formed on the closed side of the sleeve 12. During the connection between the sleeve 12 and the stranded wire end 5, the sleeve 12 can be pressed to one side, which will only slightly affect the outflow of varnish during the connection between the stranded wire end 5 and the sleeve 12, and will not cause the generation of insulating varnish bubbles and poor contact between the stranded wire end 5 and the sleeve 12. The sleeve 12 can be a core wire end sleeve, and has a funnel on at least one side in the axial direction, which makes it easier for the stranded wire end 5 to be introduced into the sleeve 12. The sleeve 12 can also have funnels on both sides. Figure 2 The funnel shape of the sleeve is not shown.

[0049] Figure 3a and Figure 3b The sleeve 12 is shown in Figure 2 Section AA in FIG. The sleeve 12 is implemented as a closed sleeve and surrounds a plurality of single wires 6. The sleeve 12 is in contact with the stranded wire end 5, and the sleeve 12 has a first width 13 and a second width 14, which are orthogonal to the axis 7 of the hollow cylindrical winding and are at right angles to each other, wherein the first width 13 is approximately three times the length of the second width 14. It can be clearly seen that the sleeve has a flat shape. Figure 3a In the embodiment, the outer edges of the first width 13 and the second width 14 extend in a straight line. Figure 3a As shown, the outer edges may be at right angles to each other. Figure 3b As shown, the outer edge of the second width may also extend in a semicircular shape.

[0050] Figure 4 The following figure shows a section AA of an alternative embodiment. The sleeve 12 is implemented as a sleeve blank 22 before contacting. Figure 4 As shown in the above figure, the sleeve blank 22 can be implemented as a strip, for example. The strip is perpendicular to the strand end 5 along its length and moves toward the strand end 5, so that the strand end 5 and the strip are in contact with each other. Subsequently, the strip is bent inwardly, that is, toward the strand end 5, several times until the strip completely or almost completely surrounds the strand end 5. Figure 4The following figure shows a possible result of this bending process. The strip is bent four times so that two of the strip surfaces produced by the bending overlap. It is also possible to bend four times, in which the two overlapping surfaces only partially overlap. Alternatively, three bends are sufficient, in which case there is no overlap. Through the subsequent contact, a reliable electrical connection is established between the bent strip and the stranded wire end 5. Compared with the closed sleeve 12 and the slotted sleeve, it has the advantage that it is not necessary to guide the sleeve blank 22 to the sensitive top of the single wire 6 of the stranded wire end 5, thereby greatly reducing the risk of breakage and the resulting improper contact. The contact of the sleeve 12 with the stranded wire end 5 is preferably implemented by crimping. Alternatively, the sleeve 12 and the stranded wire end 5 can be immersed in a tin bath together to achieve contact.

[0051] Figure 5 Two alternative embodiments of the litz wire winding 1 according to the invention are shown. It can be clearly seen that the litz wire ends 5 are distributed approximately over one quarter of the circumference of the litz wire winding 1. Figure 5 As shown in the two figures in FIG. 1 , the orientation of the stranded wire end 5 can be varied. The orientation is generally defined by the orientation of the first and second widths 13, 14 of the sleeve 12 relative to the respective radial directions 19 of the stranded wire winding 1. The orientation and arrangement of the stranded wire end 5 and the sleeve 12 preferably matches the arrangement and orientation of the recess 11 of the carrier plate 2, see Figure 6 .

[0052] Figure 6 Two preferred embodiments of a carrier plate 2 for the method according to the invention are shown. Figure 6 The right figure of FIG. 1 shows the recess 11 implemented as a through hole. In a particularly preferred embodiment of the carrier plate 2, as Figure 6 As shown in the left figure of the embodiment, the notch 11 is exposed toward the side 10. Preferably, the edge of the notch 11 is rounded toward the side 10 to facilitate the insertion of the sleeve 12 into the notch 11 during installation. Independent of the embodiment of the notch 11, the notch 11 has a first width 16 and a second width 17.

