Method for manufacturing a component

Abstract

Method for manufacturing a component (2), in particular a component (2) for an electric machine, wherein a liquid, in particular a resin material, is introduced from an insertion side (7) of the component (2) into at least one channel (3) of the component (2), in particular a groove in a sheet metal stack of the component (2), wherein a gas flow (12) is generated at a suction opening (10) of the channel (3), which is arranged on a suction side (9) of the at least one channel (3) opposite the insertion side (7), and the introduction of the liquid is at least supported by the gas flow (12).

Description

[0001] The invention relates to a method for manufacturing a component, in particular a component for an electric machine, wherein a liquid, in particular a resin material, is introduced from an insertion side of the component into at least one channel of the component, in particular a groove in a sheet metal stack of the component.

[0002] Methods for manufacturing components, specifically components for electrical machines, such as stators or laminated cores for electrical machines, in which a liquid, for example a resin material, is introduced into a channel of the component, are generally known from the prior art. Specifically in the manufacture of electrical machines, it is known to form a laminated core that has channels or slots for receiving conductor elements. To connect the conductor elements to the laminated core in a defined manner, so that they are mechanically bonded to the laminated core and thermally coupled to it for heat dissipation, the slots in which the conductor elements are inserted are filled with a resin material.

[0003] The liquid or resin material is typically introduced by dripping it into one of the entry points of each channel. The laminated core or component is usually tilted and rotated so that different channels or channel sections—that is, individual slots or multiple slots simultaneously—are filled with the liquid in succession. The liquid then flows through the slots from the entry point to the opposite side of the channel. Since the liquid may flow at different speeds or with varying degrees of efficiency in the individual channels due to the different positions of the conductor elements, this can lead to uneven filling of the channels.

[0004] This can lead to the formation of air inclusions or voids due to the uneven distribution of the liquid, which can reduce the mechanical and thermal bonding of the conductor elements to the laminated core. Since the liquid is typically relatively viscous, for example, when a resin material is used, introducing the liquid into the component's channels also results in a comparatively long time-consuming process.

[0005] The invention is based on the objective of providing an improved method for manufacturing a component, in which, in particular, the distribution of the liquid is improved and the effort is reduced.

[0006] The problem is solved by a method according to claim 1. The dependent claims relate to possible embodiments.

[0007] As described, the invention relates to a method for manufacturing a component, in particular a component for an electric machine, wherein a liquid, in particular a resin material, is introduced from an insertion side of the component into at least one channel of the component, in particular a groove in a laminated core of the component. In other words, a component, in particular a component for an electric machine, is manufactured, wherein a liquid, specifically a resin material, is introduced from an insertion side of the component into the at least one channel of the component, for example, a groove in a laminated core of the component. Specifically, the liquid is introduced to secure conductor elements arranged in the channel or to couple them with the laminated core of the component, so that these are mechanically secured in the channel in the component and heat transfer into the laminated core of the component can be carried out in a defined manner.

[0008] The invention is based on the finding that a gas flow is generated at a suction opening of the channel, which is arranged on a suction side opposite the injection side of at least one channel, and that the gas flow at least assists the introduction of the liquid. The invention thus proposes that, instead of dripping the liquid exclusively into the channel from the injection side, a gas flow is generated at the suction side opposite the injection side, which flows over or along the suction opening located on the injection side. This at least assists the introduction of the liquid, since the liquid introduced into the channel at the injection side is drawn towards the suction side.In other words, the gas flow generated perpendicular to the suction opening creates a suction flow through the channel, which draws the liquid through the channel that is introduced at the injection side.

[0009] This advantageously reduces the time required to introduce the fluid into the channel. Furthermore, the fluid flow through the channel can be improved, thus reducing or preventing the formation of air inclusions. In addition to reducing cycle time, this also advantageously leads to improved quality due to the more uniform distribution of the fluid in the individual channels of the component.

[0010] As previously described, the gas flow is generated on the suction side to at least assist the introduction of the liquid or its flow through the channel. For example, the liquid can be introduced into the channels on the injection side and flow through them due to gravity, with the generated gas flow at least assisting this gravity-driven flow. However, configurations are also possible in which the liquid flow generated by the gas flow constitutes at least the largest portion of the liquid flow through at least one channel, or even exclusively causes the liquid flow, for example, against the direction of gravity.

