Device for joining elongated part region of winding element of at least one winding of electric machine and use of such device

Abstract

The invention relates to a device (10) for joining elongated part regions (L1, L2) of a winding element of at least one winding of an electric machine, comprising a first tool part (12) having a conically designed groove (14) which tapers in an extension direction (16), and comprising a second tool part (18) having a main body part (20) and two clamping fingers (22, 24), the clamping fingers (22, 24) are spaced apart from each other in a spacing direction (26) extending perpendicular to the extension direction (16) and are held on the main body part (20) in a pivotal manner with respect to the main body part (20) about respective pivot axes (S1, S2) extending perpendicular to the extension direction (16) and perpendicular to the spacing direction (26), and are configured to clamp the elongated component regions (L1, L2) between the clamping fingers (22, 24). 24) in an extension direction (16) into the recess (14) so as to be pivotable towards each other.

Description

[0001] The present invention relates to a device for joining the elongate component regions of the winding elements of at least one winding of an electric machine. The present invention also relates to the use of such a device.

[0002] JP 2014-7794 A1, JP 2014-7795 A1 and JP 2014-183623 A disclose electric machines having corresponding windings, which have corresponding winding elements and are thus formed by the winding elements. In this case, the respective elongate component regions of the individual winding elements are welded to one another, thus connected to one another, thus joined to one another.

[0003] Furthermore, WO 2020 / 210855 A1 discloses a method for positioning a laser beam during the welding of electrical conductors of electrical components.

[0004] The object of the present invention is to provide a device and the use of such a device such that the elongate component regions of the winding elements of at least one winding of an electric machine can be joined to one another particularly advantageously.

[0005] This object is achieved by a device having the features of claim 1 and a use having the features of claim 5. Advantageous designs with suitable refinements of the present invention are given in the remaining claims.

[0006] A first aspect of the present invention relates to a device for joining the elongate component regions of the winding elements of at least one winding of an electric machine, in particular pin-shaped elongate component regions. The elongate component regions are, for example, pin-shaped and thus pin-like, and this feature is to be understood in particular as meaning that the respective elongate component regions extend in an elongate manner along their respective longitudinal extension directions and are thus, for example, linear and thread-like, and in this case in particular straight. The respective elongate component regions are part of the respective components of the respective winding elements. In particular, the elongate component regions themselves can be understood as the respective components that are joined to one another and thus welded to one another. In particular, the components or winding elements are constructed separately from one another, where the components or winding elements are joined to one another. For example, the components or winding elements are welded to one another, thus connected to one another, in particular by laser beam welding.

[0007] In particular, the winding elements are plug-in coils, in particular having a corresponding U-shaped geometry, where the plug-in coils are also referred to as hairpins. In this case, according to the so-called hairpin technology, at least one winding is constructed from plug-in coils and thus assembled together. For example, the respective elongate component regions are the respective branches of the corresponding U-shaped geometry.

