Device, method and use of a device for twisting and widening conductor sections

Abstract

Device (10) for twisting and expanding conductor sections (12), wherein the conductor sections (12) are arranged in a stator core (14), wherein each conductor section (12) has at least one leg, wherein each leg (16) projects out of the stator core (14) with a free end (18), wherein the device (10) comprises: - a holding device (20) with several holding units (24) arranged in a circle around a center point (22), wherein each holding unit (24) has a receptacle (26) for receiving a free end (18) of a leg (16) of a ladder section (12), wherein the receptacles (26) are designed and arranged to accommodate all free ends (18) of the legs (16) of the ladder sections (12) arranged on a circular path, wherein each receptacle (26) is designed to be movable between an inner position (28) and an outer position (30) along a radial direction (32) emanating from the center point (22) in order to carry out a widening process, wherein the receptacles (26) are designed to be movable along an axial direction (34) oriented orthogonally to the radial direction (32) in order to compensate for length contraction when forming the conductor sections (12), wherein the device (10) is configured to perform a rotation operation, wherein the mounts (26) and / or the stator are rotatable about a rotation axis (36) aligned through the center point (22) and along the axial direction (34) in order to perform the rotation operation, wherein the device (10) is designed such that the free ends (18) of the legs (16) of the conductor pieces (12) received in the receptacles (26) remain in contact with the conductor during the entire twisting process and during the entire The widening process of the conductor sections (12) by means of the device (10) and the intermediate steps remain in the receptacles (26) of the holding units (24) for a period of time and without interruption, characterized in that the receptacles (26) are each formed in one piece.

Description

[0001] The invention relates to a device for twisting and expanding conductor sections with features of claim 1, a method for twisting and expanding conductor sections with features of claim 9, and the use of a device for twisting and expanding conductor sections for carrying out a method for twisting and expanding conductor sections with features of claim 13.

[0002] In the manufacture of electromechanical converters, especially electric motors, particularly for traction drives, individual winding elements (conductor segments, plug-in coils, so-called "hairpins") are produced, which are then further processed to form a stator winding. For this purpose, the individual conductor segments or hairpins are inserted into the stator core.

[0003] To achieve the most compact design possible, the conductor segments used in the stator core are deformed circumferentially (twisting) and radially (expansion). The individual conductor segments are then welded together to form the stator windings.

[0004] Devices for twisting or expanding conductor segments arranged in a stator core, such as those known from DE 10 2015 217 936 A1, WO 2019 / 040960 A1 and WO 2020 / 206480 A1, are often complex in design. This complexity is a source of errors, inaccuracies, and increased maintenance. It is therefore desirable to design such devices as simply as possible.

[0005] In order to make the twisting and expanding process as precise and efficient as possible, it is also desirable to be able to carry out the twisting and expanding process with a single (the same) device.

[0006] It is therefore an object of the present invention to provide a device, a method and a use of a device for carrying out a method, wherein the twisting and expanding process can be implemented as efficiently and in an optimized manner as possible.

[0007] This problem is solved by a device for twisting and expanding conductor sections, preferably hairpins, which are in particular designed with a rectangular conductor cross-section, wherein the conductor sections are arranged in a stator core, wherein each conductor section has at least one, in particular two, legs, each leg projecting out of the stator core with a free end, with the features of claim 1.

[0008] A hairpin, in the present sense, is a ladder segment with two elongated legs (or leg sections) connected by a connecting leg (or connecting section). Hairpins are essentially U-shaped. The connecting leg can be curved, but also partially straight or stepped.

[0009] The device comprises a holding unit with several holding units arranged in a circle around a central point. The holding units are specifically arranged on a circular path around the central point.

[0010] Each holding unit has a receptacle. Each receptacle is designed to hold (exactly) one free end of a leg of a ladder section. It is conceivable that each receptacle could be configured to hold multiple free ends.

[0011] The fixtures are designed and arranged to accommodate all free ends of the ladder sections arranged on the same circular path. In other words, the fixtures are specifically designed to accommodate the same arrangement of the free ends of the ladder sections.

[0012] Each receptacle can be designed to fix a free end of a leg of a conductor within the receptacle. Fixing the free ends of the conductor legs can be achieved by inserting them into the receptacle. In this process, for example, frictional forces between the free ends of the conductor legs and the receptacle, or at their contact points, can generate a retaining force that secures the free ends of the conductor legs within the receptacle.

[0013] Each holder (or holding unit) is designed to be movable between an inner and an outer position along a radial direction radiating from the center point in order to perform an expansion process. In other words, the holders can be designed to move back and forth along the radial direction.

[0014] The expanding process can be carried out, in particular, by moving all the fixtures (or holding units) radially outward (away from the center point), especially from the inner position to the outer position. In this context, an expanding process refers to bending or forming the legs of the conductor sections or their free ends held in the fixtures along the radial direction. The free ends held in the fixtures can be bent or formed radially outward, in the radial direction, during the expanding process. It is also conceivable that the free ends held in the fixtures can be bent or formed radially inward, against the radial direction (toward the center point), during the expanding process, especially by moving the fixtures from the outer position to the inner position.

