Method and device for producing laminated wave winding pad for traction into stator or rotor

Abstract

The invention relates to a method for producing a laminated wave winding mat (1) for pulling into a stator or a rotor, in which the wave winding mat (1) is made of at least one double layer (4) per phase and each double layer (4) is made of at least two separate layers (3). Each individual layer (3) has a substantially serpentine base structure and is formed with at least two winding heads (5). Each double layer (4) is made of continuous individual wires (2), and the individual layers (3) are connected together by a transition region (8). The invention is characterized in that each double layer (4) is laminated by bending the individual wires (2) about a bending axis in the transition region (8).

Description

Summary of the Invention

[0001] The present invention relates to a method and apparatus for producing laminated wave winding pads for drawing into a stator or rotor.

[0002] Different methods for producing wave winding pads are known in the prior art. Wave winding pads can be produced by continuously winding multiple individual wires around winding blades (as shown in, for example, EP 3381108 B1) and including multiple winding heads. It is also known to bend individual wires and then assemble them into a wave winding pad. This can be achieved by varying the number of wire layers per winding through braiding or by a stacking process, for example, as shown in JP 4973544 B2.

[0003] For example, as is known from DE 10 2020 103 165 A1, it may be advantageous to provide the wave winding pad in the form of reverse winding.

[0004] When using this type of wave-wound pad containing multiple individual layers, all the individual conductors of the phases need to be connected in series or parallel, or in series between phases. The connecting conductors must be connected in circumferential areas at the outer and inner diameters of the stator. This results in a large amount of contact work, as well as installation space and complex busbars. Therefore, the advantage of the aforementioned reverse winding is that it allows for series connections at one end of the pad.

[0005] Therefore, the object of the present invention is to provide a method and apparatus for producing laminated wave winding pads for drawing into a stator or rotor, which overcomes the above-mentioned disadvantages and simplifies the manufacturing process of wave winding pads for drawing into a stator or rotor.

[0006] This objective is achieved through the subject matter of the independent claims.

[0007] Advantageous embodiments and other improvements are the subject of the dependent claims, the accompanying description and drawings.

[0008] According to one aspect of the invention, a method is provided for producing laminated wave winding pads for drawing into a stator or rotor. The wave winding pad is formed from at least one double layer per phase of a motor in which the wave winding pad is used. Preferably, at least two double layers are provided. Each double layer is formed from at least two separate layers. However, it is also conceivable to laminate more than two separate layers to form a double layer. Each separate layer is formed with a generally meandering base structure and has at least two winding heads. Each double layer is formed from continuous separate conductors, and the separate layers are interconnected via transition regions. The separate conductors are bent to achieve a meandering form with typical winding heads. The advantage of doing so is that the separate layers can be bent without twisting the conductors, thus forming a flat base structure. The lamination of the double-layer structure is achieved by bending the separate conductors about a bending axis in the transition regions. By using laminated wave winding pads produced in this way, different shapes of winding heads can be achieved, which have vertical conductors instead of the commonly used winding. This makes the winding heads more compact than winding heads formed by winding. By using bending in the transition region to achieve double-layer stacking, a series connection of the forward and return conductor paths can be achieved here based on separate wires, without the need for further steps to secure the contact. This saves time and improves the operational reliability of the wave winding pad. During the bending process, the transition region transforms into another winding head, making the transition region no longer visible in the completed double-layer stack. By using double-layer stacking, the same winding structure as wave winding pads known in the prior art can be achieved, but with significant work savings. In this way, simple stacking of individual layers can be achieved without altering the layers.

[0009] According to one exemplary embodiment, the bending axis is configured to lie on the axis of rotation passing through the winding head. Individual layers can be formed continuously side-by-side and connected through a transition region. The advantage of this bending is that the winding head can be formed from the transition region (e.g., at three bending points) and individual layers can be stacked on top of another layer by its rotation without any twisting of the winding head. This allows for the production of uniformly shaped double layers.

[0010] According to one exemplary embodiment, the bending axis is positioned on the central axis between two mirror-image separate layers in the transition region. This bending axis divides the separate layers into windings with a 180° phase shift, lies in the same plane as the separate layers themselves, and is tangent to the meandering shape of the conductors in the winding head region. This greatly simplifies the method and makes it easy to implement without requiring much space.

[0011] According to one exemplary embodiment, the bending axis is positioned on the central axis between two consecutive adjacent individual layers. This bending axis corresponds to the normal to the winding plane. This ensures that wire twisting occurs only in the series-connected winding head region between the two individual layers, thus forming a double layer. This is retained when bending about the axis of rotation. Due to its manufacturing process, the remaining winding head has a flat base structure.

[0012] According to one exemplary embodiment, the wave winding pad is configured to include at least three double layers. The wave winding pad is preferably formed of six double layers, and particularly preferably of nine double layers. By stacking numerous double layers, larger geometries can be easily represented without providing many interconnections.