[0008] In order to be able to precisely align elongated component regions with each other in a particularly simple and process-reliable manner and to be able to fix them permanently relative to each other, and in particular to fix them to each other such that the elongated component regions are joined to each other in a particularly advantageous and process-reliable manner, for example by welding, in particular by laser beam welding, and are thus connected to each other, a device which is also called a tool and which is configured, for example, as a clamping tool or a gripping tool or as a device which serves as a clamping tool or a gripping tool has a first tool part, which is also called a first tool half. The first tool part has a groove which is formed, in particular, conically on the inner circumference and thus tapers in the extension direction. The device also has a second tool part, which is also called a second tool half. The second tool part has a body part and two clamping fingers, which are also called gripping fingers or clamping pins and which project, for example, from the body part in the extension direction. The clamping fingers are spaced apart from each other in an interval direction which extends perpendicular to the extension direction. The respective clamping finger is pivotally held on the body part relative to the body part about a respective pivot axis, where the pivot axes are spaced apart from each other in the interval direction. The respective pivot axis extends perpendicular to the extension direction and perpendicular to the interval direction. In other words, for example, the extension direction and the interval direction span an extension plane, where the respective pivot axis extends perpendicular to the extension plane. The clamping fingers can be moved into the groove, in particular because the second tool part is moved relative to the first tool part in the extension direction, in particular translationally. By moving the clamping fingers into the groove, in particular in the extension direction, the clamping fingers can pivot relative to the body part about the pivot axis such that the clamping fingers can pivot relative to each other. As a result, elongated component regions which are arranged or can be arranged, in particular, between the clamping fingers and which are arranged or can be arranged continuously, in particular, in the interval direction are clamped between the clamping fingers and are pressed against each other, in particular, and are then fixed relative to each other. Furthermore, since the clamping fingers pivot towards each other while the elongated component regions are arranged, in particular, between the clamping fingers in the interval direction, the elongated component regions move relative to each other, in particular, approaching each other during the process, for example when the elongated component regions are initially offset relative to each other, and the elongated component regions are thus brought into a favorable joining position in which the elongated component regions are held by the clamping fingers, in particular by clamping the elongated component regions. In the joining position, the elongated component regions have a favorable position, orientation or alignment relative to each other such that the elongated component regions can subsequently be joined to each other in a process-reliable manner, in particular by welding to each other, and thus joined to each other. In particular, for example, by joining the elongated component regions to each other, the elongated component regions are also conductively connected to each other such that the present invention enables precise, process-reliable, rapid and cost-effective mechanical and electrical connection of the elongated component regions to each other.

[0009] The first tool part is designed, for example, as a C-shaped stirrup, in particular a solid C-shaped stirrup, and pivotable, i.e., rotatable, clamping fingers can be moved into the groove of the C-shaped stirrup. Since the clamping fingers are rotatable relative to the body part about a pivot axis, the clamping pins are movable. By a corresponding displacement movement of the tool part, the clamping pins are moved into the groove, and the clamping pins (clamping fingers) move together, i.e., pivot towards each other. As a result, for example, the clamping fingers receive the area of the elongate part to be joined and are in particular aligned relative to each other and fixed to each other during the process. For example, due to the conical shape of the clamping fingers, the clamping fingers slide or rotate together with the progressive displacement movement along the C-shaped stirrup, such that they bring the area of the elongate part to its joining position, also referred to as the end position, and permanently fix the area of the elongate part in the joining position, in particular with no or as small a gap as possible between the areas of the elongate parts and with no or as small a twist as possible of the areas of the elongate parts. In particular, it is conceivable that the tool part and the clamping fingers are coordinated with each other in terms of their angles in order to achieve a favorable clamping function within the framework of which the areas of the elongate parts can be clamped particularly favorably by means of the device, i.e., tensioned and precisely positioned relative to each other and fixed relative to each other, in particular fixed to each other. The tool part can be mechanically fixed, for example, by means of at least one or more shafts, by means of at least one or more electric motors and / or by means of at least one or more other devices and is thus in particular fixed relative to each other in order to be able to advantageously fix the areas of the elongate parts relative to each other during the joining of the areas of the elongate parts. In addition, for example, the device can be used as a single-cavity mold or a multi-cavity mold.

[0010] The present invention is particularly based on the following findings and considerations: According to the current state of the art, plug-in coils for electric machines, in particular for electric motors, also referred to as hairpins, are joined to each other by laser beam welding. For this purpose, it is advantageous to precisely position the plug-in coils, in particular the elongate part areas of the plug-in coils, relative to each other, such that defective welded joints due to possible gaps, possible distortions, etc. can be avoided. Regarding the design of electric machines, among other things, they can be divided into radial flux machines and axial flux machines. In particular, due to the limited installation space, the design of axial flux machines means that the accessibility of the clamping tool for fixing relative to each other during the joining of the elongate part areas is very limited. The device according to the present invention now makes it possible to fix the elongate part areas when they are joined, in particular relative to each other, even when there is only limited or narrow accessibility of the elongate part areas.

[0011] The second aspect of the present invention relates to the use of the device according to the first aspect of the present invention, wherein the device is used to join the winding elements of at least one winding of an electric machine, in particular the regions of the elongated parts configured as plug-in coils, to each other. In particular, the regions of the elongated parts are fixed relative to each other, in particular fixed to each other, while the regions of the elongated parts are joined to each other, in particular welded to each other, so as to be joined to each other. The advantages and advantageous design solutions of the first aspect of the present invention should be regarded as the advantages and advantageous design solutions of the second aspect of the present invention, and vice versa.