[0015] The fixtures (or the holding device and / or the holding units) can be designed to be movable along an axial direction oriented orthogonally to the radial direction in order to compensate for length contraction during the forming of the conductor segments. Length contraction of the conductor segment legs can occur during both the twisting and the expanding process. The device can incorporate a linear drive for this purpose.

[0016] It is conceivable that the fixtures (or the holding device and / or the holding units) can be fixedly arranged along the axial direction, i.e., not moved in the axial direction, and that the stator together with conductor sections is moved along the axial direction to compensate for length contraction when the conductor sections are formed.

[0017] It is also conceivable that the fixtures and the stator, including conductor sections, can be moved simultaneously along the axial direction to compensate for length contraction during the forming of the conductor sections.

[0018] The movement of the mountings along the axial direction can be a relative movement between the mountings and the stator or the conductor segments arranged within it. Therefore, the mountings and / or the stator, including the conductor segments, can be moved along the axial direction.

[0019] The mounts (or holding units) can be designed to rotate about a rotation axis running through the center point and aligned parallel to the axial direction (or orthogonal to the radial direction) in order to perform a rotational operation. In particular, the rotation axis is identical to the central longitudinal axis of the stator core. The device can incorporate a drive (see below) to implement this rotational movement.

[0020] It is conceivable that the mounts (or the holding units) can be designed to be rotationally fixed, i.e., not rotatable around the axis of rotation, and that the stator together with conductor sections is rotated around the axis of rotation in order to carry out a twisting process.

[0021] It is also conceivable that the recordings and the stator, including conductor sections, are simultaneously rotated around the axis of rotation to perform a twisting process.

[0022] The movement (rotational movement) of the mountings around the axis of rotation can be a relative movement (relative rotation) between the mountings and the stator or the conductor segments arranged within it. Thus, the mountings and / or the stator, including the conductor segments, can be rotated around the axis of rotation.

[0023] The device is designed in such a way that the free ends of the legs of the conductor pieces, which are held in the receptacles, remain in the receptacles of the holding units throughout the entire twisting process and throughout the entire expansion process of the conductor pieces by means of the device.

[0024] In other words, during the expansion and twisting processes, the free ends remain in the same holders. Specifically, the free ends are not removed from the holders or repositioned during these processes.

[0025] This allows the expanding and twisting processes to be performed with the same device. Additional devices for expanding or twisting are therefore unnecessary. The free ends are securely fixed in their respective holders, particularly during the expanding and twisting processes. This allows the expanding and twisting processes to be carried out simultaneously, resulting in significant time savings.

[0026] The device can comprise one or more further holding devices with several further holding units, in particular arranged in a circle around the center point. The further holding units can, in particular, be arranged on a circular path around the center point.

[0027] Each additional holding unit can have a further receptacle for receiving (exactly) one free end of a leg of a conductor section. It is conceivable that each additional receptacle could be configured to receive multiple free ends.

[0028] The additional supports can be designed and arranged to accommodate all free ends of the ladder segments arranged on a further circular path. In other words, the supports can be specifically configured to accommodate another layer of free ends of the ladder segments.

[0029] In this context, the term "position" refers to the free ends of the legs of the ladder sections arranged on the same circular path.

[0030] Each additional receptacle can be designed to fix a free end of a leg of a conductor segment within that receptacle. Fixing the free ends of the conductor legs can be achieved by inserting them into the additional receptacles. This can create a (retaining) force, for example, due to frictional forces between the free ends of the conductor legs and the additional receptacles, or at their contact points, which secures the free ends of the conductor legs within the additional receptacles.

[0031] Each additional receptacle (or holding unit) can be designed to be movable between an inner and an outer position along the radial direction in order to perform an expansion process. In other words, the additional receptacles can be designed to be movable back and forth along the radial direction. The expansion process can be carried out, in particular, by moving all additional receptacles (or holding units) radially outward (in the radial direction), especially from the inner position to the outer position.

[0032] In this context, an expanding process refers to bending or reshaping the legs of the conductor sections, or their free ends captured in the additional fixtures, along the radial direction. During the expanding process, the free ends captured in the additional fixtures can be bent or reshaped radially outward, in the radial direction (away from the center point). It is also conceivable that the free ends captured in the additional fixtures can be bent or reshaped radially inward, against the radial direction (toward the center point), during the expanding process, particularly by moving the additional fixtures from the outer position to the inner position.

[0033] The additional fixtures (or the additional holding device and / or the additional holding units) can be designed to be movable along the axial direction in order to compensate for length contraction during the forming of the conductor sections. Length contraction of the conductor sections' legs can occur during both the twisting and the expanding process. The device can incorporate a linear drive for this purpose.

[0034] It is conceivable that the further supports (or the further holding device and / or the further holding units) can be fixedly arranged along the axial direction, i.e., not moved in the axial direction, and that the stator together with conductor sections is moved along the axial direction to compensate for length contraction when forming the conductor sections.

