Winding mat, method and apparatus for manufacturing the winding mat, stator of an electric rotary machine

Abstract

Winding mat (1) for generating a winding of a stator of an electric rotary machine, wherein the winding mat (1) has at least one winding of a conductor element (20) in meander shape (10) and the meander shape (10) comprises several linear sections (21) of the conductor element (20) which are connected to each other by means of angled conductor sections (23) of the conductor element (20), wherein the conductor element (20) has at least a sectionally rectangular cross-section to form the meander shape (10), and that the linear sections (21) are parallel to each other and linear sections (21) of the same conductor element (20) arranged adjacent to each other along the longitudinal direction (13) of the meander shape (10) are equidistant from each other, characterized in thatthat the angle ladder sections (23) have a constant first length on a first longitudinal side (11) along the longitudinal direction (13) and a constant second length on a second longitudinal side (12) parallel to the first longitudinal side along the longitudinal direction (13).

Description

[0001] The invention relates to a winding mat for producing a winding of a stator of an electric rotary machine, a method and a device for producing the winding mat, and a stator of an electric rotary machine.

[0002] The electric powertrain of motor vehicles is known according to the state of the art. It consists of components for energy storage, energy conversion, and energy transmission. The energy conversion components include radial flux machines and axial flux machines.

[0003] However, radial flux machines often only have one operating point at which they achieve the best efficiency. Accordingly, they are not designed to adjust their operating point depending on changing requirements and thus achieve maximum efficiency at different operating points or according to the varying demands of different operating parameters.

[0004] To overcome this disadvantage, electric rotary machines adapted to the requirements of their operating range are often used, or the disadvantage is compensated by coupling the electric rotary machine to a gearbox unit or integrating a gearbox unit into the electric rotary machine, as is the case with an electric axis.

[0005] Axial flux machines are known in various designs with one or more stators and one or more rotors, according to the state of the art.

[0006] An electric axial flux machine, also known as a transverse flux machine depending on its design, is a motor or generator in which the magnetic flux between a rotor and a stator is parallel to the rotor's axis of rotation. Other names or configurations for electric axial flux machines include brushless DC motor, permanent magnet synchronous motor, and disc rotor motor.

[0007] Such an axial flux machine can be designed in various ways, differing in the arrangement of the rotor and / or stator, and offering different features and advantages in application, e.g. as a traction machine for a vehicle.

[0008] Axial flux machines exist with various winding configurations. A common winding configuration is the single-tooth winding. While single-tooth windings result in small winding heads, they generate a magnetic field with a high harmonic content—waves with a different frequency than the rotor speed of the axial flux machine—which negatively impacts acoustics and efficiency. Axial flux machines with distributed windings have the advantage that the aforementioned disadvantages do not occur or occur only to a lesser extent. However, the winding heads of these distributed windings require a large amount of installation space in the axial and / or radial direction.

[0009] Especially in axial flux machines, large winding heads are undesirable because their radial expansion restricts the maximum diameter of the active components, thereby reducing the maximum available torque or motor power. A relatively large radial expansion of the winding heads also results in a greater, and equally undesirable, radial overall length of the electric rotary machine.

[0010] Four topologies for axial flux machine windings are known in the prior art: -Circularized round or flat wire coils on individual teeth, which can be individually attached to the teeth. -Distributed loop windings based on flat wire coils, which are individually placed onto the teeth as loops. -Distributed wave windings with flat wire for ironless stators, as known, for example, from US8823238B2 and US10574110B2. Distributed wave windings with round wire for axial flux machine stators. Concentrated windings allow for easy scaling through linear winding. Distributed windings as flat wire coils offer design advantages combined with easy scaling through linear winding. Distributed

[0011] Windings as wave windings with flat wire for ironless stators can be productively manufactured, for example, in toroidal core winding.

[0012] Distributed wave windings with round wire for axial flux machine stators can be manufactured using a wave winding process.

[0013] Both concentrated windings and distributed windings with flat wire coils require assembly coil-by-coil or coil-chain-by-coil assembly, which increases the assembly effort. Furthermore, this design necessitates the arrangement of the connection contacts on the radial outer surface, which increases the radial installation space required.

[0014] Ironless stators are generally limited to lower power outputs and are not typically used as a topology for traction motors.