[0053] Figure 7The carrier plate 2 is shown after the sleeve 12 has been introduced into the recess 11. Particularly preferably, the recess 11 is designed as an elongated hole 20 which is open toward the side surface 10 of the carrier plate 2, wherein the longitudinal axis 25 of the elongated hole 20 is oriented radially at an angle 23 to the center point 21 of the second end face 9, wherein this angle is 30°-60°, preferably 40°-50°. For the method according to the invention, the sleeve 12 is advantageously aligned with the position of the elongated hole 20 accordingly. For this purpose, the second width 14 of the sleeve 12 and the first width 16 of the recess 11 are matched to each other not only in size but also in orientation. For this purpose, the first width 13 of the sleeve 12 extends in the direction of the longitudinal axis 25 of the elongated hole 20, wherein the first width 13 of the sleeve 12 and the second width 17 of the elongated hole 20 are also matched to each other, so that the sleeve 12 can be inserted almost completely into the elongated hole.

[0054] According to a particularly preferred embodiment of the method of the present invention, the sleeve 12 and the long hole 20 are at the same height and adjacent to each other in the axial direction 18 of the litz wire winding, and the litz wire winding 1 and the carrier plate 2 are coaxially aligned with each other. The litz wire end 5 is slightly bent radially outward. Advantageously, the litz wire end 5 is long enough so that the slight bending of the litz wire end 5 does not cause the single wire 6 to break or even the litz wire end 5 to break. Subsequently, the sleeve 12 is moved radially inward to be inserted into the long hole 20. Preferably, the carrier plate 2 simultaneously performs a rotational movement relative to the litz wire winding 1. This has the advantage that the sleeve 12 is easier to insert into the long hole 20 during installation. Advantageously, the side surface of the sleeve 12 is rounded.

[0055] According to another preferred embodiment of the method, after the sleeve is introduced into the recess 11 of the carrier 2, the sleeve 12 is welded to make it contact with the carrier 2. The advantage of welding is that the electrical contact is extremely firm and no other clamping mechanism is required.

[0056] Reference numerals list

[0057] 1 winding / Litten wire winding

[0058] 2 Carrier board

[0059] 3First axial end

[0060] 4 Second axial end

[0061] 5 Twisted wire ends

[0062] 6 Single Line

[0063] 7 Winding axis

[0064] 8 First end side

[0065] 9 Second end side

[0066] 10 Side

[0067] 11 Notch

[0068] 12 Casing

[0069] 13 First width of casing

[0070] 14 Second width of casing

[0071] 15 Depth of notch

[0072] 16 The first width of the notch

[0073] 17 The second width of the notch

[0074] 18 Axial direction of the stranded wire winding

[0075] 19 Radial of the stranded wire winding

[0076] 20 Long holes

[0077] 21 Center point of circular end

[0078] 22 sets of tube blanks

[0079] 23 Angle

[0080] 24 The longitudinal axis of the carrier

[0081] 25 Longitudinal axis of the long hole

Claims

1. A method for contacting a winding (1) with a carrier (2), wherein the winding (1) has a first axial end (3) and an opposite second axial end (4), and wherein the winding (1) comprises at least two stranded wire ends (5) for electrical connection to the carrier (2), and wherein the stranded wire ends (5) protrude beyond the axial ends (3), (4) of the winding (1), are substantially parallel to the axis (7) of the winding (1), and are distributed at least over a part of the circumference of the winding (1), and wherein the carrier (2) has a first end side (8) facing the stranded wire ends (5) and a second end side (9) facing away from the stranded wire ends (5), as well as a side surface (10), and wherein the first end side (8) has a recess (11) for accommodating the stranded wire ends (5), the method comprising the following method steps: - bringing the strand end (5) together with the sleeve (12) so that the sleeve (12) at least partially surrounds the strand end (5) over at least a portion of its length, - bringing the stranded wire end (5) into electrical contact with the sleeve (12), - guiding the stranded wire end (5) equipped with the sleeve (12) into the recess (11) of the carrier plate (2), It is characterized in that The winding (1) is a twisted wire winding (1), the twisted wire end (5) has an insulated single wire (6), the insulating material includes a high-temperature resistant varnish, wherein after the twisted wire end (5) equipped with the sleeve (12) is introduced into the recess (11) of the carrier (2), the twisted wire end (5) is roughly parallel to the axis (7) of the winding (1), and the sleeve (12) and the carrier (2) are in electrical contact with each other.

2. The method according to claim 1, It is characterized in that The sleeve (12) is implemented as a closed sleeve (12), and in order to close the sleeve (12) and the stranded wire end (5), the sleeve (12) is put on the stranded wire end (5), and the stranded wire end (5) is completely surrounded in the radial direction over at least a part of its length range.