[0035] It is also conceivable that the other recordings and the stator together with conductor sections can be moved simultaneously along the axial direction in order to compensate for length contraction when the conductor sections are formed.

[0036] The movement of the additional mountings along the axial direction can be a relative movement between the additional mountings and the stator or the conductor segments arranged within it. Therefore, the additional mountings and / or the stator, including the conductor segments, can be moved along the axial direction.

[0037] The additional mountings (or holding units) can be designed to rotate around the axis of rotation in order to perform a twisting operation. This rotational movement can be achieved by means of the drive (see above). Alternatively, the device can have a separate drive for this purpose.

[0038] It is conceivable that the further mounts (or the further holding units) could be designed to be rotationally fixed, i.e., not rotatable around the axis of rotation, and that the stator together with conductor sections is rotated around the axis of rotation in order to carry out a twisting process.

[0039] It is also conceivable that both the other recordings and the stator including conductor sections are rotated around the axis of rotation in order to carry out a twisting process.

[0040] The movement (rotational movement) of the additional mountings around the axis of rotation can be a relative movement (relative rotation) between the additional mountings and the stator or the conductor sections arranged within it. Thus, the additional mountings and / or the stator, including the conductor sections, can be rotated around the axis of rotation.

[0041] The device can be designed such that the free ends of the legs of the conductor pieces, which are received in the further receptacles, remain in the further receptacles of the further holding units during the entire twisting process and during the entire expansion process of the conductor pieces by means of the device.

[0042] In other words, during the expansion and twisting processes, the free ends remain in the same subsequent holders. The free ends are not removed from or repositioned in these holders during or between these processes.

[0043] This allows several, in particular two, layers of conductor sections to be twisted and expanded using the same device, especially simultaneously. With two layers, a first layer can be formed by the free ends of the legs of the conductor sections arranged on the same circular path. A second layer can be formed by the free ends of the legs of the conductor sections arranged on a further circular path.

[0044] It is conceivable that two radially adjacent layers of conductor segments can be rotated simultaneously. A first layer of conductor segments can be rotated around the axis of rotation in a first direction using the mounting points. A second layer of conductor segments, radially adjacent to the first layer, can be rotated around the axis of rotation in a second direction using the additional mounting points. The first and second directions of rotation can be opposite to each other. In other words, the two layers of conductor segments can be rotated in opposite directions (simultaneously).

[0045] The torques generated during twisting can cancel each other out, at least partially, and in particular completely.

[0046] It is also conceivable that the stator or the conductor segments arranged within it are rotated in the first or second direction of rotation, particularly simultaneously with the rotation of the supports and / or the further supports. The rotation of the supports, the further supports, and / or the stator or the conductor segments arranged within it, especially when two radially adjacent layers of conductor segments are to be rotated, can be a relative movement. Thus, the supports, the further supports, and / or the stator or the conductor segments arranged within it can be rotated in the first and / or the second direction of rotation.

[0047] It is conceivable that two layers of conductor segments, separated radially by at least one layer, can be rotated simultaneously. A first layer of conductor segments can be rotated around the axis of rotation in one direction using the mountings. A second layer, separated (spaced) from the first layer radially (in the radial direction) by at least one layer, can be rotated in the same direction using the additional mountings. In other words, both layers of conductor segments can be rotated in the same direction (simultaneously).

[0048] It is also conceivable that the stator or the conductor segments arranged within it are rotated around the axis of rotation. The rotational movement of the supports, the further supports, and / or the stator or the conductor segments arranged within it can be a relative movement, particularly when there are two layers of conductor segments to be rotated that are radially separated (spaced apart) by at least one layer. Thus, the supports, the further supports, and / or the stator or the conductor segments arranged within it can be rotated in the same direction.

[0049] The holding units can be formed in one piece. Alternatively or additionally, the other holding units can also be formed in one piece. The fixtures and, if applicable, the other fixtures are formed in one piece. This reduces the number of components and thus the complexity of the entire device.

[0050] The mountings can be cuboid in shape. Alternatively or additionally, the further mountings can also be cuboid in shape. This makes it particularly easy to mount and position conductor sections with a rectangular cross-section within the mountings or the further mountings.

[0051] The holding units can each have an extension. The extension can engage with a cam track. Several cam tracks, in particular all cam tracks, can be arranged in one cam element (camera disk). The cam tracks can be arranged on the cam element in such a way that the holding units, and thus also the mounts, can be moved by a rotational movement of the cam element along the radial direction.

[0052] The holding units can each be guided by a guide device (guide disc) such that the holding units, and therefore also the fixtures, can only move radially. By rotating the cam element, the extension of the respective holding unit can be moved along the respective cam track. Conversely, the respective holding unit can be forced onto a straight path by the respective guide device. In this way, a rotary motion can be transformed into a linear motion. The rotation of the cam element can be implemented by means of the drive (see above). Alternatively, the device can have a separate drive for this purpose.