[0012] The clamping fingers are arranged in the groove, for example, in such a way that the clamping fingers push the tool parts, which are also called claws or configured as claws, towards each other and thus push them together. By moving the clamping fingers into the groove, the clamping fingers pivot towards each other, and the clamping fingers exert a clamping force on the regions of the elongated parts arranged between the clamping fingers and following each other along the spacing direction, and this clamping force extends along the spacing direction and thus orthogonally to the extending direction. It is also conceivable that by pushing the tool parts together, the regions of the elongated parts are clamped between or supported on the tool parts along the clamping direction coinciding with the extending direction, so that the regions of the elongated parts are clamped between the tool parts not only along the spacing direction but also along the clamping direction, so as to be precisely and firmly fixed relative to each other or fixed to each other. If, for example, the regions of the elongated parts configured as webs are initially positioned or not positioned relative to each other such that the regions of the elongated parts are initially offset relative to each other, then due to the arrangement of the regions of the elongated parts between the clamping fingers and in the groove, by pushing the tool parts together, the regions of the elongated parts move relative to each other, and thus advantageously and precisely align relative to each other, so that the regions of the elongated parts move to the joining position. With the aid of the tool parts, the regions of the elongated parts are held in the joining position, in particular the regions of the elongated parts will be joined to each other. In particular, the tool according to the present invention enables the regions of the elongated parts to be moved and positioned along the spacing direction and the clamping direction, wherein the spacing direction and the clamping direction are perpendicular to each other. Therefore, the regions of the elongated parts can be firmly connected to each other, for example, by laser welding, so as to be joined to each other. In this case, simple laser welding can also be achieved through the good positioning of the regions of the elongated parts, in particular the free ends of the regions of the elongated parts, relative to each other, so as to be able to perform welding in a process-reliable and operation-reliable manner.

[0013] The corresponding regions of the elongated parts have, for example, at least substantially rectangular cross-sections, wherein, for example, the regions of the elongated parts or their cross-sections are parallel to each other in the joining position. Therefore, for example, the regions of the elongated parts clamped between the tool parts, in particular the cross-sections, form an overall rectangular shape.

[0014] Preferably, the clamping fingers, also referred to as arms or clamping arms, especially on the outer or outer circumferential side, are conical, such that they have the shape of a cone or frustum of a cone with a first angle on the outer or outer circumferential side, the first angle corresponding, for example, to the second angle of the conical groove and thus being equal to the second angle. As a result, when the clamping fingers and thus the elongate component region are compressed together and thus when the clamping fingers interact with the elongate component region, at least a substantially rectangular shape is produced in the device, such that the inner side of the clamping fingers abuts flatly against the outer side of the elongate component region, wherein the respective inner side and the respective outer side are located, for example, in a plane extending parallel to the direction of extension.

[0015] In an embodiment, especially in the region of an electric machine or an elongate component, especially at its end, a device configured as or serving as a clamping device can interact directly laterally or via angled clamping jaws with the elongate component region, the direction of the force always occurring, for example, transversely to the end of the elongate component region. Thus, the elongate component region can be clamped even in cases where the welding point cannot be accessed from the side.

[0016] In the state where the clamping fingers pivot relative to each other, for example, a restoring force acts on the clamping fingers, which is especially a restoring spring force provided, for example, by a restoring spring. Then, for example, if the tool parts are pushed apart, i.e., away from each other, the clamping fingers pivot away from each other, for example, by means of the restoring force, thus opening. As a result, for example, the clamping fingers rotate to the starting position from which they pivot again towards each other when they move into the groove. Thus, the device can be used simply, quickly, and cost-effectively for repeatedly and continuously clamping the corresponding elongate component region.