[0015] DE102021124994A1 discloses a stator for an electric rotary machine, a method for manufacturing the stator and the electric rotary machine itself.The stator comprises a stator body having several stator teeth arranged along a circumferential direction and slots formed between the stator teeth, as well as conductor sections of at least one conductor pair arranged in the slots, which forms at least a portion of the stator windings, wherein in each slot conductor sections of the conductor pair are arranged parallel to each other along the depth of the slot and the sequence of the arrangement of the parallel conductor sections in each slot through which the conductors run alternates along the circumferential direction, and wherein the conductors of the conductor pair meander radially in a direction substantially perpendicular to the circumferential direction, and each group of stator teeth is enclosed by a respective wrap formed thereby.

[0016] DE102021124995A1 discloses a method for manufacturing a winding for a stator, the stator itself, a method for manufacturing the stator, and an electric rotating machine. In the method for manufacturing a winding for a stator of an electric rotating machine, a first conductor and a second conductor are provided. The two conductors are each bent into a zigzag shape, at least in sections along their lengths. The second conductor is moved in a combined motion relative to the first conductor, which has a translational motion component along the longitudinal axis of the second conductor and a rotational motion component around the longitudinal axis of the second conductor, such that the second conductor winds around an extremity axis of the first conductor, which passes through regions of the first conductor that form the extrema of the zigzag pattern.

[0017] DE102021124996A1 discloses a method for manufacturing a winding for a stator of an electric rotating machine, the stator itself, a method for manufacturing the stator, and an electric rotating machine. In the method for manufacturing a winding for a stator of an electric rotating machine, several conductors are provided and wound onto a first blade along a first winding direction, such that the conductors encircle the first blade, and then the first blade is removed from the winding of conductors thereby produced.

[0018] EP3381108B1 discloses a method for manufacturing a coil winding that can be inserted into the slots of a stator or rotor of an electric machine. Using a winding template and a wire handling device, a sliding operation between a first and a second holding area is performed before the very first winding of the wires onto the winding template to create an inclined wire section, which is subsequently formed into winding heads by a rotating / winding operation. This allows all wires of a coil winding to be processed simultaneously with a comparatively simple winding device. The projection of the winding heads beyond the stator can also be minimized. Flat wire with a rectangular cross-section can be used in this process.

[0019] Starting from this, the present invention is based on the objective of providing a winding mat for producing a winding of a stator of an electric rotary machine, a method and a device for producing the winding mat, and a stator of an electric rotary machine, which in a cost-effective manner ensure the production and assembly of a winding of a stator with a small installation space requirement.

[0020] This problem is solved by the winding mat according to claim 1, by the method for manufacturing a winding mat according to claim 7, by the device for manufacturing a winding mat according to claim 9, and by the stator of an electric rotary machine according to claim 10. Advantageous embodiments of the winding mat are specified in dependent claims 2 to 6. An advantageous embodiment of the method for manufacturing a winding mat is specified in dependent claim 8.

[0021] The features of the claims can be combined in any technically meaningful way, taking into account the explanations from the following description as well as features from the figures, which include supplementary embodiments of the invention.

[0022] The invention relates to a winding mat for generating a winding of a stator of an electric rotary machine, wherein the winding mat has at least one winding of a conductor element in a meandering shape, and the meandering shape comprises several linear sections of the conductor element which are connected to one another by means of angled conductor sections of the conductor element. The conductor element for forming the meandering shape has a rectangular cross-section at least in sections. The linear sections are parallel to one another, and linear sections of the same conductor element arranged adjacent to one another along the longitudinal direction of the meandering shape are equidistant from one another, wherein the angled conductor sections on the two longitudinal sides of the meandering shape have different lengths. The linear sections of the conductor element are designed to be arranged in slots of a stator body.

[0023] After the wrapping mat has been rounded, the long sides of the meander shape form its radial inner and radial outer sides.

[0024] The angled conductor sections form the lateral loops of the meander. After the winding mat is rounded into a winding of the stator of an electric rotary machine, they form the winding heads protruding laterally from the stator body.

[0025] The meander shape can run linearly, essentially in one plane, or it can have a small thickness between the linear sections.

[0026] The fact that adjacent linear sections of the same conductor element are equidistant along the longitudinal direction of the meander shape means that adjacent linear sections connected by angled conductor sections have equal distances from each other. After transforming the linear meander shape into a round shape, the equidistant arrangement of the linear sections and the different lengths of the angled conductor sections result in a desired asymmetry of the winding heads formed by the angled conductor sections.