[0011] In a further embodiment of the method, a vacuum can be created on the suction side by means of the gas flow, drawing the liquid from the inlet side to the suction side. In other words, by generating the gas flow perpendicular to the suction opening, i.e., a gas flow that flows past the suction opening, a vacuum is created on the suction side due to the Bernoulli effect, thereby drawing the liquid from the inlet side to the suction side. Since the liquid thus moves through the channel faster compared to simply dripping it in, the cycle time can be reduced. Due to the pressure difference created between the inlet and suction sides, the vacuum on the suction side draws the liquid in a controlled manner from the inlet side into and through the channel, thus improving the distribution of the liquid within the channel.The resulting negative pressure can prevent or avoid air inclusions or voids.

[0012] As described at the outset, the channels in the component, or at least one channel in the component, extend from the injection side to the suction side. Specifically, the channels run parallel in the circumferential direction, distributed with respect to a central axis of the component. The liquid is introduced into the channel at the injection side, particularly by dripping. This can be achieved by combining dripping with gravity-driven flow of the liquid through the channel, along with the previously described suction flow generated by the gas flow. Alternatively, it is also possible to draw the liquid against the direction of gravity through the at least one channel using the negative pressure created by the gas flow due to the Bernoulli effect.

[0013] In one embodiment, the component can be positioned with its injection side above or against a liquid surface, and the liquid can be drawn into an injection opening of the channel located on the injection side, in the direction of the suction side. In other words, a reservoir of liquid is provided, and the component is positioned with its injection side above the liquid surface such that the injection side faces the liquid surface and the suction side faces away from the liquid surface. As previously described, generating a gas flow on the suction side creates a vacuum that draws the liquid through the channel's injection opening and into the channel towards the suction side.

[0014] In a further embodiment of the method, at least one section of the component can be sealed, in particular a core area arranged radially adjacent to the at least one channel, and / or at least one suction opening of at least one further channel, and / or at least one inlet opening of at least one further channel, and / or at least one outer surface of the component from the environment. The sealing, for example by means of a sealing device, can enhance the effect of the negative pressure generated by the gas flow on the channel into which the liquid is currently to be introduced. In particular, it can prevent stray flow that might bypass the channel currently intended for filling through other channels, the core area, or at the outer surface of the component.

[0015] For example, the core area can be sealed with a core seal, which is inserted into the opening of the component, for example, a stator opening of the component that defines a rotor chamber. Once the core seal is in place, flow through the opening of the component is no longer possible; instead, flow can only occur through the channels. If, in addition, at least one suction opening and / or at least one inlet opening of at least one further channel, into which no liquid is currently to be introduced, is sealed, and the component is sealed from the environment, for example, by attaching a sealing element around the outer surface of the component, it can be ensured that the suction flow is generated only through the channel or channels into which liquid is currently to be introduced. In other words, the sealing can be partial, so that a channel or channel section, i.e.,at least one or more adjacent grooves must remain free so that liquid can be introduced into them.

[0016] In a further development of the method, it can be provided that at least one sealing element is repositioned between two process steps, in particular between the introduction of liquid into two different channels. For example, the sealing element can be movable or adjustable. In a first process step, liquid can be introduced into a first channel or a first group of channels. In the first process step, at least a second channel or at least a second group of channels can be sealed by means of the sealing device or by means of the sealing element. Once the introduction of liquid into the first channel or the first group of channels is complete, the sealing element can be adjusted, for example, to seal the first channel or the first group of channels and / or to release the previously sealed second channel or the second group of channels.

[0017] The sealing device can, for example, correspond to the shape of the component, in particular be designed in a (circular) disc shape, wherein the sealing device or sealing element includes an opening for the channel or channel area, wherein the sealing element is adjustable relative to the component in order to always open the currently open channel and seal the other channels. The sealing element is also specifically designed to seal a channel into which liquid has already been introduced.

[0018] In one embodiment of the method, the component's channel can be arranged at a defined angle, particularly perpendicular, to the gas flow and / or parallel to a direction of gravity. When the gas flow is generated, it flows, in particular, perpendicular to the channel's central axis, i.e., perpendicularly across the channel's opening. The channel can be oriented with its axis of symmetry or longitudinal central axis parallel to the direction of gravity. It is also possible for the channel to be positioned at an angle deviating from parallel to the direction of gravity, for example, inclined, to improve the introduction of liquid. Since the negative pressure is generated by the gas flow, the susceptibility to contamination is reduced because the liquid is drawn into the channel in a controlled manner, thus minimizing contamination of the component's end face.

