Hairpin stator manufacturing method including stacking, testing, and welding

Abstract

A process for manufacturing an assembly (200) of a hairpin-shaped conductor component. In this process, after the hairpin conductor assembly is inserted into a slot in a stator (300) and the conductor ends (102, 104) of the hairpin conductor are twisted to form second winding ends, a quality control unit comprising a detection plate (501) having multiple openings (502) tests whether the spatial arrangement A of the conductor ends (102, 104) satisfies a desired spatial arrangement B. The test includes the following steps: moving the assembly along with its conductor ends (102, 104) toward the openings (502) of the detection plate with the aim of inserting the conductor ends (102, 104) into the openings (502) of the detection plate. In the event of failure, the detection plate (501) is pushed downward in the control unit.

Description

Technical Field

[0001] The present invention relates to a process for producing an assembly of shaped lead wires having a hairpin shape, more preferably to a process for producing an electric motor stator with a hairpin structure, a quality control unit, and the use of such a quality control unit in the process for producing an assembly of shaped lead wires. Background Technology

[0002] Hairpin-type motor stators are now commonly found in drive motors, especially in the automotive industry. Using this manufacturing technique, a profile (usually rectangular) is first bent into a U-shape, also known as a conductor clip or "hairpin." Then, the legs of this hairpin are arranged in a circle and inserted into slots in the laminated stator core. In the next step, on the rear side of the stator, the free ends of the legs are concentrically twisted around the stator axis at a certain angle. All free ends on a certain diameter (i.e., one layer of winding) are alternately twisted clockwise and counterclockwise. This process is also called "twisting." The free ends adjacent to each other due to the twisting are welded together, and depending on the winding scheme, so-called interconnecting bridges are placed on the winding ends and welded to the free ends to connect the conductor clips into a single winding. The free ends are then arbitrarily insulated, and the entire stator is impregnated. This technique allows for a high degree of automation and achieves a high copper fill factor, i.e., a high ratio of conductor coverage area to slot area. Due to its rectangular cross-section and fewer turns, the hairpin stator has a fill factor of approximately 73%, which is significantly higher than that of conventional winding methods (45-50%, depending on insulation thickness). Therefore, the hairpin stator is particularly suitable for the manufacture of motors in the automotive industry, especially for drive units.

[0003] In the above process, the welding of the free ends of the hairpins is typically accomplished using laser welding. A laser beam is used to at least partially melt the copper wires at the ends of adjacent legs of the hairpin. In this process, it is particularly important that each pair of adjacent ends to be welded together is positioned close to each other. To ensure this correct positioning during welding, for example, each pair of free ends of the hairpins is inserted into a support element in the form of a perforated plate, or clamped in a retaining system that also forms openings that enclose these pairs of free ends in a way that matches the spatial arrangement of the openings to the arrangement of the hairpin end pairs required by the desired winding geometry.

[0004] Before welding, it has proven advantageous to first check whether all ends of the hairpin actually have the desired geometry required for a successful welding process (e.g., whether all hairpin end pairs to be welded together are placed adjacent to each other with sufficient precision). Summary of the Invention

[0005] Purpose The present invention aims to overcome the shortcomings of the prior art in manufacturing shaped lead wires, especially shaped lead wires with a hairpin shape.

[0006] In particular, the present invention is based on a process for fabricating assemblies of shaped conductors, preferably for fabricating stators with hairpin structures, in which, prior to the welding process, it is possible to check in a simple and reliable manner whether all hairpin ends to be welded together are arranged relative to each other in the desired spatial arrangement. A further object of the present invention is to provide a quality control unit by means of which it is possible to check in a simple and reliable manner whether all hairpin ends to be welded are arranged relative to each other in the desired spatial arrangement.

[0007] Preferred embodiments of the present invention The independent claims contribute to at least partially solving at least one, and preferably more than one, of the above-described objectives. The dependent claims provide preferred embodiments that contribute to at least partially solving at least one of the stated objectives.

[0008] |1a| A first embodiment of process 1 for preparing a shaped wire component assembly according to the present invention contributes to solving at least one object of the present invention, said process comprising the following process steps: d. Arrange the shaped wires of the plurality of shaped wires relative to each other to obtain a shaped wire assembly, wherein the arrangement is achieved in such a way that the legs of the shaped wires of the plurality of shaped wires are oriented substantially in the same direction; e. The assembly is introduced into a stator comprising multiple slots, each slot having a first end and a second end, by introducing the legs of the shaped conductor into the first end of a slot in the stator. - The end of each leg extends from the stator at the second end of the slot. - Wherein, after the support leg is introduced into the groove, the end is twisted such that the end of one given shaped guide is positioned adjacent to the end of another shaped guide, thereby forming multiple such pairs of adjacent ends. - The end of the twisted shaped wire is spatially arranged A at the second end of the groove; f. By means of retaining the end pair of the twisted shaped wire in the clamping assembly of the system, wherein the retaining system includes clamping elements forming an opening in which the end pair is surrounded; or The end of the twisted shaped wire is introduced into the opening of the support element; g. Within each end pair of shaped conductors, an electrical contact is provided between the first or second end of a given shaped conductor and the first or second end of another shaped conductor; After process step e and before process step f, it is confirmed that the spatial arrangement A of the end of the twisted forming wire at the second end of the groove satisfies the desired spatial arrangement B. This confirmation is accomplished by means of a quality control unit, which includes a detection plate having a plurality of openings arranged opposite each other in the desired spatial arrangement B. The confirmation includes the step of moving the end of the forming wire toward the opening of the detection plate of the quality control unit in order to insert the end into the opening of the detection plate.

[0009] |2a| According to a preferred embodiment of process 1, the detection plate is mounted on a movable platform, wherein the movable platform is adapted and arranged to move in a direction parallel to the end of the forming guide wire toward the opening of the detection plate of the quality control unit, wherein the platform moves a distance X in this direction, the magnitude of which depends on the similarity between arrangement A and arrangement B. This preferred embodiment is a second embodiment of process 1 according to the invention, which preferably depends on the first embodiment.

[0010] |3a|According to another preferred embodiment of process 1 - If X is lower than the value Xmax, then arrangement A and arrangement B are considered sufficiently similar, and process step f is then performed. After that, steps f and g are preferably performed. - If X is higher than the value Xmax, then arrangement A and arrangement B are considered not sufficiently similar, and process step f is not performed. Subsequently, it is preferable not to perform process steps f and g.

[0011] This preferred embodiment is a third embodiment of process 1 according to the present invention, which is preferably dependent on the second embodiment.

[0012] |4a| According to another preferred embodiment of process 1 - The openings of the wires and support elements or retaining systems have a rectangular cross-sectional shape; - The cross-sectional dimension of the opening of the support element or retaining system is greater than the total cross-sectional dimension of a given pair of ends of the torsion shaped conductor.

[0013] This preferred embodiment is the fourth embodiment of process 1 according to the present invention, which is preferably based on the first to third embodiments.