[0013] According to one exemplary embodiment, the arrangement is such that individual layers are fixed during stacking to form a double layer. For example, if two separate layers are provided, a single layer can be stacked on top of the fixed single layer, and this fixing ensures that the double layers are arranged precisely as planned, since slippage is impossible. It is also conceivable that both separate layers are fixed, and only the transition areas are free to move at bends.

[0014] According to one exemplary embodiment, a layer jumper is embossed in each winding head. Providing a layer jumper allows for additional geometry of the completed wave winding pad and allows for layer variations in individual layers. Since the winding head becomes very flat through a bending process, embossing is easily achieved without the risk of damage that could be detrimental to sub-regions already subjected to high torsional stress. When a layer jumper is provided, the two conductors along the winding are always in the same position relative to each other.

[0015] According to an exemplary embodiment, the winding geometry of the winding head formed by the transition region portion is configured to have a different geometry than that of the other winding heads. It is conceivable that only the winding head formed by the transition region portion has a different shape, meaning that only one winding head in the double layer has a different shape. However, it is also conceivable that multiple winding heads in the double layer have different geometries.

[0016] According to another aspect of the invention, an apparatus for producing stacked wave winding pads is provided. The wave winding pad is formed from a plurality of double layers, each double layer consisting of two separate layers. The apparatus includes at least one bending tool, on which separate layers can be formed. The bending tool has a forming element by which separate conductors can be formed into separate layers. As separate conductors are guided through the apparatus, they can be bent around the forming element, thereby producing the shape of separate layers. The forming element ensures that all stacked double layers have the same basic geometry, which is particularly important for ensuring perfect function of the wave winding pad in the stator or rotor. Each double layer can be formed by bending movement of the apparatus about a bending axis, consisting of two or more separate layers stacked together. It is advantageous if the apparatus has, for example, two sub-regions. Then, in a first step, separate layers can be formed in each sub-region, and in a further step, separate layers can be easily stacked on top of each other by bending movement about a bending axis, and another winding head can be formed by a transition region. By integrating the bending process for stacking double layers into the device (which also determines the shape of the individual layers), the required area is smaller than performing these two steps in separate devices.

[0017] Other features, details, and advantages of the invention will become apparent from the wording of the claims and from the following description of exemplary embodiments based on the accompanying drawings. Attached Figure Description

[0018] Figures 1a–1e illustrate exemplary embodiments of a method for producing laminated wave winding pads; Figures 2a–2d illustrate another exemplary embodiment of a method for producing laminated wave winding pads; Figures 3a–3d illustrate another exemplary embodiment of a method for producing laminated wave winding pads; Figures 4a and 4b illustrate another exemplary embodiment of a method for producing laminated wave winding pads; Figure 5a shows the winding head of a non-skipped lap wave winding pad; and Figure 5b shows the winding head of a stacked wave winding pad with embossed layer jump.

[0019] Figures 1a–1e illustrate schematic diagrams of a method for producing wave winding pads for drawing into a stator or rotor. Figure 1a shows a blank 6. This blank comprises two separate layers 3, which have been bent into their meandering shapes in a device, and each layer has multiple winding heads 5. The advantage of this type of bending of the individual conductors 2 is that the conductor twisting that typically occurs in the winding heads 5 during the winding process does not occur in the winding heads 5. The two separate layers 3 are made of individual conductors 2 and are interconnected via a transition region 8. Each separate layer provides one conductor end 7. These ends will later be used to connect the wave winding pads. Figure 1b shows a sub-section of the bending process. For this purpose, one separate layer 3 can be fixed in the device (not shown here), while the other separate layer 3 is rotated by a rotational movement. As can be seen from Figures 1c and 1d, bending takes place in the transition region 8, which slowly forms additional winding heads 5 as the bending process proceeds. The axis of rotation (which represents the bending axis) passes through the winding head 5, which is formed by the conductor in the transition region 8. Thus, the two separate layers 3 move closer to each other through a U-shaped rotational movement until they are on top of each other and form a double layer 4, as shown in Figure 1d. The conductor ends 7 are arranged together on one end side of the double layer 4, which subsequently simplifies the connection. Finally, Figure 1e shows the wave winding pad 1, which is produced by stacking multiple double layers 4. For this purpose, the double layers 4 can be unfolded and inserted into additional layers, so that the wave winding pad obtains its final geometry through their stacking. The advantage is that all double layers 4 already have the same basic geometry, and therefore all conductor ends 7 can be arranged on one end side.

