Device and method for providing winding wires for a winding device for the production of windings for electrical machines

Abstract

The invention relates to a device 100 for supplying winding wires 1 to a winding unit 200 for producing windings for electrical machines. The device 100 corresponds to a linear wire magazine from which winding wires 1 are drawn to a winding unit 200. The device 100 comprises at least two column frames 31, which are mounted parallel to each other and spaced apart, on a base plate 3; a transport system 4 with transport spindles 41, which are attached to the column frames 31 to perform a circular transport movement; and several channels 2 for receiving the winding wire 1, wherein winding wire 1 in the form of an unwound wire section 11 can be inserted into a channel 2; at least two channel receptacles 42 for each channel 2 to hold the channel 2 on the column frames 31.The channel mounts each have four guide elements 43, of which one guide element 43 in succession engages with one of the transport spindles 41 of the transport system 4 to enable a paternoster-like circulation of the channels 2 on the column frames 31.

Description

[0001] The invention relates to a device and a method for providing winding wires for a winding device for winding mats of electrical machines. The device corresponds to a linear wire magazine from which winding wires are drawn to a winding device.

[0002] Electric motors are primarily considered electrical machines. Electric motors differ primarily in their winding type, which can accommodate a wide variety of operating modes. Special winding systems have been developed for electric vehicles, in particular the so-called hairpin and continuous hairpin technology. The latter – like hairpin technology, in which hairpin-like wire pieces are finally welded – uses profile wire with a rectangular cross-section, but a continuous flat wire is "braided" in a so-called winding mat. These winding mats can then be placed in prepared slots with a high fill level during the production of stators or rotors, saving space. Flat wires have a rectangular cross-section and, with regard to the filling factor of the winding space, have the advantage that the winding space can be filled more easily with flat wires than, for example, with round wires (see DE 10 2022 109 527 A1).

[0003] Various winding processes are used in the production of a winding mat. For example, in flat winding, wires are bent into a wave-like shape in a single plane and then joined together to form a winding mat. In sword winding, the wires are wound around a winding core, also known as a winding sword. In a winding mat, the winding mat has straight wire sections and roof-shaped winding heads. The straight wire sections can be inserted into the slots of stators and rotors of electrical machines, while the winding heads protrude from the outside of the axially directed housing ends and connect adjacent straight wire sections.

[0004] But the required magnetic fields are also generated differently in each motor. In addition to strong permanent magnets, electromagnets are also used, depending on the intended purpose of the electric motor. In the simplest case, a coil of copper wire is wound over a laminated core to generate the required magnetic field.

[0005] The winding technology significantly determines the properties of winding-based electromechanical assemblies, such as stators and rotors. These include insulation strength, quality factor, the size required for a specific power or magnetic force, and even the magnetic stray field.

[0006] In the known processes for producing coil windings for stators and rotors, the wires are fed into the winding machine in parallel. During the winding process, wires sometimes cross over, resulting in a phase jump. To cross the wires, one wire is placed in the slot of another wire and vice versa. The number of phase jumps within a winding is limited. At a phase jump, the wires are moved from their original position and subjected to diagonal stress. In addition, the wires rub against each other, which can lead to damage to the wire insulation. Furthermore, the wire path of individual wire coils is very complex due to the wire movements, including braking and tightening of the wire.

[0007] The production of a winding mat can require complex movement sequences for the wire crossings described above, given the normally orderly shifted positions of the wires provided from spools and processed in the winding device. The movement sequences required for this can be implemented using one or more parking areas, as described in the unpublished German patent application Akz. 102022213353.6. By parking individual selected wire feeds and simultaneously moving the remaining wire feeds, the relative positions of the wires to be processed can be changed during the braiding process of a winding mat. In other words, one or more wires can overtake the wire(s) in the parking position, enabling wires to cross over without interrupting the braiding process during the production of the winding mat.

[0008] In the prior art dealing with the feeding of wires, European patent application EP 3 512 079 A1 discloses a wave winding device comprising a feed device that provides at least one winding wire via at least one winding nozzle and transports it in a feed direction, and a winding device for winding the supplied winding wire onto a mandrel that is rotatably driven about a rotational axis and extends in a transport direction. The wave winding device is designed to grasp a plurality of windings lying on the mandrel in a wire-carrying device and to carry them along in the transport direction.