[0053] The additional holding units can each have a further extension. This further extension can engage with another cam track. Several additional cam tracks, in particular all additional cam tracks, can be arranged in a further cam element (additional cam disk). The additional cam tracks can be arranged on the additional cam element in such a way that the additional holding units, and thus also the additional mounts, can be moved by a rotational movement of the additional cam element along the radial direction.

[0054] The additional holding units can each be guided by a further guide device (additional guide disc) such that the additional holding units, and thus also the additional mounts, can only move radially. By rotating the additional cam element, the further extension of the respective additional holding unit can be moved along the respective additional cam track. Conversely, the respective additional holding unit can be forced onto a straight path by the respective additional guide device. In this way, a rotary motion can be transformed into a linear motion. The rotation of the additional cam element can be implemented by means of the drive (see above). Alternatively, the device can have a separate drive for this purpose.

[0055] This allows the movement of the receptacles and / or further receptacles required for the widening process to be implemented along the radial direction by means of one or more cam drives.

[0056] The receptacles can each have at least one, in particular two, contact surfaces, especially curved (or bent) ones. The further receptacles can each have at least one, in particular two, contact surfaces, especially curved (or bent) ones. The receptacles and / or the further receptacles can be configured such that, during the rotation process, the free end of a leg of a conductor segment held in the respective receptacle and / or the respective further receptacle is pressed against the contact surface of the respective receptacle and / or the respective further receptacle, so that the contour of the contact surface is imprinted on the respective leg or its free end. The legs (or the held free ends) can be bent or reshaped during the rotation process, particularly at the respective contact surface.

[0057] The fixtures can each have at least one, in particular two, additional contact surfaces, which are particularly curved (or bent). The additional fixtures can each have at least one, in particular two, additional contact surfaces, which are particularly curved (or bent). The fixtures and / or the additional fixtures can be configured such that, during the expansion process, the free end of a leg of a conductor segment held in the fixture and / or the additional fixture is pressed against the additional contact surface of the respective fixture and / or the respective additional fixture, so that the contour of the additional contact surface is imprinted on the respective leg or its free end. The legs (or the held free ends) can be bent or reshaped during the expansion process, particularly at the respective additional contact surface.

[0058] By choosing the shape of the contact surface or the additional contact surface, the shape of the bend in the legs or their free ends can be varied as desired.

[0059] The above problem is further solved by a method for twisting and widening conductor sections, preferably hairpins, which are in particular designed with a rectangular conductor cross-section, wherein the conductor sections are arranged in a stator core, wherein each conductor section has at least one, in particular two, legs, each leg projecting out of the stator core with a free end, with the features of claim 9.

[0060] The process includes the following steps: Receiving (arranging) the free ends, in particular all free ends arranged on the same circular path, in particular all ends, of the legs of the conductor pieces in receptacles. For this purpose, the free ends of the ladder legs can be inserted into the receptacles. The free ends of the ladder legs, once inserted into the receptacles, can then be clamped and held in place.

[0061] Performing a widening process by moving each of the fixtures along a radial direction, in particular from an inner position to an outer position, in order to widen the conductor sections. The fixtures can be moved radially (radially outwards) or against the radial direction (radially inwards).

[0062] Length compensation is performed by moving the fixtures along an axial direction orthogonal to the radial direction to compensate for length contraction during the forming of the conductor segments. Alternatively or additionally, the stator or the conductor segments arranged within it can be moved along the axial direction to compensate for length contraction during the forming of the conductor segments. It is also conceivable that the fixtures and the stator or the conductor segments arranged within it are moved simultaneously along the axial direction during the length compensation process. The movement of the fixtures along the axial direction during the length compensation process can be a relative movement between the fixtures and the stator or the conductor segments arranged within it. Thus, the fixtures and / or the stator or the conductor segments arranged within it can be moved along the axial direction to compensate for length contraction during the forming of the conductor segments.

[0063] Performing a twisting operation involves rotating the fixtures around an axis of rotation parallel to the axial direction to twist the conductor segments. Alternatively or additionally, the stator or the conductor segments arranged within it can be rotated around the axis of rotation to twist the conductor segments. It is also conceivable that during the twisting operation, both the fixtures and the stator or the conductor segments arranged within it are rotated around the axis of rotation. The rotational movement of the fixtures around the axis of rotation during the twisting operation can be a relative rotation between the fixtures and the stator or the conductor segments arranged within it. Thus, the fixtures and / or the stator or the conductor segments arranged within it can be rotated around the axis of rotation to twist the conductor segments.

[0064] The free ends of the legs of the conductor sections, captured in the recordings, remain in the (same) recordings continuously during the widening process, the length equalization process and the twisting process, and between these processes.

[0065] The twisting process can be carried out by overtightening the free ends of the conductor legs by a specific first value (i.e., twisting them beyond the desired amount). After overtightening, the free ends of the conductor legs can be untightened by a specific second value. The first value can be greater than the second value. The first and / or second value can depend on several factors, such as the angle of rotation, the conductor material, and the conductor cross-section (shape and / or size). This prevents or at least minimizes springback of the conductor legs (in the direction of their original shape), particularly in the circumferential direction, after the twisting process. The expansion, twisting, and length equalization processes can be performed simultaneously, resulting in time savings.