[0027] In an advantageous embodiment of the winding mat, it is provided that the sums of the lengths of linear sections of the same conductor element connecting angle conductor sections arranged adjacent to each other along the longitudinal direction of the meander shape are different on the two longitudinal sides of the meander shape.

[0028] This means that angled conductor sections arranged on a first longitudinal side of the meander shape, which connect adjacent linear sections of the same conductor element, together have a shorter length than the angled conductor sections arranged on a second longitudinal side of the meander shape, which connect adjacent linear sections of the same conductor element.

[0029] The sum of the lengths of adjacent linear sections of the same conductor element connecting angle conductor sections SL1 along the longitudinal direction of the meander shape on the first longitudinal side of the meander shape can be in the following ratio to the sum of the lengths of adjacent linear sections of the same conductor element connecting angle conductor sections SL2 along the longitudinal direction of the meander shape: SL1 > 1.25 SL2.

[0030] This ratio characterizes the length differences of the angled conductor sections on the two winding head sides.

[0031] In other words, one winding head side has a significantly longer wire length than the other winding head side.

[0032] The conductor element with the rectangular cross-section can be designed as a flat wire. This means that one side of the rectangular cross-section is at least 1.1 times as long as a perpendicular side of the conductor element. Alternatively, one side of the rectangular cross-section can be at most 5 to 7 times as long as a perpendicular side of the conductor element.

[0033] Adjacent angled conductor sections can be connected by folding the conductor element. This creates a so-called fold at the adjacent angled conductor sections, which, after the winding mat is formed into a stator winding, create the winding heads.

[0034] In an advantageous embodiment, it is provided that adjacent angle ladder sections are connected to each other with only one fold or turn, optionally with an angle of 180° with respect to the groove base or groove exit of a respective groove in which the angle ladder section in question is to be arranged.

[0035] The folding allows for a bending radius RB that is proportional to the thickness of the conductor element DL: RB = 0.3 ... 1.5 DL.

[0036] This means that the flat wire is bent or folded around its flat side.

[0037] When the conductor element is designed as a flat wire, the thickness of the flat wire is referred to here. This embodiment is particularly useful for optimizing the fill factors, as the conductor elements or wires lie flat in the slots of the axial flux machine, with the flat side axially aligned. However, the invention does not preclude the use of round wire instead of flat wire.

[0038] The winding mat is designed to form a distributed wave winding that partially wraps around several stator teeth. Compared to a loop winding, this allows for a reduction in the amount of copper in the winding head, as well as a reduction in installation space requirements by minimizing the number of contact points. Furthermore, the presented winding mat offers the advantage of simultaneous, and therefore time-saving, assembly of the entire winding.

[0039] The parallelism of the linear sections ensures that the pitch of the winding, or the distance between the straight, linear sections, is the same for both winding head geometries, which, when using the winding mat as a winding of an electric rotary machine, essentially corresponds to the pitch of the stator slots on the inner diameter of the stator body.

[0040] This results in different angles in the adjacent angled ladder sections.

[0041] One long side of the winding mat is designed to form one of the two radial winding heads, and the other, second long side of the winding mat is designed to form the other of the two radial winding heads.

[0042] This allows, when forming the linear winding mat into a round winding mat or into a winding of an axial flux machine, compression of the angle conductor sections at the radially inner winding head is reduced or prevented, whereas at the radially outer winding head, stretching or widening of the angle between the adjacent angle conductor sections occurs.

[0043] Another aspect of the present invention is a method for producing a winding mat for generating a winding of a stator of an electric rotary machine, wherein the winding mat is produced by at least one winding of a meandering conductor element comprising several linear sections of the conductor element connected to one another by means of angled conductor sections of the conductor element. The conductor element for forming the meandering shape has a rectangular cross-section at least in sections. The conductor element is formed by winding around a winding blade such that the linear sections are aligned and positioned parallel to one another, so that linear sections of the same conductor element arranged adjacent to one another along the longitudinal direction of the meandering shape are equidistant from one another, and the angled conductor sections on the two longitudinal sides of the meandering shape have different lengths.

[0044] The winding blade is a device that serves as a reel during the winding of the conductor element. It has an elongated shape and a flat cross-section. When the winding blade is wrapped with the conductor element, the conductor element can be held down on one of the long sides of the winding blade, with the holding occurring at different width positions on the blade on each side.