[0014] |5a| According to a further preferred embodiment of process 1, the cross-sectional dimension of the opening of the support element or retaining system is at least 5% larger than the total cross-sectional dimension of a given pair of ends of the twisted shaped wire, preferably at least 10% larger, and more preferably at least 25% larger. This preferred embodiment is a fifth embodiment of process 1 according to the invention, which preferably depends on the fourth embodiment.

[0015] |6a| According to a further preferred embodiment of process 1, the cross-sectional dimension of the opening of the detection plate is at least 5% smaller than the cross-sectional dimension of the opening in the support element or holding system, preferably at least 10% smaller, and more preferably at least 25% smaller. This preferred embodiment is the sixth embodiment of process 1 according to the invention, which preferably depends on embodiments 1 to 5.

[0016] |7a|According to a further preferred embodiment of process 1, the cross-sectional dimension of the opening of the detection plate is no more than 10%, preferably no more than 7.5%, and more preferably no more than 5% larger than the total cross-sectional dimension of a pair of given ends of the twisted shaped wire. This preferred embodiment is the seventh embodiment of process 1 according to the invention, which preferably depends on embodiments 1 to 6.

[0017] |8a| According to a further preferred embodiment of process 1, the detection plate is made of a material selected from metals, plastics, glass, ceramics, or combinations thereof. Preferably, the detection plate is made of steel. This preferred embodiment is the eighth embodiment of process 1 according to the invention, which preferably depends on any one of the first to seventh embodiments.

[0018] |9a| According to a further preferred embodiment of process 1, the support element is made of a metal selected from copper, copper-containing alloys, aluminum, or steel. This preferred embodiment is the ninth embodiment of process 1 according to the invention, and it preferably depends on any one of the first to eighth embodiments.

[0019] |10a| According to a further preferred embodiment of process 1, in process step g, electrical contact is provided by means of laser welding. This preferred embodiment is the tenth embodiment of process 1 according to the invention, which preferably depends on any one of the first to ninth embodiments.

[0020] |11a| According to a further preferred embodiment of process 1, the formed wire used in process step d is obtained by a method including the following process steps: a. Provide wires, -The conductor has a conductor surface and a conductor cross-section; - wherein at least 50% of the surface of the conductor is coated with an electrical insulating layer; b. Separate the conductors to obtain longitudinal conductor components. -The longitudinal guide member includes a first end and a second end; c. The longitudinal conductor is shaped into a shaped conductor, the shaped conductor including a first leg having a first end, a second leg having a second end, and a bridging portion connecting the first leg and the second leg.

[0021] This preferred embodiment is the 11th embodiment of process 1 according to the present invention, which preferably depends on any one of the 1st to 10th embodiments.

[0022] |12a| According to a further preferred embodiment of process 1, the formed lead wire used in process step d is a hairpin for a stator of a hairpin structure. This preferred embodiment is the 12th embodiment of process 1 according to the invention, which preferably depends on any one of the 1st to 11th embodiments.

[0023] |13a| According to a further preferred embodiment of process 1, the assembly of the formed conductor is a stator with a hairpin structure. This preferred embodiment is the 13th embodiment of process 1 according to the invention, which preferably depends on any one of the 1st to 12th embodiments.

[0024] |1b| A first embodiment of a quality control unit also contributes to solving at least one objective according to the invention. This quality control unit is used to determine whether the spatial arrangement A of the ends of the formed wires in the formed wire assembly satisfies a desired geometry. The quality control unit includes: - A detection plate having multiple openings arranged spatially relative to each other in the detection plate. B represents the desired geometry of all ends of the forming wire. -A movable platform, with the detection board mounted on it; - A descending unit, adapted and arranged to hold the component and move it downward toward the detection plate, such that the end of the formed wire moves toward the opening of the detection plate of the quality control unit, with the aim of inserting the end into the opening of the detection plate. The movable platform is adapted and arranged to move in a direction corresponding to the direction in which the end of the forming lead moves toward the opening of the detection plate of the quality control unit, wherein the platform is adapted and arranged to move a distance X in this direction, the distance depending on the similarity between arrangement A and arrangement B.

[0025] |2b| According to a preferred embodiment of the quality control unit, the detection plate is made of a material selected from metals, plastics, glass, ceramics, or combinations thereof. This preferred embodiment is a second embodiment of the quality control unit according to the invention, which preferably depends on the first embodiment.

[0026] |1c| Furthermore, contributing to solving at least one objective according to the invention is the use of the quality control unit according to the invention (preferably the quality control unit according to the first or second embodiment) in a process for producing shaped lead wire assemblies, preferably in process 1 according to any one of the first to eleventh embodiments.

[0027] |2c|In a preferred embodiment of the use described in the invention, the shaped lead is a hairpin, and the assembly of the shaped lead is part of a stator of a hairpin structure. Detailed Implementation

[0028] This disclosure will be more readily understood by referring to the following detailed description, which is incorporated herein by reference in conjunction with the accompanying drawings and embodiments, which form part of this disclosure. It should be understood that this disclosure is not limited to the specific apparatuses, methods, applications, conditions, or parameters described and / or illustrated herein, and the terminology used herein is for illustrative purposes only and is not intended to limit the scope of this disclosure. Furthermore, as used herein, the singular forms “a,” “an,” and “the” include “at least one” and multiples. Additionally, when the plural form is referred to in the specification (including the appended claims), it includes the singular forms “a,” “an,” and “the,” and also includes “at least one.” Moreover, when a specific numerical value is referred to in the specification (including the appended claims), it includes at least that specific numerical value, unless the context clearly specifies otherwise.

[0029] As used herein, the term "multiple" means more than one. When describing a range of values, another instance includes starting from and / or ending at the specified value. Similarly, when a value is expressed as an approximation using the preposition "about," it should be understood that the specified value constitutes another instance. All ranges include endpoints and are combinable.

[0030] The terms “basically,” “approximately,” and their derivatives, as well as words with similar meanings, when used to describe size, shape, spatial relationship, distance, direction, and other similar parameters, include the parameter and a range of 10% higher and lower than the parameter, including 5% higher and lower than 5%, including 3% higher and lower than 3%, including 1% higher and lower than 1%.

[0031] Process step a.

[0032] In step a of a preferred embodiment of the method of the present invention for preparing an assembly of a shaped conductor, a conductor, preferably a copper wire, is provided, wherein the conductor has a conductor surface, and wherein at least 50%, preferably at least 75%, more preferably at least 95% of the conductor surface is coated with an electrically insulating layer. The conductor surface coated with the electrically insulating layer is the peripheral surface of the conductor, which surrounds the conductor in a direction parallel to the longitudinal axis of the conductor.