[0066] The expansion and twisting processes can be carried out sequentially. For example, the expansion process can be performed first, followed by the twisting process, or vice versa.

[0067] Since the twisting process can cause the legs of the conductor segments to contract in length, the length compensation process can be carried out simultaneously with the twisting process. Similarly, since the expanding process can also cause the legs of the conductor segments to contract in length, the length compensation process can be carried out simultaneously with the expanding process.

[0068] The free ends of the conductor segments can be positioned within the receptacles by first moving the receptacles and / or the free ends of the conductor segments towards each other in a first relative movement along the axial direction. This first relative movement can be continued until the free ends of the conductor segments are at least partially positioned within the receptacles. The receptacles can then be moved along the radial direction, particularly to create a gap between two adjacent layers of conductor segments. Subsequently, the receptacles and / or the free ends of the conductor segments can be moved further towards each other along the axial direction in a second relative movement. This second relative movement can be continued until the free ends of the conductor segments are, in particular, completely positioned within the receptacles.The free ends of the legs of the conductor pieces can thus be optimally captured in the recordings, especially due to the gap created by the radial movement of the recordings between two adjacent layers of the conductor pieces.

[0069] The above problem is further solved by using a device for twisting and expanding conductor sections according to the above descriptions for carrying out a method for twisting and expanding conductor sections according to the above descriptions with the features of claim 13.

[0070] Regarding the advantages that can be achieved, reference is made to the relevant explanations concerning the device and / or the method. Further measures described in connection with the device and / or the method and / or those explained below can be used to further develop its application.

[0071] Further features, details and advantages of the invention will become apparent from the wording of the claims and from the following description of exemplary embodiments with reference to the drawings. The drawings show: Fig. 1. A perspective view of a device for twisting and widening conductor sections; Fig. 2 a section of a perspective view of holding units of the device according to Fig. 1; Fig. 3 a top view of the device according to Fig. 1 with shots taken in an inner position; Fig. 4 a top view of the device according to Fig. 1 with shots taken in an external position; Fig. 5 a perspective view of the device for twisting and widening conductor sections according to a second embodiment; Fig. 6 a sectional view of the device according to Fig. 5 and Fig. 7 a section of a top view of the device according to Fig. 5.

[0072] In the following description and in the figures, corresponding components and elements bear the same reference symbols. For the sake of clarity, not all reference symbols are shown in every figure.

[0073] Fig. Figure 1 shows a perspective view of a device 10 for twisting and expanding conductor sections 12. The conductor sections 12 are arranged in a stator core 14. Each conductor section has two legs 16. Each leg 16 projects from the stator core 14 with a free end 18 (see Figure 1). Fig. 6) The stator core 14 and the conductor pieces 12 are in Fig. 1 only schematically indicated.

[0074] The device 10 has a holding device 20. The holding device 20 comprises several holding units 24. The holding units 24 are arranged in a circle around a center point 22 (see figure). Fig. 3 or Fig. 4).

[0075] Fig. Figure 2 shows a section of a perspective view of the holding units 24 of the device 10 according to Fig. 1. Each holding unit 24 has a receptacle 26. Each holding unit 24, and therefore also each receptacle 26, is formed in one piece.

[0076] Fig. Figure 3 shows a top view of the device 10 according to Fig. 1, wherein the recordings 26 are arranged in an inner position 28.

[0077] Fig. Figure 4 shows a top view of the device 10 according to Fig. 1, wherein the recordings 26 are arranged in an outer position 30

[0078] The mounts 26 are arranged in a circle around the center point 22. The mounts 26 are designed to be movable along a radial direction 32 extending from the center point 22. The mounts 26 can be positioned between the in Fig. 3 shown inner position 28 and the one in Fig. The outer position shown in section 4 can be moved to 30 degrees.

[0079] This radial movement of the mounts 26 is implemented here by means of a cam drive. For this purpose, each holding unit 24 has a projection 44. The projections 44 each engage in a cam track 46. The cam tracks 46 are arranged in a cam element 48.

[0080] In this case, the cam element 48 is designed in the form of a cam disc. The holding units 24 are guided by a guide device 50 such that the holding units 24, and thus the receptacles 26, are movable exclusively along the radial direction 32 (see figure). Fig. 1).

[0081] This allows the radial movement of all holding units 24 or all receptacles 26 to be implemented by rotating the cam element 48 (relative to the guide device 50). The receptacles 26 move simultaneously and in the same manner. In other words, the receptacles 26 are always arranged on a circular path.

[0082] The rotation of the cam element 48 is implemented by a drive 49, which is mounted on a base plate 51 and rotates the cam element 48. The drive 49 is located in the Fig. 1, Fig. 2 and Fig. 3 only schematically indicated.