[0045] The hold-down is achieved by means of a hold-down device that presses the conductor element against the winding blade in order to prevent the conductor element from detaching from the winding blade during the subsequent winding of an edge of the winding blade, thus creating a positionally accurate course of the conductor element around the winding blade and thus in the meander shape, with the desired different lengths of the angled conductor sections on the two winding blade or meander shape sides.

[0046] This means that the hold-down device acts asymmetrically. This allows for the simple and reliable creation of the folds of the conductor element on both long sides of the meander shape, with the different lengths of the angled conductor sections.

[0047] Furthermore, according to the invention, a device for producing a winding mat for generating a winding of a stator of an electric rotary machine is provided, which comprises a winding blade and a conductor element feeding device for feeding the conductor element to the winding blade, wherein the winding blade is designed with different contours on its two longitudinal sides, so that in the case of a winding of a conductor element with a rectangular cross-section in a meandering shape, which comprises several linear sections of the conductor element that are connected to each other by means of angled conductor sections of the conductor element, linear sections of the conductor element can be aligned and positioned parallel to each other around the winding blade, so that linear sections of the same conductor element arranged adjacent to each other along the longitudinal direction of the meandering shape are equidistant from each other.and the angled ladder sections on the two longitudinal sides of the meander shape have different lengths. The different lengths of the angled ladder sections on the two longitudinal sides of the meander shape result from the different contours of the longitudinal sides in the cross-section of the winding blade, which, when wrapped by the conductor element, create angled ladder sections that have different lengths on the two longitudinal sides of the winding blade or the meander shape to be created. In other words, the winding blade is shaped at its longitudinal edges in such a way that, when the winding blade is wrapped with the conductor element, angled ladder sections of different lengths are formed on both sides of the blade.

[0048] However, the thickness of the winding blade is constant over its length, resulting in a constant division of the generated winding mat, i.e., constant distances between the linear sections of the conductor elements.

[0049] The present invention is supplemented by a stator of an electric rotary machine comprising at least one winding produced from a described winding mat or a winding produced according to the described method for producing a winding mat.

[0050] The electric rotary machine can be an axial flux machine, but a radial flux machine is also possible.

[0051] This invention can be used for stators and rotors both with and without a laminated core. In the latter case, an advantage lies in the creation of a double-layered wave winding mat, which offers improved electrical symmetry properties for ironless stators and rotors and allows for simpler scaling to accommodate higher numbers of conductors per pole.

[0052] The invention described above is explained in detail below against the relevant technical background with reference to the accompanying drawings, which show preferred embodiments. The invention is in no way limited by the purely schematic drawings, and it should be noted that the embodiments shown in the drawings are not limited to the dimensions depicted. It is illustrated in Fig. 1: A conductor element as part of a linear winding mat in top view, Fig. 2: a transformed conductor element as part of a round-shaped winding mat in top view, Fig. 3: A round-shaped changing mat in top view, Fig. 4: A coiled sword in perspective view, Fig. 5: a linear winding mat in top view, Fig. 6: the use of a printing tool in a first perspective view, Fig. 7: the use of the printing tool in a second perspective view, Fig. 8: A forming device with a conductor element in its initial state, shown in a first perspective view, Fig. 9: The forming device with conductor element in the initial state, top view, Fig. 10: the forming device in its initial state in a second perspective view, Fig. 11: the transformed forming device with conductor element in top view, Fig. 12: The transformed forming device with conductor element in perspective view, Fig. 13: The forming device in its initial state with rail system and ejector in perspective view, Fig. 14: The forming device in its initial state with ejector in top view, Fig. 15: a magazine for recording the round-shaped changing mat in a first perspective view, Fig. 16: the magazine with lifting mechanism in a first perspective view, Fig. 17: the magazine with lifting mechanism in a second perspective view, Fig. 18: a system for the simultaneous production of several round-shaped winding mats in top view, Fig. 19: An assembly device with magazine and stator body in a pre-assembly state in perspective view, Fig. 20: The assembly device with magazine and stator body in a post-assembly state in perspective view, Fig. 21: a section of the magazine and the stator body during the assembly process, Fig. 22: a round-shaped winding mat during the assembly process with positioning pins, and Fig. 23: a stator body with a round-shaped winding mat in the assembled state.