[0009] DE 10 2018 102 914 A1 discloses a wire feeding device comprising a movable support unit with a first spool that provides wire at a working position, and a conveyor device for conveying the wire into the production system. In addition to the first spool, a second spool is mounted on the support unit. The second spool is alternately moved into the working position with the first spool by the support unit, in order to move one of the spools into an exchange position.

[0010] The closest prior art is known from DE 10 2010 047 531 B4, a device for feeding wire to wire processing machines. Wire is drawn from a reel holding a wire coil and rotatable about an axis and fed to a wire feeder upstream of the wire processing machine. At least one wire deflection device is arranged downstream of the reel in the wire draw-off direction, through which the wire drawn from the reel is guided and delivered to the wire feeder. A wire storage device is provided upstream of the wire feeder.This wire storage device provides a guideway forming a closed circuit on which the wire runs and whose diameter can be changed between a smaller value corresponding to an inner radial position of the guideway and a larger value corresponding to an outer radial position of the guideway, wherein the guideway is spring-loaded in the direction of assuming its outer radial position.

[0011] However, to create complex windings, a special transport system is required that enables wire braiding. This allows the wires to be moved relative to the winding device in such a way that wire can be arranged one upon the other. This allows for the production of winding mats that require particularly complex movement sequences.

[0012] It is the object of the invention to find a new possibility of wire feeding for a winding device for producing winding mats of electrical machines, which enables easier handling of the wire feed movements in wave winding processes with intersecting wire windings and does not require a wire brake drive.

[0013] The object is achieved with a device for providing winding wires to be fed to a winding device for producing winding mats for electrical machines, comprising at least two column frames which are fastened to a base plate at a distance from one another in parallel, a transport system with transport spindles which are attached to the column frames in such a way as to carry out a circular transport movement; several channels for receiving the winding wire, wherein winding wire in the form of an unwound wire section can be inserted into one channel, at least two channel receptacles for each channel in order to hold the channel on the column frames, wherein the channel receptacles each have four guide elements, of which one guide element in each case engages successively with one of the transport spindles of the transport system in order to enable a paternoster-like circulation of the channels on the column frames.

[0014] An advantageous design provides that the column frames have two vertical sides and two horizontal sides with internal transport spindles in order to realize a rectangular circumferential transport movement within the at least two column frames.

[0015] It is expediently provided that the column frames can be folded open on one side in order to equip the channel holders with new wire-equipped channels or empty channels with new wire sections.

[0016] A further advantageous aspect provides that the column frames are extendable horizontally on at least one side in order to vary the distance of the paternoster-like transport movement on the vertical sides of the column frames depending on the winding requirements of the subsequent winding device.

[0017] Preferably, the column frames have two vertical sides and two horizontal sides on a cuboid hollow profile with external transport spindles in order to realize a rectangular circumferential transport movement outside around the hollow profile.

[0018] Preferably, the column frames have a parking area with a separable spindle part at two opposite corners in order to remove a selected channel from the paternoster-like circulation by means of the channel holder and to park it so that other channels with wire sections can overtake the channel located in the parking area.

[0019] The channels are advantageously formed from open or closed extruded profiles. The channels are preferably U-shaped in cross-section.

[0020] It is particularly advantageous if the channels are partially or completely covered or locked. The channels can also advantageously be designed as tubes.

[0021] In a preferred embodiment, the channels are designed as tubes with a rectangular cross-section in order to be able to hold flat wire without twisting or twisting.

[0022] According to a further preferred aspect, the channels are closed at least at one end in front of the winding device with end panels which have a cross-section adapted to the wire cross-section in order to prevent twisting or twisting of the wire sections within the channels.

[0023] According to a particularly advantageous aspect, the length of the device and the number of column frames can be freely selected to adapt to the winding wire lengths required for the winding mats. It can be dimensioned up to 15 m, preferably between 5 and 10 m, as required. The number of column frames can preferably be selected between 2 and 15.

[0024] An advantageous aspect includes that the channels can be designed to insert two or more wire sections.

[0025] Advantageously, the device is designed to provide straight wire sections with a rectangular cross-section.