[0017] In particular, the present invention can achieve at least the following advantages:

[0018] - Especially suitable for laser beam welding of plug-in coils (hairpins) for axial flux machines

[0019] - Very good and precise feeding of the elongate component region to be joined, thus having favorable welding conditions

[0020] - Reduction of component scrap

[0021] - Can compensate for lateral offset and rotation of the elongate component region

[0022] - Only requires little accessibility

[0023] - New design possibilities

[0024] - Can be flexibly applied to axial flux machines and radial flux machines

[0025] - Especially suitable for small batch welding joints

[0026] - It can fix two or more slender component regions or insert coils

[0027] Further advantages, features, and details of the present invention are given in the following description of the preferred embodiments and with reference to the drawings. Without departing from the scope of the present invention, the above-mentioned features and combinations of features mentioned in the specification, as well as the features and combinations of features mentioned in the description of the drawings and / or shown individually in the drawings, can be used not only in their respective combinations but also in other combinations or individually.

[0028] In the drawings:

[0029] Figure 1 A schematic plan view of a device for engaging a slender component region of a winding element for at least one winding of an electric machine is shown;

[0030] Figure 2 Another schematic plan view of the device is shown; and

[0031] Figure 3 A schematic side view of the device is shown.

[0032] In the figures, identical or functionally identical elements have the same reference numerals.

[0033] Figure 1 A device 10 for engaging slender component regions L1 and L2 of a winding element for at least one winding of an electric machine is shown in a schematic plan view. The device 10 is also referred to as a tool and is, for example, configured or used as a clamping tool or a chuck. The corresponding winding element is, for example, an insert coil, also referred to as a hairpin. The at least one winding of the electric machine is, for example, constructed and formed from insert coils (hairpins) according to the so-called hairpin technology. In this case, for example, the slender component region L1 is the slender component region of the first winding element, and the slender component region L2 is the slender component region of the second winding element. The first winding element and the second winding element are constructed separately from each other, wherein the slender component regions L1 and L2 and thus the first winding element and the second winding element are joined to each other, i.e., connected to each other. For example, the slender component regions L1 and L2 are welded to each other so as to be mechanically and electrically connected to each other. The welding of the slender component regions L1 and L2 is, for example, achieved by laser welding, i.e., laser beam welding. As will be explained in more detail below, the device 10 is used to engage the slender component regions L1 and L2, in particular during the engagement of the slender component regions L1 and L2, in order to fix the slender component regions L1 and L2 relative to each other, and thus in particular to fix them to each other.

[0034] From Figure 1It can be seen that the respective free ends of the elongate component regions L1 and L2, denoted by E, are initially offset relative to each other. As explained in more detail below, the elongate component regions L1 and L2 are positioned relative to each other by means of the device 10, i.e., aligned relative to each other. For this purpose, the elongate component regions L1 and L2, in particular their free ends E, are moved relative to each other by means of the device 10, and thus moved to Figure 2 the engagement position F shown. The elongate component regions L1 and L2 occupy the engagement position F when connected to each other, wherein the elongate component regions L1 and L2 are held in the engagement position F by means of a tool (device 10).

[0035] The device 10 has a first tool part 12, which has a groove 14. The groove 14 is conical on the inside, i.e., on the inner circumferential side, such that the groove 14 tapers in the Figure 1 direction of extension shown by the arrow 16.

[0036] The device 10 has a second tool part 18, which has a body part 20 and two clamping fingers 22 and 24. The clamping fingers 22, 24 are also referred to as arms, clamping arms or clamping pins. The respective clamping fingers 22, 24 are pivotally held on the body part 20 relative to the body part 20 about respective pivot axes S1, S2. It can be seen that the clamping fingers 22 and 24 are spaced apart from each other along the spacing direction shown by the double arrow 26, and the pivot axes S1 and S2 are spaced apart from each other along the spacing direction. In Figure 1 it, the double arrow 28 shows the clamping direction, also referred to as the fixing direction, which coincides with the direction of extension. The respective outer stops 30, 32 adjoin the respective clamping fingers 22, 24 along the spacing direction, which will be explained in more detail below. In addition, in the figure, the spatial directions extending perpendicular to each other in pairs are denoted by x, y and z.