[0033] Preferably, the conductor can have any cross-sectional shape, such as circular, elliptical, or rectangular, with a rectangular cross-section being particularly preferred. In the case of such a rectangular shape, the length of side A of the rectangular cross-sectional area A×B is preferably in the range of 2 to 6 mm, more preferably in the range of 2.5 to 5 mm, and even more preferably in the range of 3.3 to 4 mm, and the length of side B is preferably in the range of 1 to 5 mm, more preferably in the range of 1.3 to 4 mm, and even more preferably in the range of 1.5 to 3 mm. Furthermore, the lengths of side A and side B defining the rectangular cross-sectional shape of the conductor can differ from each other by at least 0.25 mm, at least 0.5 mm, or at least 1 mm. Suitable examples of conductors are those with a cross-sectional size of 4×3 mm or 3.3×1.5 mm, preferably copper wire.

[0034] The conductive material on which the wire is based is preferably a metal selected from the group consisting of copper, iron, gold, aluminum, silver, and combinations of at least two of these metals, with copper being particularly preferred. Therefore, the most preferred wire is copper wire.

[0035] The electrical insulation layer covering at least a portion of the conductor surface can be based on any material, such as varnish, paper, polymer, glass fiber, mica, and combinations thereof. In one specific example, the electrical insulation layer can be a polyamide-imide film. Furthermore, the method used to coat the conductor can be any method, as long as it is a method commonly used for insulating coating, such as impregnation, electrodeposition coating, oxidation film formation, or electroplating. Copper wire coated with this electrical insulation layer is suitable for use in process step a. It is commercially available from Hitachi Cable America, Inc., located in White Plains, New York.

[0036] In process step a, the conductor is provided, preferably by a continuous process in which the conductor wound on a spool is continuously unwound from the spool by a feed element and subsequently straightened in multiple stages to reduce residual curvature and residual stress. The process of providing the conductor may also include an additional step in which, after the straightening process, the electrical insulation layer of the conductor is preferably partially stripped (removed) at regular intervals. Both laser-based and mechanical processes are used here to at least partially remove the electrical insulation layer.

[0037] Process step b.

[0038] In step b of a preferred embodiment of the process for preparing a shaped lead wire assembly according to the present invention, the lead wires provided in step a are separated to obtain longitudinal lead wires, preferably multiple longitudinal lead wires, wherein each of the longitudinal lead wires or multiple longitudinal lead wires includes a first end and a second end. Preferably, the separation is performed within a stripping region of the lead wire, preferably substantially at the center of the stripping region, so that the resulting longitudinal lead wire is stripped at its first and second ends by a certain length—this length depends on the length of the lead wire region stripped in step a.

[0039] The length of the longitudinal conductor produced in process step b, or the length of each of a plurality of longitudinal conductors, depends on the shape of the shaped conductor to be formed in process step c, and preferably on the shape of the hairpin.

[0040] Process step b may additionally include a process step in which the ends of the longitudinal guide wires are sharpened or chamfered to facilitate the arrangement of the shaped guide wires (preferably hairpins) in the slots of the stator, as described below.

[0041] Process step c.

[0042] In step c of a preferred embodiment of the process for preparing a shaped lead wire assembly according to the present invention, a longitudinal lead wire is shaped to obtain a shaped lead wire comprising a first leg having a first end, a second leg having a second end, and a bridging portion connecting the first leg and the second leg, preferably forming a hairpin. Preferably, the forming is performed in such a manner that a shaped lead wire is obtained wherein the first leg and the second leg point substantially in the same direction and are substantially parallel to each other.

[0043] According to one embodiment of the invention, the shaped guide wire is characterized by a two-dimensional structure, i.e., two legs extending in one plane. According to another embodiment of the invention, the shaped guide wire is characterized by a three-dimensional structure, i.e., two legs extending in two parallel planes offset from each other; this embodiment is particularly preferred. To obtain such a three-dimensional shape, the bridging portion connecting the first and second legs has a twisted "U" shape. Figure 1 An example of this 3D structure hair clip is shown in the image.

[0044] The forming of longitudinal conductors can be achieved by any method that a person skilled in the art would deem suitable for forming conductors such as copper wires. Preferred forming methods include CNC bending, rotary bending, press bending, free bending, and combinations of at least two of these methods. CNC bending allows for 2D and 3D bending of the conductor. The conductor is directly bent into the desired final profile using one or more bending tools. When using rotary bending, the conductor is positioned on a stop system, where an upper beam clamps the copper wire onto a lower beam. These bending fixtures impart the desired 2D geometry to the conductor. The desired 3D geometry can be obtained by combining the rotary bending process with a die bending process or a free bending process. When using press bending, a 2D-bent hairpin is positioned on a die. Subsequently, the 3D shape is imparted to the hairpin by the downward movement of the press bending machine. When using free bending, one leg of the 2D-bent hairpin is placed between the upper and lower jaw plates. The gripper then grasps the free hairpin leg and pulls the hairpin apart to obtain the desired 3D shape.

[0045] It should be noted that, in a preferred embodiment of the process according to the invention, process step c does not necessarily have to be performed after process step b, but may also be performed before process step b. In this case, a shaped wire component is first prepared at the free end of the wire provided in process step a. After the shaped wire component is prepared, it is separated from the wire to obtain the shaped wire component, which is then used in process step d to prepare the components of the shaped wire component.

[0046] Process step d.

[0047] In step d of the process for preparing the assemblies according to the invention, the shaped wires, preferably the shaped wires obtained in step c, are arranged relative to each other such that the first leg and the second leg of each of these shaped wires are oriented substantially in the same direction. "Oriented substantially in the same direction" is preferably understood to mean that the longitudinal axes of the first and second legs of each shaped wire extend parallel to each other (therefore, in the case of n shaped wires, all 2×n legs preferably extend parallel to each other). In this case, it is also preferred that the first and second ends of each of these shaped wires are substantially in the same plane. The total number n of the shaped wires arranged in step d depends on the required size of the assembly and can be, for example, in the range of 25 to 3000, in the range of 50 to 2000, or in the range of 100 to 1000.

[0048] Preferably, the formed conductors are arranged in one or more loops, wherein, in the case of more than one loop, these loops can be arranged concentrically. In this case, it is particularly preferred that multiple formed conductors are arranged in a nest-like manner for insertion into a stator core, preferably into a cylindrical stator core, the stator core including an outer peripheral surface, an inner peripheral surface, and multiple slots formed between the inner peripheral surface and the outer peripheral surface, the inner peripheral surface defining an internal space, preferably an internal cylindrical space, extending axially within the stator core, wherein the formed conductors are placed in the slots of the stator core. The longitudinal axis of the legs of the formed conductors, preferably the longitudinal axis of the legs of the hairpin, extends parallel to the internal space of the stator core along its axial direction. Depending on the width of the slot, each slot can accommodate m legs of formed conductors, preferably legs of formed conductors with a hairpin shape, where m is preferably an even number in the range of 2 to 12, more preferably an even number in the range of 4 to 8. Within a given slot, the slot positions of the legs of the formed conductor can be numbered from 1 (the slot position farthest from the stator's internal space) to x (the slot position closest to the stator's internal space). An example of a cylindrical stator core in which the formed conductor obtained in process step c can be placed is shown below. Figure 3 As shown. For example, the process for manufacturing such a hair clip "pre-installed nest" is disclosed in US 11,652,392 B2. Figure 2 An example of such a basket is shown, which includes two concentric rings of hairpin-shaped shaped guide wires.