[0053] Fig. Figure 1 shows a section of a conductor element 20 according to the invention, which is shaped in a wave form, such that it forms a winding mat 1 with a linear meander shape 10, as shown in Fig. 5 shows, forming. The conductor element 20 comprises linear sections 21 which are configured to be inserted as active lengths of a winding in slots of a stator body. The linear sections 21 are parallel to each other at equidistant intervals 22 along the longitudinal direction 13 of the meander shape 10, as shown in Fig. 5 indicated, arranged, and connected to each other by paired angled conductor sections 23. The angles between the angled conductor sections 23 are determined by the diameter and the slot pitch of the stator body in which the winding mat 1 is to be arranged after the round shape has been created.

[0054] The sum of the lengths of the angle ladder sections SL1 between two adjacent linear sections 21 on the first longitudinal side 11 of the meander shape 10 is greater than the sum of the lengths of the angle ladder sections on the second longitudinal side 12 of the meander shape 10. Due to the fact that the adjacent linear sections 21 have equidistant distances 22 to each other, angle ladder sections 23 arranged in pairs form different angles between them.

[0055] Angle conductor sections 23, arranged in pairs and forming an angle between them, are connected to each other by a fold 30, also referred to as a so-called fold. Such a fold 30 is suitable for the flat wire used here as a conductor element 20.

[0056] The like in Fig. The conductor element 20 shown can be formed into a shape according to Fig. 2 are transferred, in which the linear sections 21 run at angles to each other to form a round-shaped winding mat as in Fig. Figure 3 is shown. However, the angled conductor sections 23 on the second longitudinal side of the meander shape, or on the radial inner side 41, are not changed in their angular positions relative to each other. The angles between the angled conductor sections 23 on the first longitudinal side of the meander shape, or on the radial inner side 42, are changed so that these angled conductor sections 23 form a larger angle between them. This means that the radial inner side 41 is essentially kept stress-free and is not compressed, whereas the radial outer side 42 is stretched. By appropriately deforming the entire conductor element or a linear meander shape, the Fig. Figure 3 shows a round-shaped winding mat 40, which can form the winding of a stator of an axial flux machine. Here, the linear sections 21 have equal angles 43 to each other.

[0057] Fig. Figure 4 shows a device for producing a changing mat 1 in a linear meander shape 10, as described in Fig. 5 is shown.

[0058] This device for producing a winding mat 1 comprises as its essential element a winding blade 50, which has a first edge 51 and a second edge 52 running parallel to the first edge. The winding blade 50 is rotatable about a rotation axis 53, which runs parallel to the two edges 51 and 52.

[0059] It may be provided that the axis of rotation 53 of the winding blade 50 does not run in the geometric center of the winding blade 50, but is slightly offset to the side in order to favor the asymmetry in the winding heads to be produced in terms of manufacturing technology.

[0060] As the winding blade 50 rotates, a conductor element 20 can be wound onto the winding blade 50 as a continuous wave winding, with the winding blade 50 acting as a reel. To reliably produce a defined shape for the conductor element 20, a hold-down device 54 is provided, which presses the conductor element onto the flat side of the winding blade 50 after each half rotation. The hold-down device 54 acts asymmetrically with respect to a geometric center axis of the winding blade 50, affecting the conductor element 20 wound around it. This also has a positive effect on achieving the desired different shapes of the winding heads to be produced.

[0061] This can involve several conductor elements 20, as in Fig. 5 shown, are simultaneously wound around the winding sword 50.

[0062] This results in the following: Fig. 5 depicted linear meander shape 10, which then as in relation to Fig. 2 described can be shaped into a round form to accommodate the in Fig. 3. To produce the round-shaped winding mat 40 shown. This continuous winding makes it possible to form differently shaped winding heads on the two radial sides after rounding.

[0063] Depending on the thickness of the two edges 51, 52 of the winding blade 50, different bends or folds 30 of the conductor element 20 result. However, it is provided that the two edges 51, 52 of the winding blade 50 have different contours in order to accommodate the different angles between the angled conductor sections 23, as described above. Fig. 1 described, to train.

[0064] The generated changing mat 1, as shown in Fig. The winding shown in Figure 5 may not be essentially two-dimensional after its rounding, but has an axial extent that is too large for use as a winding in a stator body.

[0065] To reduce this axial extent or thickness of the round-shaped wrapping mat 40, as in Fig. Figure 6 shows a printing tool 60 for use, which, as in Fig. Figure 7 shows that compressive forces 61 are applied in the axial direction to the angled ladder sections 23 on the radial inner side 41 as well as on the radial outer side 42 of the roundly shaped winding mat 40 in order to reduce the axial extent of the winding mat 40. This pressure application to the roundly shaped winding mat 40 can take place in a magazine 141, as shown in Fig. 6 shown, or directly into a stator body.