[0020] Figures 2a–2d illustrate another exemplary embodiment of a method for producing wave-wound pads. Furthermore, an apparatus 10 for producing wave-wound pads is shown. Apparatus 10 has two sub-regions 12a, 12b, on which a separate layer 3 has been formed. To ensure a consistent shape throughout the manufacturing process, a forming element 11 is used to bend the individual conductors 2 around them. The forming element 11 can also be used to fix the individual layers 3. In the manufacturing process shown here, one winding head has a different geometry than the other winding heads in the bending region. A wider winding head has been produced, in which a transition region 8 between the individual layers 3 is partially located. Sub-regions 12a, 12b can be moved toward each other to produce a double layer, and apparatus 10 can be folded together. The bending movement for stacking is along a bending axis on the central axis between two consecutive adjacent individual layers 3. Conductor twisting occurs in the winding head 5' located in the transition region 8. The remaining winding heads 5 do not have this feature. Therefore, the double layer produced in this way only exhibits conductor twisting in the region where the layers are connected in series. The independent winding head geometry of the winding head 5' shown here (formed in the transition region 8 between separate layers 3) allows for intentional alteration of the torsion. However, it is also conceivable that this variation can be implemented without changing the winding head geometry, or with other modifications to, for example, another winding head 5.

[0021] Figures 3a–3d illustrate another exemplary embodiment of the method and apparatus 10 for producing wave winding pads. Here, bending occurs along a bending axis that passes through a point of rotation in the winding head 5 to bend from the transition region 8. After the bending process, a double layer 4 consisting of two separate layers 3 has been uniformly formed in the winding head 5 throughout the process. An advantage of this method is that there is no wire twisting in any of the winding heads 5. The separate layers 3 are formed from separate wires 2 using forming elements 11 on sub-regions 12a, 12b and are interconnected via the transition region 8. The method shown in Figures 3a–3d is particularly gentle on the individual wires 2. Because the multiple bending points in the transition region 8 can be adjusted, there is less local stress on the individual wires 2 compared to methods that bend only at one point for stacking the double layers 4. This method is also more flexible in its implementation and can achieve a uniformly formed double layer 4 with the same geometry in all winding heads 5.

[0022] Figures 4a and 4b illustrate another exemplary embodiment of the method and apparatus 10 for producing wave winding pads. First, two separate layers 3 are formed in opposite, mirror-image positions in the apparatus 10. A transition region 8 connects the two separate layers 3 and bends them into another winding head 5 during this process. Two sub-regions 12a, 12b can be folded on top of each other, with the separate layers 3 stacked on top of each other by the bending of the winding head 5 created by the transition region 8. The bending axis lies on the central axis between the two mirror-image separate layers 3. In this embodiment, wire twisting is also found only in this one winding head 5. The method shown here represents a particularly easy-to-implement production process. Winding occurs in two stages within a plane in the apparatus 10. However, the bending points in the winding head 5 are always clearly defined, thus ensuring consistent winding results.

[0023] Figures 5a and 5b each show the winding head 5. In Figure 5b, the winding head 5 has a layer jumper 9, which has previously been imprinted into the simple winding head 5 shown in Figure 5a. By providing the layer jumper 9 in the winding head 5, layer variations of individual layers 3 are created after stacking, thereby expanding the possibilities for winding geometries for wave winding pads.

[0024] List of reference numerals 1-wave winding pad 2. Individual wires 3 separate layers 4 Double layer 5, 5' winding head 6. Blank 7. Wire end 8. Transition Zone 9-story jump 10 devices 11 Forming Components Subregions 12a and 12b

Claims

1. A method for producing a laminated wave winding pad (1) for drawing into a stator or rotor, wherein the wave winding pad (1) is formed of at least one double layer (4) per phase, wherein each double layer (4) is formed of at least two separate layers (3), wherein each separate layer (3) has a generally meandering basic structure and forms at least two winding heads (5), wherein each double layer (4) is formed of a continuous separate conductor (2), and the separate layers (3) are connected together by a transition region (8), characterized in that Each double layer (4) is stacked by bending the individual conductors (2) around the bending axis in the transition region (8).

2. The method according to claim 1, characterized in that... The bending axis is located on the rotation axis passing through the winding head (5).

3. The method according to claim 1, characterized in that... The bending axis is located on the central axis between two mirror-image separate layers (3) in the transition region (8).

4. The method according to claim 1, characterized in that... The bending axis is located on the central axis between two consecutive adjacent individual layers (3).

5. The method according to any one of claims 1 to 4, characterized in that... The wave winding pad (1) comprises at least three double layers (4).

6. The method according to any one of claims 1 to 5, characterized in that... During the stacking process, one of the individual layers (3) is fixed to form the double layer (4).

7. The method according to any one of claims 1 to 6, characterized in that... Layer jumpers (12) are embossed in each winding head (5).

8. The method according to any one of claims 1 to 7, characterized in that... The winding geometry of the winding head (5') formed by the portion of the transition region (8) becomes a geometry different from the winding geometry of the other winding heads (5).

9. An apparatus (10) for producing a laminated wave winding pad (11) formed of a plurality of double layers (4), each of the plurality of double layers consisting of two separate layers (3), the apparatus comprising at least one bending tool, wherein the separate layers (3) can be formed on the bending tool, wherein the bending tool has a forming element (11) by which separate conductors (2) can be formed into the separate layers (3), characterized in that Each double layer (4) can be formed by bending movement of the device (10) about a bending axis.

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