[0049] Preferably, in this stator core, the forming conductors (preferably hairpin-shaped forming conductors) form m / 2 turns, each turn extending circumferentially, wherein the first turn r1 is the turn closest to the inner cylindrical space, and the last turn rm / 2 is the turn farthest from the inner cylindrical space, wherein the forming conductors are arranged in these turns in such a way that the first leg of a given forming conductor is placed at slot position y in one of a plurality of slots (where y can be, for example, position 1, position 3, position 5, etc.), and the second leg of the same forming conductor can be positioned at slot position y+1 in another slot (for example, if the first leg is placed in position 1 of the first slot, then the second leg is placed in position 2 of the other slot). The circumferential distance between two slots in the stator core depends, for example, on the distance between the first end and the second end of the given forming conductor. When the forming conductors (preferably hairpin-shaped forming conductors) are placed into the slots in this way, a plurality of concentrically arranged forming conductor turns, the number of turns being m / 2, are obtained. According to a specific embodiment of the process of the present invention, m is 4, 6, 8, or 10, thus there are 2, 3, 4, or 5 hairpin rings in the assembly. At the end of process step e (described below), each of these rings forms a conductive stator winding, which are arranged concentrically.

[0050] It should be noted that not all hairpin-shaped shaped conductors assembled in a cylindrical stator core must have exactly the same shape. Typically, two, three, or more different types of hairpins can be assembled in the stator, as disclosed in US2014 / 319953 A1.

[0051] The stator core, preferably cylindrical, can be designed as a single piece or in multiple pieces, particularly in multiple segments. A single-piece stator core is characterized in that, viewed circumferentially, the entire stator core appears as a single unit. The stator core is preferably formed from a large number of electrically insulated laminations, which are layered and encapsulated into a laminated core. This structure keeps the eddy currents induced by the stator magnetic field within the stator low. These laminations are typically made of electrical steel and are stacked and encapsulated to form a stack. The individual laminations are then held in the laminated core by bonding, welding, or screwing. A segmented stator core is characterized by being composed of individual stator segments. The stator core can be composed of individual stator teeth, each individual stator tooth formed by an electrical lamination. The stator teeth are components of the stator core, designed as circumferentially spaced, tooth-like, radially inwardly extending portions of the stator body, with the free space between two adjacent teeth forming the aforementioned slots.

[0052] In addition to these slots, the cylindrical stator core may also include separate cooling channels, which may be integrated into the laminated core of the stator (as disclosed in EP 3 157 138 A1) or integrated into the slots together with the conductive stator windings (as disclosed by Markus Schiefer: “Indirect winding cooling of a high-utilization permanent magnet excitation synchronous motor with toothed coil windings”, dissertation, Karlsruhe Institute of Technology (KIT), 2017).

[0053] Before the shaped conductor assemblies are introduced into the slots of the cylindrical stator core in the next process step e, these slots are preferably insulated. For this purpose, insulating paper is typically fed from a roll and then continuously folded and cut into the appropriate shapes. After the paper is cut and folded, the insulating paper is inserted into the slots of the stator, preferably slot by slot. In a subsequent process step, the insulating paper can be expanded using a forming die that moves to both sides of the stator and expands the slot insulation by applying heat.

[0054] Process step e.

[0055] In step e of the process for preparing a shaped lead wire assembly according to the present invention, the assembly is introduced into the stator by introducing the legs of the shaped lead wire into the first end of a slot in the stator, the stator comprising a plurality of slots, each slot having a first end and a second end.

[0056] -The end of each leg extends from the stator at the second end of the slot. -In this process, after the legs are introduced into the groove, their ends are twisted such that the end of one given shaped guide is positioned adjacent to the end of another shaped guide, thereby forming multiple such pairs of adjacent ends. -The end of the twisted shaped wire is spatially arranged A at the second end of the groove.

[0057] Before the ends are twisted, the process may include a step of radially separating the ends of the formed wires (= necking process) to allow the twisting tool to better enter axially during the subsequent twisting step. In this necking process, the ends of the formed wires can be radially shaped by a forming tool to create sufficient distance between them.

[0058] The first and second ends of each formed conductor in the assembly, preferably the first and second ends of each formed conductor having a hairpin shape, are twisted according to the requirements of the desired winding scheme, such that the first or second end of one formed conductor is in close contact with the first or second end of another formed conductor (=twisting process), thereby forming multiple pairs of adjacent ends that will be welded together in process step g. To achieve this contact, the first leg of a given formed conductor is bent toward the direction of the first or second leg of the formed conductor to be connected to that given formed conductor, and vice versa. When the ends of the formed conductors are bent (or twisted) in this way, an S-shaped structure of the ends is preferably obtained. In this context, it is particularly preferred that the formed conductors be twisted in this way after they are arranged in the cylindrical stator core, such that two connecting ends of different hairpins represent adjacent connecting ends (see...). Figure 5 For the purposes of this invention, adjacent connection ends are understood to be two connection ends that are closest to each other, and may even be adjacent to each other, i.e., can be in mechanical contact with each other, as disclosed in, for example, DE 10 2017 201 533 A1 or DE 2019 219 683 A1.

[0059] Process step f.

[0060] In step f of the process for preparing a shaped lead assembly according to the invention, the ends of the twisted shaped lead in the assembly are clamped by means of a retaining system, wherein the retaining system includes clamping elements forming openings in which the paired ends are enclosed, or the ends of the twisted shaped lead in the assembly are introduced into openings in a support element. The openings of the retaining system or support element are preferably arranged in a spatial arrangement opposite to each other, corresponding to the arrangement of the end pairs in the assembly obtained in step e. The ends of the twisted shaped lead are inserted in such a manner that in each opening of the support element or retaining system, there is a pair of adjacent ends that will be welded together in step g, and are introduced or enclosed therein. The support element or retaining system ensures that the ends of each pair of lead ends maintain a defined distance and arrangement during subsequent welding steps.

[0061] In this respect, the preferred option is, - The openings in the conductors and support elements or retaining systems have a rectangular cross-sectional shape; and - The cross-sectional dimension of the opening of the support element or retaining system is greater than the total cross-sectional dimension of a given pair of ends of the torsion shaped conductor.

[0062] In this respect, it is particularly preferred that the cross-sectional dimension of the opening of the support element or retaining system is at least 5% larger than the total cross-sectional dimension of the ends of a given pair of torsioned shaped guide wires, preferably at least 10% larger, and more preferably at least 25% larger.

[0063] Process step g.