[0026] Furthermore, the object of the invention is achieved by a method for producing windings for electrical machines. The method comprises the steps of providing at least two column frames spaced parallel to one another for receiving orderly arranged channels which are moved in a closed circuit by a transport system located on the column frames; suspending channels with a square inner cross-section in channel receptacles on the at least two column frames; inserting unwound wire sections into the channels; moving the channels on the at least two column frames in a paternoster-like manner by means of transport spindles attached to the column frames in order to displace the channels on each column frame parallel in a closed circuit transverse to the longitudinal direction of the channel for feeding the inserted wire sections for braiding a winding mat for electrical machines.

[0027] An advantageous further development of the method provides that during paternoster-like movement at two opposite corners of the column frames, a decoupling step for a selected channel into a parking area takes place, which is carried out by means of a separable spindle part in order to move other channels past the channel located in the parking area.

[0028] Yet another advantageous aspect of such a method provides that when refilling unwound wire sections into the device, either new wire sections are inserted into the channels or new channels equipped with wire sections are inserted into the channel receptacles on the column frames.

[0029] A special embodiment of the method provides that the paternoster-like movement of the channels takes place within closed column frames or is carried out outside a cuboid hollow profile along vertical sides and horizontal sides of the hollow profile.

[0030] The key advantage of the invention is the use of a quickly loadable magazine with wires of the required lengths and a required number of wires for feeding the wire to the winding device instead of unwinding, guiding, and braking devices for wire spools. Particularly in the wave winding process (continuous hairpin process), smaller wire masses need to be moved when winding mats are "braided" with intersecting wires. Furthermore, simple loading with channels or channel-equipped column frames (cassette loading) eliminates the need to retool the magazine, because larger channel inner diameters make the magazine largely independent of the wire cross-section. Furthermore, pay-off spools and associated braking mechanisms are not required in the area of ​​the wire feed to the winding device.

[0031] The invention makes it possible to realize a wire feed for a winding device for producing winding mats of electrical machines, which allows easier handling of the wire feed movements in wave winding processes with intersecting wire windings and does not require a wire brake drive.

[0032] The invention will be explained in more detail below by means of exemplary embodiments based on the drawings. They show: Fig. 1 shows a schematic diagram of a device for providing winding wires for a winding device for winding mats of electrical machines according to an embodiment; Fig. 2 shows in four views a device for providing winding wires for a winding device for winding mats of electrical machines; Fig. 2a shows a perspective view of an opened device with three exemplary column frames and several accommodated channels; Fig. 2b the front view of the device according to Fig. 2a; Fig. 2c shows a perspective view of a closed device with three exemplary column frames and several accommodated channels; Fig. 2d the front view of the device according to Fig. 2c; Fig. 3 in a perspective view a transport spindle of the transport system and a channel holder which engages in the transport spindle via one of the four guide elements; Fig. 4 in two detailed views a canal image with an inserted U-shaped canal; Fig. 4a in a perspective view the channel holder with an open U-shaped channel; Fig. 4b in a perspective view the channel holder with a closed U-shaped channel; Fig. 5 shows in two schematic views a cube variant of the device for providing winding wires for a winding device for winding mats of electrical machines; Fig. 5a shows a perspective view of a cube variant of the device with three exemplary column frames; and Fig. 5b the front view of the device according to Fig. 5a.

[0033] In Fig. 1 shows an embodiment of a device 100 for providing winding wires 1 for a winding device 200 for winding mats 300 of electrical machines. From the left side to the right side, parallel channels 2 extend, which are framed by two exemplary column frames 31. More than two column frames 31 are also possible, whereby the length of the device 100 can be adjusted. A transport system 4 - here located internally - is located on the column frames 31, into which several channel receptacles 42 engage. The channel receptacles 42 carry the individual channels 2. The two column frames 31 each have two vertical sides 32 and two horizontal sides 33 and are therefore rectangular in shape. In the right side of Fig. 1 shows a winding device 200 that produces a winding mat 300. The winding wires 1 emerging from the parallel channels 2 are brought together at a specific spreading angle on the winding device 200.