[0083] The holding units 24, and thus also the receptacles 26, are designed to rotate about a rotation axis 36 extending in an axial direction 34. In this case, the rotation axis 36 is identical to the central longitudinal axis of the stator core 14. The axial direction 34 and the radial direction 32 are arranged orthogonally to each other.

[0084] The rotational movement of the holding units 24, and thus also of the receptacles 26, can be achieved by a joint rotation of the cam element 48 and the guide device 50. This is accomplished here by means of the drive 49. In other words, the drive 49 can rotate the cam element 48 and the guide device 50.

[0085] If the cam element 48 and the guide device 50 are rotated in the same manner (at the same speed and in the same direction of rotation) and simultaneously (by means of the drive 49), the mounts 26 are moved on a circular path around the axis of rotation 36, whereby the mounts 26 do not move along the radial direction 32. This allows for a circumferential movement of the mounts 26 around the axis of rotation 36.

[0086] To reshape the ladder sections 12 by twisting and widening, the free ends 18 of the legs 16 of the ladder sections 12 are inserted into the receptacles 26. Thus, each receptacle 26 contains a free end 18 of a leg 16 of a ladder section 12.

[0087] To perform a twisting operation, the cam element 48 and the guide device 50 are rotated about the axis of rotation 36 by means of the drive 49 (as described above). Due to the rotation of the cam element 48 and the guide device 50, the supports 26 move in a circular path about the axis of rotation 36 and bend the conductor sections 12 circumferentially. In this case, the circumferential direction corresponds to the direction of rotation of the supports 26.

[0088] To perform a widening process, the recordings 26 together with the free ends 18 recorded therein are removed from the in the Fig. 3 shown inner position 28 into the in the Fig. The outer position 30 shown in Figure 4 moves. This causes each captured free end 18 to move along the radial direction 32 (radially outwards). This movement can be implemented, as described above, by rotating the cam element 48.

[0089] The twisting and expanding processes can be performed simultaneously. For this purpose, the cam element 48 and the guide device 50 are moved simultaneously by means of the drive 49, resulting in a relative rotational movement between the cam element 48 and the guide device 50. Thus, the cam element 48 and the guide device 50 are not moved in the same manner (at the same speed), but with a relative difference in rotational speed (at different speeds).

[0090] During both the twisting and expanding processes, the conductor sections 12 undergo a length contraction. Due to this deformation, the longitudinal extent of the conductor sections 12 along the axial direction 34 decreases. To compensate for this length contraction, the holding units 24, and thus also the receptacles 26, are designed to be movable along the axial direction 34. This can be achieved, for example, by axially moving (shifting) the base plate 51 using a linear drive (not shown). It is also conceivable that the cam element 48 and the guide device 50 are moved relative to the base plate 51 along the axial direction 34.

[0091] The axial movement of the receptacles 26 is carried out simultaneously with the twisting and expanding processes. This ensures that the free ends 18 of the legs 16 of the conductor sections 12, which are held in the receptacles 26, remain in the receptacles 26 and that no material stresses or damage occur within the conductor sections 12.

[0092] With the device 10 according to the Fig. 1 to 4, a layer of ladder sections 12 can be transformed simultaneously. In this context, a layer refers to free ends 18 of the legs 16 of the ladder sections 12 arranged on the same circular path.

[0093] The images 26 each show two opposing, curved, mounting surfaces 60 (see Fig. 2 and Fig. 7) During the twisting process, the legs 16, or their free ends 18, are pressed or bent against one of these contact surfaces 60. The bent (deformed) section of the respective leg 16, or its free end 18, assumes the contour of the contact surface 60 against which the bending occurs. Thus, by varying the shape of the contact surface 60, the shape of the bend (or deformation) of the respective leg 16, or its free end 18, can be adjusted as desired.

[0094] The images 26 each show two opposing, curved, further mounting surfaces 62 (cf. Fig. 2 and Fig. 7) During the expansion process, the legs 16, or their free ends 18, are pressed or bent against one of these additional contact surfaces 62. The bent (deformed) section of the respective leg 16, or its free end 18, assumes the contour of the additional contact surface 62 against which the bending occurs. Thus, by varying the shape of the additional contact surface 62, the shape of the bend (or deformation) of the respective leg 16, or its free end 18, can be adjusted as desired.

[0095] Fig. Figure 5 shows a perspective view of the device 10 for twisting and expanding conductor sections 12 according to a second embodiment. The device 10 according to the illustrated second embodiment differs from the one shown in the Fig. The device 10 shown in Figures 1 to 4 is modified by the fact that, according to the second embodiment, the device 10 has a further holding device 38. The further holding device 38 has several further holding units 40, which are arranged in a circle. Each further holding unit 40 has a further receptacle 42 for receiving a free end 18 of a leg 16 of a conductor section 12.

[0096] In the present case, images 26 and the further images 42 are identically configured. The further images 42, therefore, also have, analogous to images 26, two attachment surfaces 60 and two further attachment surfaces 62.

[0097] Fig. Figure 6 shows a sectional view along the axis of rotation 36 of the device 10 according to Fig. 5. Fig. Figure 7 shows a section of a top view of the device 10 according to Fig. 5.