[0064] In step g of the process for preparing a shaped conductor assembly according to the invention, within each adjacent end pair, electrical contact is provided between the first or second end of a given shaped conductor and the first or second end of another shaped conductor, thereby forming a conductive winding in the stator according to a desired winding scheme. For this purpose, corresponding adjacent connection ends within each adjacent end pair are electrically connected to each other, for example by brazing, welding, or, as is also conceivable, by mechanical interlocking. Particularly preferred is the melting of the surfaces of the copper ends by absorbing laser power, followed by joining them together during subsequent cooling (laser welding). If the adjacent connection ends are already electrically connected to each other, a corrosion-resistant insulating layer can then be provided for them according to the invention, wherein the corrosion-resistant insulating layer covers only the connection ends.

[0065] To achieve phase switching and winding connection, the process for fabricating an assembly of multiple shaped conductors preferably includes, as a further process step, connecting switching elements or components to the windings. This process is typically also performed via laser welding. Examples of interconnecting elements are contact rings, jumpers, and terminals. The process for providing such connections is disclosed in DE 10 2018 009206 A1.

[0066] The process for preparing an assembly of a shaped wire according to the present invention is now characterized in that, after process step e and before process step f, it is confirmed that the spatial arrangement A of the ends of the twisted shaped wire at the second end of the groove satisfies a desired spatial arrangement B, wherein this confirmation is performed by means of a quality control unit, the quality control unit comprising a detection plate having a plurality of openings arranged opposite each other in the desired spatial arrangement B, wherein the confirmation includes the step of moving the ends of the shaped wire toward the openings of the detection plate of the quality control unit with the aim of inserting the ends into the openings of the detection plate. Furthermore, the ends of the twisted wire are inserted in such a manner that an adjacent end to be welded together in process step g is inserted into and introduced into each opening of the detection plate.

[0067] The “spatial arrangement A” of the ends of the twisted formed wire is the arrangement obtained in process step e, corresponding to the actual spatial arrangement of the ends of these parts obtained after the twisting process. However, this does not necessarily have to correspond to the “desired spatial arrangement B”. The “desired spatial arrangement B” corresponds to the arrangement of the ends of the twisted formed wire, in which two ends from different formed wires, forming such end pairs, and to be welded together in process step g, are as close as possible to each other, for as many adjacent end pairs to be welded as possible, preferably all pairs, so that the best possible electrical contact can be formed when these ends are welded. Due to the twisting process or other process parameters, in some pairs of adjacent ends of the formed wire, the two ends may not be close enough to each other, and therefore optimal welding cannot be performed. In this case, the actual “spatial arrangement A” does not match the “desired spatial arrangement B”.

[0068] According to a preferred embodiment of the process of the present invention, prior to performing the welding process, a quality control unit is used to check whether and to what extent the "spatial arrangement A" deviates from the "desired spatial arrangement B". This quality control unit includes a movable platform on which a detection plate is mounted. In this context, it is particularly preferred that the movable platform of the quality control unit is adapted and arranged to move in a direction parallel to the end of the forming guide member toward the opening of the detection plate of the quality control unit, wherein the platform moves a distance X in this direction, the magnitude of which depends on the similarity between arrangement A and arrangement B. The platform can move a distance X as the end of the forming guide member in the assembly moves toward the opening of the detection plate of the quality control unit. If X is less than the value Xmax, arrangement A and arrangement B are considered sufficiently similar, and process step f is then performed (and preferably process step g is also performed). If X is greater than the value Xmax, arrangement A and arrangement B are considered insufficiently similar, and process step f is not performed (and preferably process step g is also not performed).

[0069] In this context, it is particularly preferred that the cross-sectional dimension of the opening of the detection plate is smaller than the cross-sectional dimension of the opening in the support element or holding system. Preferably, the cross-sectional dimension of the opening of the detection plate is at least 5% smaller than the cross-sectional dimension of the opening in the support element or holding system, more preferably at least 10% smaller, and more preferably at least 25% smaller. In this context, it is also preferred that the cross-sectional dimension of the opening of the detection plate is no greater than 10%, preferably no greater than 7.5%, and more preferably no greater than 5%, larger than the total cross-sectional dimension of a given pair of twisted shaped wire ends. The closer the cross-sectional area of ​​the opening of the detection plate is to the total cross-sectional dimension of a given pair of twisted shaped wire ends, the more accurately even small deviations from the desired spatial arrangement B can be detected.

[0070] According to the present invention, a component, preferably a hairpin-type motor stator, which contributes to solving at least one inventive objective, is also included, which can be obtained by the process.

[0071] Also contributing to solving at least one objective according to the invention is an electric motor comprising a stator of a hairpin structure obtainable by a process for preparing a hairpin structure motor stator, and a rotor located in an internal cylindrical space within the stator.

[0072] The motor according to the invention may further include a motor housing. The motor housing surrounds the motor. In particular, the stator is housed within the motor housing and fixed relative to the motor housing in an anti-rotational manner. The motor housing may also house control and power electronics. The motor housing may also be part of a cooling system for the motor, and is designed such that cooling fluid is supplied to the motor via the motor housing, particularly to the stator and cooling channels present in the stator, and / or heat is dissipated to the outside via the housing surface. Furthermore, the motor housing protects the motor and any electronic components that may be present from external influences. The motor housing may be formed, in particular, from a metallic material. Advantageously, the motor housing may be formed from a cast metallic material, such as gray cast iron or cast steel. In principle, it is also conceivable that the motor housing may be formed entirely or partially from plastic.

[0073] Contributing to the resolution of at least one object of the present invention is a device comprising a moving part driven by such an electric motor. This motor is particularly intended for use in the powertrain of hybrid or fully electric vehicles. Specifically, the size of the motor can be designed to enable vehicle speeds exceeding 50 km / h, preferably exceeding 80 km / h, and especially exceeding 100 km / h. The motor particularly preferably has a power output greater than 30 kW, preferably greater than 50 kW, and especially greater than 70 kW. Furthermore, it is preferred that the motor provides a rotational speed greater than 5,000 rpm, particularly preferably greater than 10,000 rpm, and very particularly preferably greater than 12,500 rpm.

[0074] The motor can be mounted in an electrically operable final drive system. The electric final drive system of a motor vehicle includes a motor and a transmission, which form a structural unit. Specifically, it can be specified that the motor and transmission are arranged in a common drive system housing. Alternatively, the motor can have its own motor housing, and the transmission its own transmission housing; in this case, the structural unit can be implemented by fixing the transmission relative to the motor. This structural unit is sometimes also referred to as the E-axis.

[0075] In this application, a motor vehicle refers to a land vehicle that is powered by mechanical means and is not restricted by railway tracks. For example, a motor vehicle may be selected from categories such as passenger cars (cars), trucks (vans), mopeds, light motor vehicles, motorcycles, buses (COM), or tractors. Attached Figure Description

[0076] The accompanying drawings are for illustrative purposes only and should not be construed as limiting the invention. Furthermore, the drawings are not to scale.

[0077] Figure 1 A shaped lead wire 100 with a hairpin shape is shown, which can be obtained by the process according to the invention.

