Interlocking tool for forming stator winding end windings

Abstract

Interlocking tool (10) for forming stator end windings, wherein the interlocking tool (10) comprises: a first organ (12) comprising a first basic body (20) with a first surface (22) and with an opposing second surface (24), wherein a first ring (28) extends from the first surface (22) and a second ring (30) extends from the first surface (22), the second ring (30) being radially within the first ring (28) and spaced from the first ring (28) by a first gap (31); and a second organ (14) comprising a second basic body (64) with a first surface section (66) and with an opposing second surface section (68), wherein a first ring element (70) extends from the first surface section (66) and a second ring element (72) extends radially inwards from the first ring element (70) of the first surface section (66), wherein the second ring element (72) is spaced apart from the first ring element by a second space (73); wherein the second ring (30) is positioned in the second space (73) and wherein the second ring element (72) is positioned in the first space (31), wherein the first organ (12) is rotatable relative to the second organ (14); characterized by the fact that the first ring element (70) comprises a first annular surface section (79), a first outer edge section (81) and a first inner edge section, which is spaced apart from the second basic body (64) and defines a second window (83); that the first ring (28) comprises a first annular surface (36) and a first outer edge (38), wherein the first annular surface (36) is connected to the first base body (20) by a ring support (40) bridging the first gap (31) and extending through the second window (83) of the inner edge section of the first ring element (70); and that the first organ (12) and the second organ (14) are produced additively.

Description

INTRODUCTION

[0001] The present disclosure relates to the field of electrical machines and, in particular, to an interlacing tool according to the preamble of claim 1 for forming stator winding end turns for an electrical machine, as is essentially known from DE 10 2019 211 713 A1. Further prior art can also be found in the documents DE 10 2018 221 562 A1, US 2013 / 0 276 295 A1, CN 2 11 981 691 U, and JP 2021-151 136 A.

[0002] Electric machines include a housing that supports a stator. Within the stator, a rotor rotates, supported by a shaft. The rotor can support a magnetic field that induces a current in the stator to generate electricity (generator), or energy passing through the stator can induce a magnetic field in the rotor (motor). The stator includes a core that supports windings. A first portion of the windings extends axially outward from a first end of the core to form a first stator end turn, and a second portion of the windings extends axially outward from a second, opposite end of the core to form a second stator end turn. The first end turn or the second end turn includes terminal ends of the windings that are connected to establish a desired electrical connection for the stator.

[0003] Before the electrical connection is made, the corresponding end turn is twisted and bent to reduce the overall axial length of the stator. A multi-component tool is used to form the end turn. The multi-component tool comprises a series of coaxial rings, each with a different diameter. A first number of the rings are rotated in a first direction, and a second number of the rings are rotated in a second, opposite direction to form the end turn. Each ring engages and forms different layers of the windings.

[0004] To ensure proper alignment of the terminal ends, the rings must be precisely positioned relative to each other. Connecting the rings, aligning the rings, and mounting the rings on a forming tool all take time and require specialized tooling and expertise, which contribute to the overall cost of forming the stator. Accordingly, the industry would welcome a less labor-intensive system for forming end turns. SUMMARY

[0005] According to the invention, an interlacing tool for forming stator end windings is presented, which is characterized by the features of claim 1.

[0006] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the second body comprising an opening circumscribing the first body.

[0007] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the first member comprising a first mounting element extending outwardly from the second surface, and the second member comprising a second mounting element extending outwardly from the second surface portion.

[0008] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the second ring comprising a second annular surface and a second outer edge, the second annular surface comprising a first window aligned with the ring carrier.

[0009] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the ring carrier extending at an angle from the first base body to form the first gap.

[0010] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the first ring comprising an inner rim spaced from the second base body.

[0011] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the second ring element comprising a second annular surface portion and a second outer edge portion, wherein the second annular surface portion is connected to the main body portion by a ring support member disposed at the second window.

[0012] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the ring support member extending at an angle from the second base body to form the second gap.