[0066] For the transformation of the linear winding mat 1, as described in Fig. 5 is shown, into a round-shaped changing mat 40 or into a circular arc shape, as shown in Fig. As shown in Figure 3, a forming device 70 is used, as shown in the Fig. 8-14.

[0067] This forming device 70 comprises pivoting segments 80 arranged in series and parallel to one another along a first coordinate direction 71, the individual pivoting segments 80 extending along a second coordinate direction 72 transversely to the first coordinate direction. Each of the pivoting segments 80 includes drivers 81, and between the drivers 81, at least one receptacle 82 for receiving a linear section 21 of a conductor element 20 is defined. Pivoting segments 80 adjacent to one another along the first coordinate direction 71 are connected to one another via joints 90, the axes of rotation 91 of which extend along a third coordinate direction 73, perpendicular to both the first coordinate direction 71 and the second coordinate direction 72.

[0068] The Fig. 8 and Fig. Figure 9 shows the forming device 70 in an initial state in which the conductor element 20 is arranged with linear sections 21 running parallel to each other, so that the forming device 70 takes on a linear meander shape 10.

[0069] Fig. Figure 10 shows the forming device 70 in a perspective side view, showing that the forming device 70 also has a rail system 110 comprising several guide rails 111, against which system elements 120, designed here as wheels, rest. These system elements 120 are connected to respective swivel segments 80.

[0070] On the upper side, the forming device includes several holding devices 94 for holding down the conductor element (not shown here) during its forming process.

[0071] By relative rotational movements of the individual pivot segments 80 around the joint rotation axes 91, the pivot segments 80 can be fanned out, as shown in the Fig. 11 and Fig. 12 shown.

[0072] The angular positions of the drivers 81 are defined by pivot segments 80 adjacent to each other along the longitudinal direction or the first coordinate direction 71 with respect to the joint rotation axis 91 of a joint 90 which connects these two adjacent pivot segments 80 at the vertex 92.

[0073] During the relative rotational movements of the individual pivot segments 80, their drivers 81 exert forces 93 on the linear sections 21. This results in the rounding of the conductor element 20, as described above, namely that on the radial inner side 41 there is no compression of the distance between the linear sections 21, and on the radial outer side 42 there is an elongation of the conductor element 20, and thus an increase in the angle between the angled conductor sections 23 there.

[0074] The conductor element is bent on its radial inner side at the transitions between the angle conductor sections 23 and the respective linear sections 21, which form the active lengths, but not between the interconnected angle conductor sections 23.

[0075] On the radial outer side, the angle between the interconnected angle conductor sections 23 is increased.

[0076] To effect this fanning out or relative rotational movements of the swivel segments 80 to each other, the forming device 70 uses the rail system 110. This has, as in Fig. 13 shows a linear section 112 followed by a curved section 113. If the pivot segments 80 are still within the linear section 112, as well as in the Fig. 13 and Fig. As shown in 14, they are still arranged parallel to each other, see also Fig. 8 and Fig. 9.

[0077] However, when the pivot segments 80 are moved onto the curved section 113 of the rail system 110, they follow this curvature due to the contact of the system elements 120 with the guide rails 111 and perform the described fanning or relative rotational movements of the pivot segments 80.

[0078] During and / or after the movement of the pivot segments 80 on the curved section 113, the curved conductor element is lifted out of the receptacles 82 of the pivot segments 80 by means of at least one lifting device 100, which essentially follows the curvature of the curved section 113 and thus engages and lifts the conductor element. This means that the lifting out of the forming device 70 can occur successively as the winding mat is rounded. Alternatively, the winding mat can first be rounded and then lifted out of the forming device 70.

[0079] The round-shaped winding mat 40 removed from the forming device 70 can then be fed to a stator body or to a magazine 141 for intermediate storage, as shown in Fig. 15 is shown.

[0080] This magazine 141 includes receiving grooves 142 formed on a carrier 143 for receiving the linear sections of the conductor element.