[0078] Figure 2 This illustrates a basket-shaped assembly composed of shaped wires 100, obtainable by a process according to the invention for manufacturing components, each shaped wire 100 having a hairpin shape, the assembly 200 being placed as... Figure 3 The previous state of the laminated stator core 300 in slot 303.

[0079] Figure 3 A side view of a laminated stator core 300 is shown, into which a shaped conductor 100 or one or more components 200 of such a shaped conductor 100, which is available according to the process of the present invention, may be introduced to form a stator 400 with a hairpin structure.

[0080] Figure 4 A top view of this laminated stator core 300 is shown.

[0081] Figure 5 The diagram shows the connection end of a shaped wire 100 obtained by the process according to the invention after bending in opposite directions.

[0082] Figure 6 A stator 400 with a hairpin structure is shown, which can be manufactured by a process according to the invention for preparing components.

[0083] Figure 7 A shows an assembly 200 of a shaped wire 100 in a state after the ends 102, 104 have been twisted and before the adjacent ends are welded together, wherein the ends 102, 104 of the shaped wire 100 are inserted into the opening 601 of the support element 600. Figure 7 B shows the relationship between the size of the opening 601 of the support element 600 and the total cross-sectional area of ​​the paired end pairs 204 of the ends 102, 104 of the two adjacent shaped conductors that will be welded together in process step g.

[0084] Figure 8 An assembly 200 of a shaped conductor 100 is shown, wherein paired end pairs 204 of ends 102, 104 are enclosed by an opening 701 of a retaining system 700.

[0085] Figure 9 The diagram shows how the ends 102, 104 extending from the second end 303b of the stator 300 are inserted into the opening 502 of the detection plate 501 of the mass control unit 500.

[0086] Figure 10 A shows a detection plate 501 of a quality control unit 500 according to the present invention. Figure 9B shows the relationship between the size of the opening 502 of the detection plate 501 and the total cross-sectional area of ​​the paired end pairs 204 of the ends 102, 104 of two adjacent shaped conductors that will be welded together in process step g.

[0087] Figure 11 The following situation is shown: the spatial arrangement A of the ends 102, 104 of the twisted shaped wire 100 at the second end 303b of the groove 300 corresponds to the spatial arrangement of the opening 502 in the detection plate 501 of the quality control unit.

[0088] Figure 12 The following situation is shown: the spatial arrangement A of the ends 102, 104 of the twisted shaped wire 100 at the second end (303b) of the groove 300 does not correspond to the spatial arrangement of the opening 502 in the detection plate 501 of the quality control unit.

[0089] Attached Figure Description Figure 1 A shaped conductor 100 with a hairpin shape is shown, which can be obtained by a process according to the invention. The hairpin is preferably a copper hairpin, its outer surface comprising an insulating layer (shown in black). The hairpin includes two generally parallel legs 101 and 103, the first leg 101 having a first end 102 and the second leg 103 having a second end 104, wherein the insulating layer is preferably removed at the first end 102 and the second end 104 (shown in gray). The copper wire used to form the hairpin 100 preferably has a rectangular cross-sectional shape, for example, a width of 3.24 mm and a thickness of 2.84 mm. However, the actual dimensions of the rectangular cross-sectional shape depend, for example, on the size of the stator into which the hairpin is to be introduced, and / or the density of the shaped conductor assembly to be introduced into the stator slot. The thickness of the insulating layer coated on at least a portion of the surface of the copper wire can, for example, range from 0.01 mm to 0.1 mm, preferably from 0.03 to 0.07 mm. Preferably, the bridging part 105 of the hairpin (the two legs 101 and 103 are interconnected through this bridging part, such as...) Figure 1 (As shown by the dashed circle in the middle) It is three-dimensionally curved such that when the outer edges of the cross-sectional areas of the two legs 101 and 103 of a particular shaped conductor 100 are aligned in the same way, the two legs are not in the same plane.

[0090] Figure 2A basket-shaped assembly consisting of hairpin-shaped shaped conductors 100, obtainable in step d of the component manufacturing method of the present invention, is shown, wherein the shaped conductors 100 are arranged in circular or annular structures 202, 203; in the case of two or more such circular structures, these annular structures are formed in a concentric arrangement. This shaped conductor assembly can be placed into a slot 303 of a laminated stator core 300, such as... Figure 3 As shown, a stator 400 is used to form a hairpin structure. At the end of the process for fabricating the component, when the ends 102 and 104 of the hairpin are interconnected in a clearly defined manner, each circle or loop 202, 203 forms a conductive winding. As... Figure 2 As shown, the shaped lead members 100 are arranged relative to each other such that the first end 102 and the second end 104 of each shaped lead member are oriented in substantially the same direction. In this case, it is also preferable that the first ends 102 and the second ends 104 of all these shaped lead members 100 are substantially located within the same plane 201 (indicated by the dashed circle at the bottom of the assembly). On opposite sides of the assembly, the bridging portions 105 of the hairpin (through which the two legs 101 and 103 of a particular hairpin are connected to each other) can also be substantially located within the same plane.

[0091] Figure 3 A side view of a laminated cylindrical stator core 300 is shown, along with a shaped conductor 100 or a component 200 comprising such a shaped conductor 100, which can be obtained according to the process of the present invention (e.g., Figure 2 (As shown) can be introduced into the stator core to form a stator of hairpin structure 400. The cylindrical stator core 300 includes an outer peripheral surface 301 and an inner peripheral surface 302, with a plurality of slots 303 formed between the inner peripheral surface 302 and the outer peripheral surface 301. The inner peripheral surface 302 defines an axially extending inner cylindrical space 306 within the stator 300 (e.g., ...). Figure 4 As shown in the figure, the first leg 101 and the second leg 103 of the forming conductor 100 are introduced into the slot 303 of the cylindrical stator core 300. Figure 3 The cylindrical stator core 300 shown is formed by a large number of stacked electrical laminations 304, each of which closes to form a ring. The cylindrical stator core 300 includes individual stator core teeth 305, each formed by a large number of stacked electrical laminations 304. The stator core teeth 305 are components of the stator core 300 and are designed as circumferentially spaced, radially inwardly oriented, toothed stator body portions, wherein the free space between two adjacent teeth 305 forms a slot 303 into which a shaped conductor 100 can be introduced as described above.

[0092] Figure 4A top view of a laminated stator core 300 is shown, which is similar to... Figure 3 The stator core shown is an example. Figure 4 As shown, based on the width of the slot 303, each slot 303 can accommodate a certain number m of the support legs 101 and 103 of the formed wire component 100. Figure 4 (m is 6).