[0098] The further recordings 42 are, analogous to the recordings 26, movable along the radial direction 32 and the axial direction 34 and rotatable about the rotation axis 36.

[0099] The radial movement of the further mounting 42 is implemented, analogously to the mountings 26, by means of a cam drive. For this purpose, each further holding unit 40 has a further extension 52. The further extensions 52 each engage in a further cam track 54. The further cam tracks 54 are arranged in a further cam element 56. In this case, the further cam element 56 is designed in the form of a further cam disk. The further holding units 40 are guided by a further guide device 58 such that the further holding units 40, and thus the further mountings 42, are movable exclusively along the radial direction 32 (cf. Fig. 6).

[0100] This allows the radial movement of all further holding units 40 or all further mounts 42 to be implemented by means of a rotation of the further cam element 56 (relative to the further guide device 58).

[0101] The further holding units 40 and thus also the further recordings 42 can be implemented by a joint rotation of the further backdrop element 56 and the further guide device 58.

[0102] The rotation of the further cam element 56 and / or the further guide device 58 is implemented in this case by the drive 49. The drive 49 of the device 10 according to the second, in which in Fig. The embodiment shown in Figure 6 is designed to drive the cam element 48, the further cam element 56, the guide device 50, and the further guide device 58 individually and / or jointly in a rotary motion. The mounts 26 and the further mounts 42 can be rotated in the same direction or in opposite directions.

[0103] The axial movement of the further mounts 42 along the axial direction 34 can be achieved, for example, by axially displacing the base plate 51 using a linear drive (not shown). It is also conceivable that the further cam element 56 and the further guide device 58 are moved relative to the base plate 51 along the axial direction 34.

[0104] The drive 49 and the base plate 51 are in Fig. 6 is only indicated schematically.

[0105] With the device 10 according to the second embodiment, two layers of conductor sections 12 can be simultaneously twisted and expanded (formed). A first layer of conductor sections 12 is formed by means of the first holding device 20, and the second layer of conductor sections 12 is formed by means of the further holding device 38. For this purpose, the free ends 18 of the first layer of conductor sections 12 are received in the receptacles 26, and the free ends 18 of the second layer of conductor sections 12 are received in the further receptacles 42. The receptacles 26 and the further receptacles 42 are moved, as described above, to carry out the expansion and twisting process on both layers of conductor sections 12 (simultaneously).