[0081] The Fig. 16 and Fig. Figure 17 shows the relationship between the ejector 100 and the magazine 141. Due to the screw thread shape 101 of the ejector 100, the roundly shaped winding mat is fed to the magazine 141 in an axial direction, so that the linear sections of the conductor element of the winding mat, which are not shown here, are received in the receiving grooves 142 of the magazine 141.

[0082] Fig. Figure 18 shows a special embodiment for feeding several linear winding mats 1, after their described transformation into circular arc-shaped winding mats, into a common magazine 141. It can be seen here that the two depicted linear winding mats 1 move on their own guide tracks 125 and are fed to the magazine 141 from diametrically opposite sides via two units 130 of pivoting segments, so that several winding mats can be received by the magazine 141 within the same time unit. Furthermore, this embodiment saves installation space during the assembly of the winding mats.

[0083] The magazine 141 is part of an assembly device 140 for mounting the round winding mat 40 into a stator body, as used in the Fig. 19 and Fig. Figure 20 shows the magazine 141, which comprises openings 145 arranged in the carrier 143 in a first plane 144. Furthermore, the assembly device 140 includes a push unit 150 with several axially projecting push elements 151 arranged in a second plane parallel to the first plane. The angular positions of the push elements 151 correspond to those of the openings 145, allowing the push elements 151 to engage in the openings 145. Fig. Figure 19 shows the pusher unit 150 and the magazine 141 in an initial state. Fig. Figure 20 shows the push unit 150 and the magazine 141 in an operating state in which the push elements 151 are guided through the openings 145 along an axial direction 154. As a result, the push elements 151 exert push forces 152 on the ladder element (not shown here), which is located in the receiving grooves 142 of the magazine 141.

[0084] The conductor element is thereby moved in grooves 180 of a stator body 170 arranged on the side of the magazine 141 facing axially away from the push unit 150.

[0085] To facilitate this process and to avoid damaging the insulating paper 200 arranged in the slots 180, the stator body 170 can have projections 191 on its slot edges 181, forming undercuts 190, as shown in Fig. 21 shown.

[0086] With appropriate dimensioning of the receiving grooves 142 of the magazine 141 and the grooves 180 in the stator body 170, linear sections of the conductor element 20 can be inserted unhindered into the grooves 180 in the stator body 170 without forces from the conductor elements 20 acting on the end faces 201 of the insulating paper 200 and deforming it in an undesirable manner. Alternatively or additionally to the undercuts 190 at the groove edges 181, positioning pins 160 can also be used, as described in Fig. 22 are shown. Such positioning pins 160 can be arranged on the magazine 141 and in the areas of the conductor element 20 where the conductor element 20 forms loops 161 between the linear sections 21 and the angled conductor sections 23.

[0087] By means of the aforementioned methods and devices, a stator body 170 of an axial flux machine can be equipped with a roundly shaped winding 40, as shown in Fig. Figure 23 shows the conductor element 20 being essentially stress-free on its radially inner side 41 and stretched on its radially outer side 42. The angled conductor sections 23 form the winding heads of the winding.

[0088] The winding mat, the method and device for manufacturing the winding mat, and the stator of the electric rotary machine proposed here ensure the cost-effective manufacture and assembly of a stator winding with a small space requirement. Reference symbol list 1 changing mat 10 meander shape 11 First long side of the meander shape 12 Second long side of the meander shape 13 Longitudinal direction of the meander shape 20 ladder element 21 linear section 22 Equidistant distance 23 Angle ladder section 30 folds 40 round-shaped changing mats 41 radial inside 42 radial outer side 43 equal angle 50 winding sword 51 First edge of the winding sword 52 Second edge of the winding sword 53 Rotation axis of the winding blade 54 hold-down devices 60 printing tools 61 compressive force 70 Converter 71 first coordinate direction 72 second coordinate direction 73 third coordinate direction 80 swivel segment 81 drivers 82nd entry 90 joint 91 Joint rotation axis 92 angle vertices 93 force 94 Suppression device 100 lifters 101 Screw thread shape 110 rail system 111 Guide rail 112 linear range 113 curved section 120 plant element 125 Guide rail 130 units of swivel segments 140 Mounting device 141 Magazine 142 recordings 143 carriers 144 first level 145 Opening 150 thrust units 151 Shear element 152 thrust 153 second level 154 axial direction 160 positioning pin 161 loop 170 stator bodies 180 slot of the stator body 181 Groove edge 190 undercut 191 Overhang 200 sheets of insulating paper 201 Front side of the insulating paper SL1 Sum of the lengths of the angled ladder sections on the first longitudinal side SL2 Sum of the lengths of the angled ladder sections on the second longitudinal side QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] US 8823238B2