[0037] In the embodiment shown in the figure, the first tool part 12, also referred to as the first tool half, is configured as a solid C-shaped stirrup. From Figure 1 and Figure 2It can be seen that the elongate component regions L1 and L2 are arranged, for example, in the recess 14. The elongate component regions L1 and L2 are also arranged between the clamping fingers 22 and 24, in particular in such a way that the elongate component regions L1 and L2 are arranged between the clamping fingers 22, 24 along the spacing direction and are arranged continuously along the spacing direction. In particular, the tool parts 12 and 18 move towards each other along the clamping direction, in particular are pushed together, such that the clamping fingers 22 and 24 move into the recess 14 in the extension direction. In the process, the respective outer faces 34 and 36 of the clamping fingers 22 and 24 that face away from each other along the spacing direction slide on the respective inner faces 38 and 40 of the tool part 12, in particular slide directly, the inner faces 38 and 40 being spaced apart from each other along the spacing direction and in particular directly defining the recess 14. The respective inner faces 38, 40 extend in respective inner face planes that extend parallel to the respective rotational axes S1, S2 and are inclined with respect to the spacing direction and with respect to the extension direction and thus with respect to the clamping direction. Furthermore, when viewed in the extension direction, the inner face planes extend towards each other.

[0038] Figure 1 The clamping fingers 22 and 24 are shown in their respective starting positions of the clamping fingers 22 and 24. In the starting position, the outer faces 34 and 36 are supported on the stops 30 and 32. The respective clamping fingers 22, 24 also have a conical design, in which case the respective clamping fingers 22, 24 have respective outer faces 34, 36 and respective other inner faces 42, 44. The respective outer faces 34, 36 and the respective inner faces 42, 44 of the respective clamping fingers 22, 24 form respective faces, where the respective outer faces 34, 36 and the respective inner faces 42, 44 of the respective faces are also referred to as surfaces. It can be seen that the surfaces of the faces extend in respective surface planes such that the respective outer faces 34, 36 extend into respective first surface planes and the respective inner faces 42, 44 extend into respective second surface planes. The surface planes of the respective faces extend parallel to the respective rotational axes S1 and S2 and are inclined with respect to the extension direction and with respect to the clamping direction such that the respective surface planes of the respective faces extend towards each other in the extension direction. In this case, for example, the inner face plane forms a first angle with the extension direction or the clamping direction, and in the starting position, for example, the respective second surface plane forms a second angle with the extension direction, where the first angle and the second angle are preferably equal, and where the second angle thus corresponds to the first angle.

[0039] From Figure 2It can be seen that by pushing the tool parts 12 and 18 together and the resulting movement of the clamping fingers 22, 24 in the recess 14, the outer surfaces 34 and 36 are in supporting contact with the inner surfaces 38 and 40, and the inner surfaces 42 and 44 are in direct supporting contact with the respective other outer surfaces 46 and 48 of the elongate member regions L1 and L2. Thus, Figure 2 a state is shown in which the outer surfaces 34, 36 are in particular in direct abutment against the inner surfaces 38 and 40 and the inner surfaces 42 and 44 are in particular in direct abutment against the outer surfaces 46 and 48. In this state, the clamping fingers 22 and 24 are in a clamping position different from the initial position. In the clamping position, the second surface planes are parallel to each other and extend parallel to the extension direction and thus parallel to the clamping direction. The first surface planes are inclined relative to each other, and inclined relative to the extension direction, and inclined relative to the clamping direction, and are parallel to the respective pivot axes S1 and S2, such that the second surface planes extend towards each other in the extension direction, and so do the inner surface planes. From Figure 2 it can be seen that in Figure 2 the state shown, the outer surfaces 34 and 36 are in direct abutment against the inner surfaces 38 and 40, which directly define the recess 14 along the spacing direction and are spaced apart from each other along the spacing direction. The respective second surface planes and thus the respective outer surfaces 34, 36 enclose a respective first angle α with a plane (also referred to as the extension plane) that extends parallel to the extension direction and thus parallel to the clamping direction, and the respective inner surface planes and thus the respective inner surfaces 38, 40 enclose a respective second angle δ with the extension plane, where the angle α corresponds to the angle δ. For example, the angle α is the above-mentioned first angle, and for example, the angle δ is the above-mentioned second angle. Furthermore, for example, in Figure 2 the state shown, the elongate member regions L1 and L2 are supported along the clamping direction, in particular directly supported on the tool parts 12 and 18, such that in this state, the elongate member regions L1 and L2 are clamped not only along the spacing direction (double arrow 26) but also along the clamping direction (double arrow 28) that extends perpendicular to the spacing direction between and by means of the tool parts 12 and 18, so as to be fixed relative to each other. In this state, the elongate member regions L1 and L2 occupy the engagement position F, in which the elongate member regions L1 and L2 are engaged with each other, in particular welded to each other.