[0034] Fig. 2 consists of four views of the device 100 for providing winding wires 1 for a winding device 200 for winding mats 300 of electrical machines. Fig. Figure 2a shows the device 100 in the open state with three exemplary column frames 31. For opening and closing, the column frames 31 can be hinged open on one side in order to equip the channel receptacles 42 with new wire-equipped channels 2 or empty channels 2 with new wire sections 11. In the present embodiment, the channels 2 with the wire sections 11 have been lowered from above into the interior space between the column frames 31. Six exemplary channels 2 are shown on each side of the column frames 31. The details of this opened device 100 are shown in Fig. 2b is shown as a front view. The transport system 4 located inside the column frame 31 is drawn with thick lines and includes two exemplary parking areas 35 (see bottom right and top left). The transport system 4 can also have only one or more than two parking areas 35. In the present illustration, the two parking areas 35 are located outside the circulation of the transport system 4, but the parking areas 35 could also be located within the circulation. Fig. 2c, the device 100 is shown in a closed state and the associated Fig. 2c shows the front view. At two opposite corners of the column frames 31, there is a parking area 35 for removing a selected channel 2 from the paternoster-like circuit and parking it there using the channel holder 42. The transport system 4 can move other channels 2 past the channel 2 located in the parking area 35 using a separable spindle part 44.

[0035] In Fig. Figure 3 shows an enlarged section of the transport system 4 with a vertical transport spindle 41. The transport spindle 41 (left) is connected to a channel holder 42 (right). The channel holder 42 has four guide elements 43 arranged at the top, bottom, and on both sides. This arrangement allows the channel holder 42 to always engage with one of the four guide elements 43 in one of the transport spindles 41 on the vertical sides 32 or the horizontal sides 33 of the column frames 31, resulting in a circular movement of the channel 2 upon rotation of the transport spindle 41.

[0036] In Fig. 4 shows a channel holder 42 with an inserted U-shaped channel 22. This channel 22 can contain one or more wire sections 11. The four guide elements 43 have an elliptical or circular cross-section at their ends, which fits into a transport spindle 41 of the circulating transport system 4 (see Fig. 3). The U-shaped channel 22 can be arranged as shown in Fig. 4a shown open or as in Fig. 4b, it can be covered with a cover 21. It is also possible to use channels 2, which are designed as tubes 23.

[0037] Fig. Figure 5 shows another embodiment of the device 11 for providing winding wires 1 for a winding device 200 for winding mats 300 of electrical machines. This embodiment is referred to as a cube variant and is designed as a linear support magazine. As can be seen from Fig. 5a shows a linear shape, which can be 10 meters long, and therefore requires support. For this purpose, the linear support magazine has two hollow profile supports 38, which can be designed to be retractable. In the view according to Fig.5b, the transport system 4 is located on the outside, i.e., the channel receptacles 42 for the channels 2 are located and move outside the vertical sides 32 and horizontal sides 33 of the cuboid hollow profile 36. The hollow profile 36 cannot be opened due to the external position of the transport system 4. There is a parking area 35 at each of two opposite corners of the cuboid hollow profile 36 for removing a selected channel 2 from the paternoster-like circuit by means of the channel receptacle 42 and parking it. The transport system 4 can move other channels 2 past the channel 2 located in the parking area 35 by means of a separable spindle part 44. List of reference symbols 1 winding wire 11 Wire section 12 flat wire 2 channel 21 Cover 22 U-profile 23 pipe 3 Base plate 31 Column frame 32 vertical side (of the column frame) 33 horizontal side (of the column frame) 34 split column frame 35 Parking area 36 (cuboid) hollow profile 37 Front plate 38 (retractable) hollow profile support 4 Transport system 41 Transport spindle 42 channel recording 43 Guide element 44 separable spindle part (for the parking area) 100 device 200 winding device 300 changing mat QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2022 109 527 A1

[0002] EP 3 512 079 A1

[0008] DE 10 2018 102 914 A1

[0009] DE 10 2010 047 531 B4

[0010]