[0013] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the first window defining a first travel limiter that sets an amount of rotation of the second member relative to the first member.

[0014] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include that the amount of rotation is about.

[0015] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the ring carrying a first plurality of comb fingers and the second ring carrying a second plurality of comb fingers.

[0016] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the first ring member carrying a first plurality of comb finger elements and the second ring member carrying a second plurality of comb finger elements.

[0017] In addition to one or more of the features described above or below, or as an alternative, further embodiments could include that the first member and the second member are additively manufactured to form the entangling tool.

[0018] The above features and advantages and other features and advantages of the present disclosure are readily apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Further features, advantages and details appear only as examples in the following detailed description, which refers to the drawings; they show: Fig. 1 is a perspective view of an interlacing tool for forming a stator end turn according to a non-limiting example; Fig. 2 a perspective cross-sectional view of the interlacing tool from Fig. 1 according to a non-limiting example; Fig. 3 a cross-sectional plan view of the interlacing tool from Fig. 1 by line 3-3 according to a non-limiting example; Fig. 4 a disassembled view of the interlacing tool from Fig. 1 according to a non-limiting example; Fig. 5 a perspective cross-sectional view of the interlacing tool from Fig. 4 according to a non-limiting example; Fig. 6 a cross-sectional plan view of the interlacing tool from Fig. 4 by line 6-6 according to a non-limiting example; Fig. 7 a cross-sectional view of the interlacing tool from Fig. 1 by line 7-7 according to a non-limiting example; Fig. 8 a cross-sectional view of the interlacing tool from Fig. 1 along line 8-8 according to a non-limiting example; Fig. 9 a plan view of a tool used in the interlacing tool Fig. 1 formed window according to a non-limiting example; Fig. 10 is a schematic view of the interlacing tool engaged with terminal ends of a stator end turn, according to a non-limiting example; Fig. 11 a schematic view of the entanglement tool from Fig. 10, which forms the terminal ends of the stator end winding, according to a non-limiting example; and Fig. 12 an axial partial cross-sectional end view of a stator end winding. DETAILED DESCRIPTION

[0020] The following description is merely exemplary in nature. It should be understood that corresponding reference characters designate like or corresponding parts and features throughout the drawings.

[0021] An entanglement tool according to a non-limiting example is shown in Fig. 1 is shown generally at 10. The interleaving tool 10 includes a first member 12 that is nested and interleaved with a second member 14. The first member 12 can rotate relative to the second member 14, and the second member 14 can rotate relative to the first member 12. By way of non-limiting example, the first member 12 and the second member 14, in addition to being nested with one another, are also interleaved with one another. The interleaving is achieved through an additive manufacturing process that builds the first member 12 and the second member 14 substantially simultaneously. Thus, the first member 12 and the second member 14 are interleaved with one another, although they are rotatable relative to one another. That is, by way of non-limiting example, the first member 12 cannot be easily separated from the second member 14.According to one non-limiting example, the first member 12 and the second member 14 are formed from metal and / or metal alloys. According to other non-limiting examples, the first member 12 and the second member 14 may be formed from various forms of plastics, ceramics, composite materials, and the like.

[0022] According to a non-limiting example, the first member 12 comprises a first base body 20 having a first surface 22 and a second surface 24. The second surface 24 is opposite the first surface 22. The first member 12 comprises a first ring 28 ( Fig. 2) and a second ring 30. The second ring 30 is radially inside the first ring 28 and through a first space 31 ( Fig. 3) arranged at a distance from it.

[0023] Based on Fig. 2-8 and further based on Fig. 1, the first ring 28 includes a first annular surface 36 with a first outer edge 38. The first ring 28 is coupled to the first base body 20 by a ring carrier 40. The ring carrier 40 includes an angled portion 42 that creates the first gap 31. According to a non-limiting example, the first ring 28 includes an inner edge 44 ( Fig. 2), which is spaced from the first base body 20. At this point, it should be understood that the number and spacing of the one or more ring carriers 40 may vary.