3. The method according to claim 1, It is characterized in that When closed with the stranded wire end (5), the sleeve (12) is implemented as a sleeve blank (22), which is deformed into the shape of the sleeve (12) so that the stranded wire end (5) is completely surrounded in the radial direction over at least a part of its length.

4. The method according to any one of claims 1 to 3, It is characterized in that The sleeve (12) is exposed on both sides in the axial direction, so that when the twisted wire end (5) is in electrical contact with the sleeve (12), the insulating varnish can be exposed from both sides.

5. The method according to any one of claims 1 to 4, It is characterized in that The sleeve (12) is brought into contact with the individual wires (6) of the stranded wire end (5) resting against the inner circumference by crimping, preferably by thermo-crimping.

6. The method according to claim 5, It is characterized in that To perform the thermocompression bonding, the region of the stranded wire end (5) surrounded by the sleeve (12) is heated to 500° C. to 900° C., preferably 750° C., thereby melting off the insulating varnish of the individual wires (6) of the stranded wire end (5).

7. The method according to any one of claims 1 to 6, It is characterized in that The sleeve (12) has a first width (13) and a second width (14), wherein the first and second widths (13), (14) are orthogonal to the longitudinal axis of the stranded wire end (5), and wherein after the sleeve (12) is in contact with the stranded wire end (5), the spatial extension of the first width (13) of the sleeve (12) is at least twice, preferably at least four times, the second width (14) of the sleeve (12).

8. The method according to any one of claims 1 to 7, It is characterized in that To make the contact, the stranded wire end (5) and the sleeve (12) are immersed in a tin bath for a period of time so that the insulating material of the stranded wire end (5) melts.

9. The method according to any one of claims 1 to 8, It is characterized in that The recess (11) of the first end side (8) of the carrier (2) has a depth (15), which extends from the first end side (8) in a direction perpendicular to the second end side (9), and the recess (11) has a first width (16) and a second width (17), wherein the first width (16) and the second width (17) are at right angles to each other, and wherein the sleeve (12) is in contact with the carrier (2) in such a way that at least one width (13), (14) of the sleeve (12) can be brought together with at least one width (16), (17) of the recess (11) of the first end side (8), thereby generating a gap of at least 0.1 mm, preferably at least 1 mm, further preferably at least 2 mm.

10. The method according to any one of claims 1 to 9, It is characterized in that The recess (11) on the first end side (8) of the carrier plate (2) extends through to the second end side (9) and the side surface (10), wherein the carrier plate (2) and the litz wire winding (1) are aligned with each other so that the axis (7) of the litz wire winding (1) is parallel to a longitudinal axis (24) of the carrier plate (2) which is orthogonal to the first end side (8) of the carrier plate (2), and wherein the carrier plate (2) and the litz wire winding (1) are matched to each other in the axial direction (18) such that the sleeve (12) can be introduced into the recess (11) by radially displacing the carrier plate (2) or by radially displacing the litz wire winding (1) or by radially displacing the sleeve (12).

11. The method according to claim 10, It is characterized in that The recess (11) is designed as an elongated hole (20) which is open toward the side surface (10) of the carrier plate (2), wherein the longitudinal axis (25) of the elongated hole (20) is oriented radially at an angle (23) to the center point (21) of the end face (8), (9), wherein the angle (23) is 30°-60°, preferably 40°-50°, and wherein the sleeve (12) is introduced into the elongated hole (20) of the carrier plate (2) by a radial displacement, and the displacement is superimposed on an additional rotational movement about the axis (7) of the litz wire winding (1) or about the center point (21) of the circular end face (8), (9).

12. The method according to any one of claims 1 to 11, It is characterized in that After the sleeve (12) is introduced into the recess (11) of the carrier plate (2), the sleeve (12) is welded to make it contact with the carrier plate (2).

13. A litz wire winding (1) produced according to the method according to any one of claims 1 to 12.

14. The litz wire winding (1) according to claim 13, It is characterized in that A stranded wire end (5) comprises at least five individual wires (6), preferably at least fifteen individual wires (6).

15. The litz wire winding (1) according to any one of claims 12 to 14, It is characterized in that The litz wire ends (5) are arranged on a circumferential section of the litz wire winding (1) of at most 180°, preferably at most 150°.

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