Claims

[1] Device (10) for twisting and expanding conductor pieces (12), wherein the conductor pieces (12) are arranged in a stator core (14), wherein each conductor piece (12) has at least one leg, wherein each leg (16) protrudes with a free end (18) from the stator core (14), wherein the device (10) comprises: - a holding device (20) with a plurality of holding units (24) arranged in a circle around a center point (22), wherein each holding unit (24) has a receptacle (26) for receiving a free end (18) of a leg (16) of a conductor piece (12), wherein the receptacles (26) are designed and arranged to receive all free ends (18) of the legs (16) of the conductor pieces (12) arranged on a circular path, wherein each receptacle (26) is designed to be movable between an inner position (28) and an outer position (30) along a radial direction (32) emanating from the center point (22) in order to carry out an expansion process, wherein the receptacles (26) are designed to be movable along an axial direction (34) oriented orthogonally to the radial direction (32) in order to compensate for a length contraction during the forming of the conductor pieces (12), wherein the device (10) is designed to carry out a twisting process, wherein the receptacles (26) and / or the stator are rotatable about a rotation axis (36) aligned through the center point (22) and along the axial direction (34) in order to carry out the twisting process, wherein the device (10) is designed such that the free ends (18) of the legs (16) of the conductor pieces (12) received in the receptacles (26) remain in contact with the conductor pieces (12) during the entire twisting process and during the entire Expansion process of the conductor pieces (12) by means of the device (10) and between these precursors remain temporally and under temperatures in the receptacles (26) of the holding units (24), characterized by that the receptacles (26) are each formed in one piece. [2] Device (10) according to claim 1, characterized by that the device (10) comprises at least one further holding device (38) with a plurality of further holding units (40), in particular arranged in a circle around the center point (22), wherein each further holding unit (40) has a further receptacle (42) for receiving a free end (18) of a leg (16) of a conductor piece (12), wherein the further receptacles (42) are designed and arranged to receive all free ends (18) of the legs (16) of the conductor pieces (12) arranged on a further circular path, wherein each further receptacle (42) is designed to be movable between an inner position and an outer position along the radial direction (32) in order to carry out an expansion process, in particular wherein the further receptacles (42) are designed to be movable along the axial direction (34) in order to compensate for a length contraction during the forming of the conductor pieces (12), in particular wherein the further receptacles (42) are designed to be rotatable about the rotation axis (36) in order to carry out a twisting process, wherein the device (10) is designed such that the free ends (18) of the legs (16) of the conductor pieces (12) received in the further receptacles (42) remain in the further receptacles (42) of the further holding units (40) during the entire twisting process and during the entire expansion process of the conductor pieces (12) by means of the device (10). [3] Device (10) according to claim 1 or 2, characterized bythat the further receptacles (42), the holding units (24) and / or the further holding units (40) are each formed in one piece. [4] Device (10) according to one of the preceding claims, characterized by that the receptacles (26) and / or the further receptacles (42) are cuboid-shaped. [5] Device (10) according to one of the preceding claims, characterized byin that the holding units (24) each have an extension (44) which engages in a guide track (46), wherein in particular a plurality of guide tracks (46), in particular all of the guide tracks (46), are arranged in a guide element (48), wherein the guide tracks (46) are arranged on the guide element (48) in such a way that the holding units (24) and the receptacles (26) can be moved along the radial direction (32) by a rotational movement of the guide element (48), wherein the holding units (24) are each guided via a guide device (50) in such a way that the holding units (24) and the receptacles (26) can be moved exclusively along the radial direction (32). [6] Device (10) according to one of claims 2 to 5, characterized byin that the further holding units (40) each have a further extension (52) which engages in a further guide track (54), wherein in particular a plurality of further guide tracks (54), in particular all further guide tracks (54), are arranged in a further guide element (56), wherein the further guide tracks (54) are arranged on the further guide element (56) in such a way that the further holding units (40) can be moved along the radial direction (32) by a rotational movement of the further guide element (56), wherein the further holding units (40) are each guided via a further guide device (58) in such a way that the further holding units (40) can be moved exclusively along the radial direction (32). [7] Device (10) according to one of the preceding claims, characterized bythat the receptacles (26) and / or the further receptacles (42) each have at least one, in particular two, in particular curved, contact surfaces (60), wherein the receptacles (26) and / or the further receptacles (42) are designed such that during the twisting process the free end (18) of a leg (16) of a conductor piece (12) received in the receptacle (26) and / or the further receptacle (42) is pressed against the contact surface (60) of the respective receptacle (26) and / or the respective further receptacle (42), so that the contour of the contact surface (60) is impressed on the respective free end (18). [8] Device (10) according to one of the preceding claims, characterized bythat the receptacles (26) and / or the further receptacles (42) each have at least one, in particular two, in particular curved, further contact surfaces (62), wherein the receptacles (26) and / or the further receptacles (42) are designed such that during the expansion process the free end (18) of a leg (16) of a conductor piece (12) received in the receptacle (26) and / or the further receptacle (42) is pressed against the further contact surface (62) of the respective receptacle (26) and / or the respective further receptacle (42), so that the contour of the further contact surface (62) is impressed on the respective free end (18). [9] A method for twisting and expanding conductor pieces (12), wherein the conductor pieces (12) are arranged in a stator core (14), wherein each conductor piece (12) has at least one leg (16), wherein each leg (16) protrudes from the stator core (14) with a free end (18), the method comprising the steps of: - receiving all free ends (18) arranged on the same circular path, or all three ends (18), of the legs (16) of the conductor pieces (12) in receptacles (26); - performing an expansion process by moving each of the receptacles (26) along a radial direction (32), in particular from an inner position (28) to an outer position (30), in order to expand the conductor pieces (12); - carrying out a length compensation process by moving the receptacles (26) and / or the conductor pieces (12) along an axial direction (34) oriented orthogonally to the radial direction (32) in order to compensate for a length contraction during the forming of the conductor pieces (12); - carrying out a twisting operation by rotating the receptacles (26) and / or the conductor pieces (12) about a rotation axis (36) which is held by a central pin (22) and aligned along the axial direction (34) in order to twist the conductor pieces (12); - wherein the free ends (18) of the legs (16) of the conductor pieces (12) received in the receptacles (26) remain in the receptacles (26) during the expansion process, the length compensation process and the twisting process and between them, characterized by that the receptacles (26) are each formed in one piece. [10] Method according to claim 9, characterized bythat the expansion process, the twisting process and the length compensation process are carried out simultaneously. [11] Method according to claim 9, characterized by that the expanding process and the twisting process are carried out one after the other. [12] Method according to one of claims 9 to 11, characterized bythat the receiving of the free ends (18) of the legs (16) of the conductor pieces (12) in the receptacles (26) is carried out by firstly moving the receptacles (26) and / or the free ends (18) of the legs (16) of the conductor pieces (12) towards one another along the axial direction (34) in a first relative movement until the free ends (18) of the legs (16) of the conductor pieces (12) are at least partially received in the receptacles (26), then the receptacles (26) are moved along the radial direction (32) and then the receptacles (26) and / or the free ends (18) of the legs (16) of the conductor pieces (12) are moved further towards one another along the axial direction (34) in a second relative movement until the free ends (18) of the legs (16) of the conductor pieces (12) are completely received in the receptacles (26). [13] Use of a device (10) for twisting and expanding conductor pieces (12) according to one of claims 1 to 8 for carrying out a method for twisting and expanding conductor pieces (12) according to one of claims 9 to 12.

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