[0024] By way of non-limiting example, the second ring 30 includes a second annular surface 48 extending from the first base body 20 and including a second outer edge 50. The second annular surface 48 includes a first window 52 disposed adjacent the ring carrier 40. By way of non-limiting example, the number and spacing of the one or more first windows 52 may vary. The first ring 28 supports a first plurality of comb fingers 55, and the second ring 30 supports a second plurality of comb fingers 58. As discussed more fully below, the first plurality of comb fingers 55 and the second plurality of comb fingers 58 are arranged to form two non-adjacent layers of a stator end turn. That is, the first member 12 is supported on a first rotating machine (not shown) by a first mounting member 60 extending from the second surface 24.As will be explained in detail here, the first organ 12 is rotated in a first direction relative to the second organ 14.

[0025] By way of non-limiting example, the second member 14 includes a second base body 64 having a first surface portion 66 and a second surface portion 68. The second surface portion is opposite the first surface portion 66. The second member 14 includes a first ring member 70 and a second ring member 72. The second ring member 72 is disposed radially inward of the first ring member 70 and spaced therefrom by a gap 73. By way of non-limiting example, the first ring 28 is disposed within the second gap 73 and the second ring member 72 is disposed in the first gap 31. With this arrangement, the first member 12 and the second member 14 are interleaved. As discussed herein, it is to be understood that the first member 12 and the second member 14, although interleaved, are capable of movement relative to one another, as detailed herein.

[0026] According to one non-limiting example, the first ring member 70 includes a first annular surface portion 79 extending from the first surface portion 66. The first annular surface portion 79 includes a first outer edge portion 81 and a second window 83. As shown in more detail herein, the ring carrier 40 extends through the second window 83 to support the first ring 28 in the second space 73 ( Fig. 3). In this way, the second window acts as a travel limiter. That is, when the second member 14 rotates relative to the first member 12, an amount of travel is determined by a circumferential width "w" of the second window 83 ( Fig. 9). A similar restriction is imposed on the first member 12. As a non-limiting example, the second window 83 may allow 30° of rotation of the first member 12 relative to the second member 14 and 30° of rotation of the second member 14 relative to the first member 12, thereby allowing a combined relative rotation of 60°.

[0027] According to a non-limiting example, the second ring element 72 comprises a second annular surface portion 86, Fig. 5 extending from the first surface portion 66. The second annular surface portion 86 includes a second outer edge portion 88. A ring support member 92 connects the second ring member 72 to the first surface portion 66. The ring support member 92 includes an angled surface portion 94 that establishes the second gap 73. By way of non-limiting example, the first ring member 70 includes a first plurality of comb finger elements 97 extending from the first outer edge portion 81, and the second ring member 72 includes a second plurality of comb finger elements 99 extending from the second outer edge portion 88. As discussed in more detail herein, the first plurality of comb finger elements 97 and the second plurality of comb finger elements 99 are arranged to form two additional non-adjacent layers of a stator end turn.

[0028] By way of non-limiting example, the first and second pluralities of comb fingers 55 and 58 are arranged relative to each other and to the first and second pluralities of comb finger elements 97 and 99 as shown in Fig. 3. As shown in Fig. 10, the interlacing tool 10 is engaged in this configuration with the terminal ends 120 of a stator end winding. When the terminal ends 120 interact with the first and second plurality of comb fingers 55 and 58 and with the first and second plurality of comb finger elements 97 and 99, the first and second members 12 and 14 are rotated relative to each other to interlace the terminal ends 120 as shown in Fig. 11. By way of non-limiting example, the interlacing tool 10 forms the four radially outermost layers of the terminal ends 120. The amount of bending is determined, for example, by the amount of rotation provided by the width of the second window 83.