[0040] The respective clamping fingers 22, 24 can be assigned return springs, which are clamped when the clamping fingers 22, 24 pivot towards each other from the initial position and subsequently provide a restoring force in the form of an elastic force by means of which, for example, when the tool parts 12 and 18 move away from each other, the respective clamping fingers 22, 24 pivot backwards relative to the body part 20, in particular until the respective clamping fingers 22, 24 come into contact support with the respective associated stops 30, 32.

[0041] Figure 3 shows the device 10 and the elongate component regions L1 and L2 in the Figure 2 shown state. When the elongate component regions L1 and L2 are in the engagement position F, welding is performed, in particular in the form of laser welding, by means of which the elongate component regions L1 and L2 are connected to each other mechanically and electrically, in particular. In this case, in particular, the free ends E of the elongate component regions L1 and L2 are melted and welded to each other in the Figure 3 shown as the melt S.

[0042] List of Reference Signs

[0043] 10 Device

[0044] 12 First tool part

[0045] 14 Groove

[0046] 16 Arrow

[0047] 18 Second tool part

[0048] 20 Body part

[0049] 22 Clamping finger

[0050] 24 Clamping finger

[0051] 26 Double arrow

[0052] 28 Double arrow

[0053] 30 Stop

[0054] 32 Stop

[0055] 34 Outer surface

[0056] 36 Outer surface

[0057] 38 Inner surface

[0058] 40 Inner surface

[0059] 42 Other inner surface

[0060] 44 Other inner surface

[0061] 46 Other outer surface

[0062] 48 Other outer surface

[0063] E End

[0064] F Engagement position

[0065] L1 Elongate component region

[0066] L2 Elongate component region

[0067] S melt

[0068] S1 pivot axis

[0069] S2 pivot axis

[0070] x spatial direction

[0071] y spatial direction

[0072] z spatial direction

[0073] α angle

[0074] δ angle

Claims

1. An apparatus (10) for joining elongate component regions (L1, L2) of a winding element of at least one winding of an electric machine, comprising a first tool part (12) having a conical configuration and thus a groove (14) that tapers in an extension direction (16), and comprising a second tool part (18) having a body part (20) and two clamping fingers (22, 24) that are spaced apart from each other along a spacing direction (26) extending perpendicular to the extension direction (16), and are pivotally held on the body part (20) relative to the body part (20) about respective pivot axes (S1, S2) extending perpendicular to the extension direction (16) and perpendicular to the spacing direction (26), and in order to clamp the elongate component regions (L1, L2) between the clamping fingers (22, 24), the clamping fingers are movable into the groove (14) in the extension direction (16) and are thus pivotable towards each other.

2. The apparatus according to claim 1, characterized in that in a state where outer faces (34, 36) of the clamping fingers (22, 24) directly adjoin inner faces (38, 40) of the first tool part (12), the inner faces define the groove (14) and are spaced apart from each other along the spacing direction (26), respective outer faces (34, 36) enclose a respective first angle (α) with a plane extending parallel to the extension direction (16) and parallel to the respective rotation axes (S1, S2), and respective inner faces (38, 40) enclose a respective second angle (δ) corresponding to the first angle (α) with the plane.

3. The apparatus (10) according to claim 1 or 2, characterized in that a drive is provided, by means of which the clamping fingers (22, 24) are movable into the groove (14).

4. The apparatus (10) according to any one of the preceding claims, characterized in that a fixing device is provided, by means of which the tool parts (12, 18) are fixable relative to each other.

5. Use of an apparatus (10) according to any one of the preceding claims, wherein the apparatus (10) is used for joining elongate component regions (L1, L2) of a winding element of at least one winding of an electric machine to each other.

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