Claims

[1] Device for providing winding wires (1) to be fed to a winding device (200) for producing winding mats (300) of electrical machines, comprising: - at least two column frames (31) which are fixed to a base plate (3) at a distance from one another, - a transport system (4) with transport spindles (41) which are mounted on the column frames (31) in such a way as to carry out a circular transport movement, - several channels (2) for receiving the winding wire (1), wherein winding wire (1) in the form of an unwound wire section (11) can be inserted into one channel (2), - at least two channel receptacles (42) for each channel (2) in order to hold the channel (2) on the column frames (31), wherein the channel receptacles (42) each have four guide elements (43), of which one guide element (43) is successively engaged with one of the transport spindles (41) of the transport system (4) in order to enable a paternoster-like circulation of the channels (2) on the column frames (31). [2] Device according to claim 1, characterized by that the column frames (31) have two vertical sides (32) and two horizontal sides (33) with internal transport spindles (41) in order to realize a rectangular circumferential transport movement within the at least two column frames (31). [3] Device according to claim 1 or 2, characterized bythat the column frames (31) can be folded open on one side in order to equip the channel holders (42) with new wire-equipped channels (2) or empty channels (2) with new wire sections (11). [4] Device according to claim 2 or 3, characterized by that the column frames (31) are extendable horizontally on at least one side in order to vary the distance of the paternoster-like transport movement on the vertical sides (32) of the column frames (31) depending on the winding requirements of the subsequent winding device (200). [5] Device according to claim 1, characterized by that the column frames (31) have two vertical sides (32) and two horizontal sides (33) on a cuboid hollow profile (36) with external transport spindles (41) in order to realize a rectangular circumferential transport movement outside around the hollow profile (36). [6] Device according to one of the preceding claims, characterized bythat the column frames (31) have a parking area (35) with a separable spindle part (44) at two opposite corners in order to remove a selected channel (2) from the paternoster-like circulation by means of the channel holder (42) and to park it, so that other channels (2) with wire sections (11) can overtake the channel (2) located in the parking area (35). [7] Device according to one of the preceding claims, characterized by that the channels (2) are formed from open or closed extruded profile. [8] Device according to claim 7, characterized by that the channels (2) are U-shaped in their cross-section. [9] Device according to claim 8, characterized by that the channels (2) are partially or completely provided with a cover (21) or locking device. [10] Device according to claim 7, characterized by that the channels (2) are designed as tubes (23). [11] Device according to claim 7, characterized by that the channels (2) are designed as tubes (23) with a rectangular cross-section in order to be able to hold flat wire (12) without twisting or twisting. [12] Device according to one of the preceding claims, characterized by that the channels (2) are closed at least at one end in front of the winding device (200) with end panels which have a cross-section adapted to the wire cross-section in order to prevent twisting or twisting of the wire sections (11) within the channels (2). [13] Device according to one of the preceding claims, characterized by that the length of the device (100) and the number of column frames (31) can be adjusted as desired. [14] Device according to one of the preceding claims, characterized by that the channels (2) are designed for inserting two or more wire sections (11). [15] Device according to one of the preceding claims, characterized by that the device (100) is intended to provide straight wire sections (11) with a rectangular cross-section. [16] Method for providing winding wires (1) to be fed to a winding device (200) for producing windings of electrical machines, comprising the following steps: - Providing at least two column frames (31) spaced parallel to one another for receiving orderly mounted channels (2), which are moved in a closed circuit by a transport system (4) located on the column frames (31), - Hanging channels (2) with a square inner cross-section in channel holders (42) on at least two column frames (31), - Inserting unwound wire sections (11) into the channels (2), - paternoster-like movement of the channels (2) on the at least two column frames (31) by means of transport spindles (41) attached to the column frames (31), in order to move the channels (2) on each column frame (31) in parallel in a closed circuit transverse to the longitudinal direction of the channel for feeding the inserted wire sections (31) for braiding a winding mat (300) for electrical machines. [17] Method according to claim 16, characterized by that during paternoster-like movement at two opposite corners of the column frames (31), a decoupling step for a selected channel (2) into a parking area (35) takes place, which is carried out by means of a separable spindle part (44) in order to move other channels (2) past the channel (2) located in the parking area (35). [18] Method according to claim 16, characterized bythat when refilling unwound wire sections (11) into the device (100), either new wire sections (11) are inserted into the channels (2) or new channels (2) equipped with wire sections (11) are inserted into the channel receptacles (42) on the column frames (31). [19] Method according to claim 16, characterized by that the paternoster-like movement of the channels (2) takes place within closed column frames (31) or is carried out outside a cuboid hollow profile (36) along vertical sides (32) and horizontal sides (33) of the hollow profile (36).

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