[0029] That is, according to one non-limiting example, the terminal end 120 comprises, as shown in Fig.12, four layers: a first or radially outermost layer 124, a second layer 126 disposed radially inward of the first layer 124, a third layer 128 disposed radially inward of the second layer 126, and a fourth layer 130 disposed radially inward of the third layer 128. It should be understood that the number of layers may vary. By way of non-limiting example, a first plurality of comb finger elements 97 of the second member 14 engage and act upon the terminal ends 120 in the first layer 124. The second plurality of comb finger elements 99 of the second member 14 engage and act upon the terminal ends 120 in the third layer 128.The first plurality of comb fingers 55 of the first member 12 are engaged with and act upon the terminal ends 120 in the second layer 126 and the second plurality of comb fingers 58 are engaged with and act upon the terminal ends 120 in the fourth layer 130.

[0030] The non-limiting examples discussed here describe a multi-component interleaving tool for forming stator end turns. By forming two members, each with two spaced-apart rings, there is no need to separately connect and align multiple components while ensuring relative rotation between the tool components. The interleaving design allows for easy alignment and maintenance of gaps, eliminating the need for spacers, mechanical fasteners, and expertise required to assemble a tool for forming end turns. Furthermore, it should be understood that the number of members and the number of rings per member may vary depending on the end turn configuration and electrical connection scheme.

[0031] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. Further, when used in this specification, the terms "comprises" and / or "comprising" are understood to specify the presence of the recited features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

Claims

[1] Interlacing tool (10) for forming stator end windings, the interlacing tool (10) comprising: a first member (12) comprising a first base body (20) having a first surface (22) and an opposite second surface (24), a first ring (28) extending from the first surface (22) and a second ring (30) extending from the first surface (22), the second ring (30) being radially inward of the first ring (28) and spaced from the first ring (28) by a first gap (31); and a second member (14) comprising a second base body (64) with a first surface portion (66) and with an opposite second surface portion (68), wherein a first ring element (70) extends from the first surface portion (66) and a second ring element (72) extends radially inwardly from the first surface portion (66) of the first ring element (70), wherein the second ring element (72) is spaced from the first ring element by a second intermediate space (73); wherein the second ring (30) is positioned in the second space (73) and wherein the second ring element (72) is positioned in the first space (31), wherein the first member (12) is rotatable relative to the second member (14); characterized by , that the first ring element (70) comprises a first annular surface portion (79), a first outer edge portion (81) and a first inner edge portion spaced from the second base body (64) and defining a second window (83); that the first ring (28) comprises a first annular surface (36) and a first outer edge (38), wherein the first annular surface (36) is connected to the first base body (20) by a ring carrier (40) bridging the first intermediate space (31) and extending through the second window (83) of the inner edge portion of the first ring element (70); and that the first organ (12) and the second organ (14) are manufactured additively. [2] The interlocking tool (10) of claim 1, wherein the second base body (64) includes an opening circumscribing the first base body (20). [3] The interlocking tool (10) of claim 1, wherein the first member (12) comprises a first mounting element (60) extending outwardly from the second surface (24) and the second member (14) comprises a second mounting element extending outwardly from the second surface portion (68). [4] The interlocking tool (10) of claim 1, wherein the second ring (30) includes a second annular surface (48) and a second outer edge (50), the second annular surface (48) including a first window (52) aligned with the ring carrier (40). [5] The interlocking tool (10) of claim 1, wherein the second ring member (72) comprises a second annular surface portion (86) and a second outer edge portion (88), the second annular surface portion (86) being connected to the first base body (20) by a ring support member (92) disposed at the second window (83). [6] An interlacing tool (10) according to claim 5, wherein the first window (52) defines a first travel limiter that sets an amount of rotation of the second member (14) relative to the first member (12). [7] Interlocking tool (10) according to claim 1, wherein the first ring (28) carries a first plurality of comb fingers (55) and the second ring (30) carries a second plurality of comb fingers (58); and wherein the first ring element (70) carries a first plurality of comb finger elements (97) and the second ring element (72) carries a second plurality of comb finger elements (99).

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