[0010] US 10574110B2

[0010] DE 102021124994A1

[0015] DE 102021124995A1

[0016] DE 102021124996A1

[0017] EP 3381108B1

[0018]

Claims

[1] Winding mat (1) for generating a winding of a stator of an electric rotary machine, wherein the winding mat (1) has at least one winding of a conductor element (20) in meander shape (10) and the meander shape (10) comprises several linear sections (21) of the conductor element (20) which are connected to each other by means of angle conductor sections (23) of the conductor element (20), characterized by , that the conductor element (20) for forming the meander shape (10) has at least a rectangular cross-section in sections, and that the linear sections (21) are parallel to each other and that linear sections (21) of the same conductor element (20) arranged adjacent to each other along the longitudinal direction (13) of the meander shape (10) are equidistant from each other and that the angle conductor sections (23) on the two longitudinal sides (11,12) of the meander shape (10) have different lengths. [2] Changing mat according to claim 1, characterized by, that the sums of the lengths of linear sections (21) of the same conductor element (20) connecting angle conductor sections (23) along the longitudinal direction (13) of the meander shape (10) are different on the two longitudinal sides (11,12) of the meander shape (10). [3] Changing mat according to claim 2, characterized by , that the sum of the lengths of adjacent linear sections (21) of the same conductor element (20) connecting angle conductor sections (23) SL1 on the first longitudinal side (11) of the meander shape (10) to the sum of the lengths of adjacent linear sections (21) of the same conductor element (20) connecting angle conductor sections (23) SL2 on the second longitudinal side (12) of the meander shape (10) is in the following ratio: SL1>1.25 SL2. [4] Changing mat according to any one of the preceding claims, characterized by , that the conductor element (20) with the rectangular cross-section is designed as a flat wire. [5] Changing mat according to any one of the preceding claims, characterized by , that adjacent angle conductor sections (23) are connected to each other by a fold (30) of the conductor element (20). [6] Changing mat according to claim 5, characterized by , that with the folding (30) a bending radius RB is realized which is in relation to the thickness of the conductor element DL: RB = 0.3 ... 1.5 DL. [7] Method for producing a winding mat for generating a winding of a stator of an electric rotary machine, wherein the winding mat (1) is produced by at least one winding of a conductor element (20) in meander shape (10) comprising several linear sections (21) of the conductor element (20) which are connected to each other by means of angle conductor sections (23) of the conductor element (20), wherein the conductor element (20) has a rectangular cross-section at least section by section to form the meander shape (10), and wherein the conductor element (20) is formed by winding around a winding blade (50) such that the linear sections (21) are aligned and positioned parallel to each other, so that linear sections (21) of the same conductor element (20) arranged adjacent to each other along the longitudinal direction (13) of the meander shape (10) are equidistant from each other, and the angle conductor sections (23) are connected at the two longitudinal sides (11,12) the meander shape (10) have different lengths. [8] Method for producing a winding mat for generating a winding of a stator of an electric rotary machine according to claim 7, characterized by , that when the winding sword (50) is wrapped with the ladder element (20) the ladder element (20) is held down on a respective longitudinal side of the winding sword (50), the holding down on the two sword sides taking place in different width positions of the winding sword (50). [9] Device for producing a winding mat for generating a winding of a stator of an electric rotary machine, comprising a winding blade (50) and a conductor element feeder for feeding the conductor element (20) to the winding blade (50), wherein the winding blade (50) is designed with different contours on its two longitudinal sides, so that in the case of a winding of a conductor element (20) with a rectangular cross-section in meander shape (10), which comprises several linear sections (21) of the conductor element (20) which are connected to each other by means of angle conductor sections (23) of the conductor element (20), linear sections (21) of the conductor element (20) can be aligned and positioned parallel to each other around the winding blade (50), so that linear sections (21) of the same conductor element (20) arranged adjacent to each other along the longitudinal direction (13) of the meander shape (10) are equidistant from each other,and the angle ladder sections (23) on the two longitudinal sides (11, 12) of the meander shape (10) have different lengths. [10] Stator of an electric rotary machine, comprising at least one winding produced from a winding mat (1) according to any one of claims 1 to 6 or a winding produced according to the method for producing a winding mat for generating a winding according to claim 7.

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