[0093] Figure 5 The connecting ends 102 and 104 of the formed conductors in the assembly, which can be obtained by the process according to the invention, are shown, having been twisted in opposite directions. To form the hairpin structure of the stator 400, the first end 102 and the second end 104 of each formed conductor 100 introduced into the slots 303 of the cylindrical stator core 300 are twisted in such a manner that an S-shaped end is obtained, wherein the first end 102 of a given formed conductor 100 (hairpin) is twisted in one direction and the other end 104 is twisted in the opposite direction, such that the first end 102 of one formed conductor 100 is adjacent to the second end 104 of another formed conductor 100. The ends 102 and 104, thus so close together, are then joined to each other, for example, by laser welding. If this process is performed for all the formed conductors 100 in a given loop 202, 203 of the circularly arranged formed conductors 100, a conductive winding is obtained in the cylindrical stator core 300.

[0094] Figure 6 A stator 400 with a hairpin structure is shown, which can be manufactured by a process for preparing components according to the invention. The stator 400 includes a stator core 300 into which assemblies 200 of shaped conductors 100 (preferably hairpin-shaped assemblies 200 of shaped conductors 100) have been introduced, and wherein the ends 102 and 104 of each hairpin have been twisted and connected as described above. The stator 400 also includes a connecting portion 401 to achieve electrical contact between the various windings of the stator 400.

[0095] Figure 7 A shows an assembly 200 of a shaped conductor 100 in a state after the ends 102, 104 have been twisted and before the adjacent ends are welded together, wherein the twisted ends 102, 104 of the shaped conductor 100 are inserted into the opening 601 of the support element 600. The support element 600 serves as a protective cover, which is slidably fitted onto the free ends 102, 104 of the twisted shaped conductor 100 extending from the second (lower) side 303b of the slot 303 of the stator 300, to protect the surface of the stator 300 on that side during the welding process of process step g (according to the invention). After the welding process is completed, the support element 600 is removed again. Figure 7Figure B illustrates the relationship between the size of the opening 601 of the support element 600 and the total cross-sectional area of ​​a pair 204 of the ends 102, 104 of two adjacent twisted and shaped conductors 100 that will be welded together in process step g. As shown in the figure, the cross-sectional area of ​​the opening 601 of the support element is greater than the total cross-sectional area of ​​a pair of adjacent end pairs 204, which are formed by the ends of two different twisted and shaped conductors that will be welded together in process step g (according to the invention).

[0096] Figure 8 An assembly 200 of a shaped wire member 100 is shown, wherein the end pairs 204 are enclosed by an opening 701 of a retaining system 700. As shown in the figure, the retaining device includes a plurality of clamping elements 701a, 701b arranged in a circular pattern. Adjacent clamping element pairs 701a, 701b can be positioned adjacent to each other to form an opening 701 enclosing adjacent end pairs 204 (see Figure 1). Figure 8 (circles in the middle).

[0097] Figure 9 The diagram illustrates how the ends 102, 104 extending from the second end 303b of the stator 300 are inserted into openings 502 of the detection plate 501 of the mass control unit 500. This operation must be performed after process step e and before process step f to confirm whether the spatial arrangement A of the ends 102, 104 of the twisted forming wire 100 at the second end 303b of the slot 303 satisfies a desired spatial arrangement B. The desired arrangement B is represented by the spatial arrangement of the openings 502 in the plate 501 of the mass control unit. As shown in the figure, the mass control unit 500 includes a detection plate 501 having a plurality of openings 502 arranged relative to each other in the plate 501 with a desired spatial arrangement B. The confirmation includes the step of moving the ends 102, 104 of the forming wire 100 toward the openings 502 of the detection plate 501 of the mass control unit 500 to insert the ends 102, 104 into the openings 502 of the detection plate 501. The ends 102, 104 are inserted in such a manner that a pair of adjacent ends 102, 104 are inserted into each opening 502, and these pairs of ends 204 will be welded together and introduced therein in process step g. As can also be seen in the figure, the detection plate 501 is mounted on a movable platform 503, wherein the movable platform 503 is adapted and arranged to move in a direction parallel to the direction in which the ends 102, 104 of the formed lead 100 move toward the opening 502 of the detection plate 501, wherein the platform 503 moves a distance X in this direction, the magnitude of which depends on the similarity between arrangement A and arrangement B.

[0098] Figure 10Figure A shows a detection plate 501 of a quality control unit 500 according to the present invention. As can be seen in the figure, the detection plate 501 includes a plurality of openings 502, wherein each opening preferably has a rectangular shape. When the ends 102, 104 of a twisted shaped wire are inserted into these openings 502, each opening 502 accommodates a pair of adjacent ends 102, 104 of the wire, which will be welded together in process step g. When compared Figure 7 B and Figure 10 At point B, it can be seen that the cross-sectional dimension of the opening 502 of the detection plate 501 is smaller than the cross-sectional dimension of the opening 601 in the support element 600. Preferably, the cross-sectional dimension of the opening 502 of the detection plate 501 is no greater than 10%, more preferably no greater than 7.5%, and more preferably no greater than 5%, which is greater than the total cross-sectional dimension of the ends 102, 104 of a given pair of twisted shaped wire members 100. The closer the cross-sectional area of ​​the opening 502 of the detection plate 501 is to the total cross-sectional dimension of the given end pair 204 of the twisted shaped wire member 100, the more accurately even small deviations from the desired spatial arrangement B can be detected.

[0099] Figure 11 The following scenario illustrates that the spatial arrangement A of the ends 102, 104 of the twisted shaped wire 100 at the second end 303b of the groove 300 corresponds to the spatial arrangement of the opening 502 in the detection plate 501 of the quality control unit. In this case, the detection plate 501 of the quality control unit 500 moves downward only a small distance (if it does move downward at all), indicating that arrangement A and arrangement B are completely consistent. This further demonstrates that the arrangement of the ends 102, 104 of the twisted shaped wire 100 allows for a reliable welding process for all adjacent end pairs 204.

[0100] Figure 12 The following situation is illustrated: the spatial arrangement A of the ends 102, 104 of the twisted shaped wire 100 at the second end (303b) of the groove 300 does not correspond to the spatial arrangement of the opening 502 in the detection plate 501 of the quality control unit (dashed circles indicate that the ends of the twisted wire 100 are not correctly oriented). In this case, the detection plate 501 of the quality control unit 500 moves downward a large distance (because the incorrectly oriented ends get stuck on the edge of the opening 502, pushing the entire detection plate 501 downward).

[0101] List of Attachments 100 formed wire component The first leg of the 101-shaped wire component 100 102 The first end of the formed wire component 100 The second leg of the 103 forming wire component 100 104 The second end of the formed wire component 100 105 A bridging portion of the formed conductor 100, through which legs 101 and 103 are connected. 200 An assembly consisting of multiple shaped lead wires 100 201 The plane containing the ends 102, 104 of the first leg 101 and the second leg 103 of each formed guide wire 100 202 The first turn of the assembled shaped lead wire 100 203 The second turn of the assembled shaped lead wire 100 204 An end pair consisting of two adjacently positioned ends 102 and 104 of two different shaped wire components. 300 Cylindrical stator core 301 peripheral surface 302 inner peripheral surface 303 slot The first end of 303a slot 300 The second end of slot 303b 300 304 Electrical laminate 305 teeth 400 hairpin structure stator 401 Connection Part 500 quality control unit 501 test board The opening in plate 502 501 503 Mobile Platform 504 Falling Unit 600 support element 601 Opening in support element 600 700 Keeping System 701a retaining system clamping element 701b retaining system clamping element 702 Keep the system open.

Claims

1. A process for fabricating an assembly (200) of a shaped conductor (100), the process comprising the following steps: d. Arranging a plurality of shaped wire members (100) relative to each other to obtain an assembly (200) composed of shaped wire members (100), wherein, This arrangement is achieved in such a way that the legs (101, 103) of the shaped wires (100) among the plurality of shaped wires (100) are oriented in substantially the same direction; e. The assembly (200) is introduced into a stator (300) comprising a plurality of slots (303), each slot (303) having a first end (303a) and a second end (303b), by introducing the legs (101, 103) of the formed conductor (100) into the first end (303a) of a slot (303) of the stator (300). - The ends (102, 104) of each leg (101, 103) extend from the stator (300) at the second end (303b) of the slot (303). - in, After the legs (101, 103) are introduced into the slot (303), the ends (102, 104) are twisted such that the ends (102, 104) of one given shaped guide (100) are positioned adjacent to the ends (102, 104) of another shaped guide (100), thereby forming a plurality of such adjacent end pairs (204). - The ends (102, 104) of the twisted shaped wire (100) are spatially arranged A at the second end (303b) of the groove (303); f. The end pair (204) of the twisted shaped wire (100) in the assembly (200) is clamped by means of a retaining system (701), wherein the retaining system (701) includes clamping elements (701a, 701b) forming an opening (701), and the end pair (204) is surrounded in the opening (701); or The end pair (204) of the twisted shaped wire (100) is introduced into the opening (601) of the support element (600); g. In each end pair (204) of the shaped conductor, an electrical contact is provided between the first end (102) or the second end (104) of a given shaped conductor (100) and the first end (102) or the second end (104) of another shaped conductor (100); In this process, after process step e and before process step f, it is confirmed that the spatial arrangement A of the ends (102, 104) of the twisted shaped wire (100) at the second end (303b) of the groove (303) satisfies the desired spatial arrangement B. This confirmation is performed by means of a quality control unit (500), which includes a detection plate (501) having a plurality of openings (502) arranged opposite each other in the detection plate (501) in the desired spatial arrangement B. The confirmation includes the following steps: moving the ends (102, 104) of the twisted shaped wire (100) toward the openings (502) of the detection plate (501) of the quality control unit (500) in order to insert the ends (102, 104) into the openings (502) of the detection plate (501).

2. The process according to claim 1, wherein, The detection plate (501) is mounted on a movable platform (503), wherein the movable platform (503) is adapted and arranged to move in a direction parallel to the ends (102, 104) of the forming guide (100) toward the opening (502) of the detection plate (501) of the quality control unit (500), wherein the platform (503) moves a distance X in this direction, the magnitude of which depends on the similarity between arrangement A and arrangement B.

3. The process according to claim 2, wherein when the ends (102, 104) of the formed lead wires (100) in the assembly (200) move toward the opening (502) of the detection plate (501) of the quality control unit (500), the platform (503) moves a distance X, and wherein -If X is lower than the value X max If arrangement A and arrangement B are considered sufficiently similar, then process step f is executed. -If X is higher than value X max If the arrangement is not sufficiently similar to the arrangement, then process step f will not be performed.

4. The process according to any one of claims 1 to 3, wherein - The openings (601, 701) of the wires and support elements (600) or retaining systems (700) have a rectangular cross-sectional shape; - The cross-sectional dimension of the opening (601, 701) of the support element (600) or the retaining system (700) is greater than the total cross-sectional dimension of the given end pair (204) of the torsion shaped wire (100).

5. The process according to any one of claims 1 to 4, wherein the cross-sectional dimension of the opening (502) of the detection plate (501) is smaller than the cross-sectional dimension of the opening (601, 701) in the support element (600) or the holding system device (700).

6. The process according to claim 5, wherein the cross-sectional dimension of the opening (502) of the detection plate (501) is at least 5% smaller than the cross-sectional dimension of the opening (601, 701) in the support element (600) or the holding system (700).

7. The process according to any one of claims 2 to 5, wherein the test plate (501) is made of a material selected from metal, plastic, glass, ceramic or a combination of these materials.

8. The process according to any one of claims 1 to 7, wherein the support element (600) is made of a metal selected from the group consisting of copper, copper alloys, aluminum or steel.

9. The process according to any one of claims 1 to 8, wherein in process step g, the electrical contact is provided by means of laser welding.

10. The process according to any one of claims 1 to 9, wherein the formed wire (100) used in process step d is obtained by a method comprising the following process steps: a. Provide wire (501). -The conductor (501) wherein the conductor has a conductor surface and a conductor cross-section; - wherein at least 50% of the surface of the conductor is coated with an electrical insulating layer; b. Separate the conductor (501) to obtain a longitudinal conductor component. -The longitudinal guide member includes a first end (102) and a second end (104). c. The longitudinal conductor is shaped into a shaped conductor (100), the shaped conductor (100) including a first leg (101) having a first end (102), a second leg (103) having a second end (104), and a bridging portion (105) connecting the first leg (101) and the second leg (103).

11. The process according to any one of claims 1 to 10, wherein the shaped lead wire (100) used in process step d is a hairpin for a stator (400) of a hairpin structure.

12. The process according to any one of claims 1 to 11, wherein the assembly (200) formed by the shaped lead wire (100) is a stator (400) of a hairpin structure.

13. A quality control unit (500) for determining whether the spatial arrangement A of the ends (102, 104) of the formed wire (100) in an assembly (200) of the formed wire (100) satisfies a desired geometry, the quality control unit (500) comprising: - A detection plate (501) having a plurality of openings (502) arranged spatially relative to each other in the detection plate (501) B represents the desired geometry of all ends (102, 104) of the forming wire (100); -A movable platform (503) is mounted on which the detection board (501) is installed; - A descending unit (504) is adapted and arranged to hold the assembly (200) and move it downward toward the detection plate (501) such that the ends (102, 104) of the formed wire (100) move toward the opening (502) of the detection plate (501) of the quality control unit (500) for the purpose of inserting the ends (102, 104) into the opening (502) of the detection plate (501); The movable platform (503) is adapted and arranged to move in a direction corresponding to the direction in which the ends (102, 104) of the forming guide (100) move toward the opening (502) of the detection plate (501) of the quality control unit (500), wherein the platform (502) is adapted and arranged to move a distance X in this direction, the distance depending on the similarity between arrangement A and arrangement B.

14. The quality control unit (500) according to claim 12, wherein the detection plate (501) is made of a material selected from the group consisting of metal, plastic, glass, ceramic or combinations thereof.

15. Use of the quality control unit (500) according to claim 13 or 14 in a process for preparing an assembly (200) composed of a shaped lead wire (100) according to any one of claims 1 to 12.

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