[0019] As previously described, the component can be used in an electric machine. For example, the component can be designed as a stator lamination stack, with resin material being introduced into at least one stator slot that accommodates at least one insulating element, in particular insulating paper, and / or at least one conductor element. In other words, the component can be used to form a stator for an electric machine. The stator slots contain an insulating element, usually insulating paper, and at least one conductor element. In this state, liquid, in particular resin material, is introduced into the stator slots as previously described. Alternatively, an adhesive can also be introduced into the channels of the component, for example, to join a lamination stack.

[0020] In addition to the method, the invention relates to a component, in particular a component for an electric machine, wherein the component is manufactured by the method described above. Furthermore, the invention relates to a device for manufacturing a component, in particular a component for an electric machine, wherein the device is configured to introduce a liquid, in particular a resin material, from an insertion side of the component into at least one channel of the component, in particular a groove in a laminated core of the component, wherein the device is configured to generate a gas flow transverse to the suction opening at a suction opening of the channel, which is arranged on a suction side of the at least one channel opposite the insertion side, and to at least assist the introduction of the liquid by the gas flow.

[0021] The device can be used in particular to carry out the previously described procedure, especially to manufacture the previously described component.

[0022] All advantages, details, designs and / or features described in relation to the process are fully transferable to the component and the device.

[0023] The invention is explained with reference to exemplary embodiments and the figures. The figures are schematic representations and show: Fig. 1 a schematic representation of a device for manufacturing a component according to a first embodiment; Fig. 2 a schematic representation of a device for manufacturing a component according to a second embodiment; Fig. 3 a schematic representation of a detail of a device for manufacturing a component according to a third embodiment; and Fig. 4 a schematic representation of a device for manufacturing a component according to a fourth embodiment.

[0024] Fig. Figure 1 shows a device 1 for manufacturing a component 2, specifically a component 2 for an electrical machine not shown in detail. The component 2 can, for example, be part of a stator, in particular forming the stator's laminated core. The component 2 has several channels 3 arranged circumferentially around a central axis 4, for example, the axis of rotation of a rotor of an electrical machine, or the central axis of an opening 5 of the component 2. If the component 2 is designed as a stator or stator body, the channels 3 typically contain elements such as insulating paper and electrical conductors.

[0025] As it is in Fig. As shown in Figure 1, a liquid is introduced into the channels 3 of the device 1 by means of an introduction device 6, for example, sequentially in the circumferential direction. The liquid is introduced from an introduction side 7 through an introduction opening 8, so that the liquid can flow through each channel 3 towards a suction side 9 or in the direction of a suction opening 10 arranged on the suction side 9.

[0026] Component 2 can be oriented in any direction, for example, with its central axis being parallel to a direction of gravity, so that the flow of liquid through the channels 3 can also be assisted by gravity. On the suction side 9, a flow-generating device 11 is shown as an example, which is designed to generate a gas flow 12. The gas flow 12 flows past component 2 on the suction side 9, in particular transversely to the suction opening 10. An axis of the channels 3 parallel to the central axis 4 can, for example, be perpendicular to a flow direction of the gas flow 12. It is evident that the gas flow 12 itself is therefore not generated by the channels 3, but is specifically generated in such a way that it flows past the channels 3, in particular their suction openings 10.

[0027] Due to the Bernoulli effect, the gas flow 12 creates a negative pressure on the suction side 9 relative to the injection side 7. This negative pressure, or pressure difference, between the suction side 9 and the injection side 7 causes the liquid introduced into the channel 3 through the injection opening 8 on the injection side 7 to flow more efficiently through the channel 3. Specifically, the negative pressure draws the liquid through the channel 3 towards the suction side 9.

[0028] This advantageously reduces the cycle time because the liquid flow rate is increased. Furthermore, the even distribution of the liquid in the channels 3 is improved. Additionally, contamination in the area of ​​the inlet opening 8 is reduced, as the liquid is drawn into the inlet opening 8, resulting in less liquid wetting of the edge areas on the inlet side 7.

[0029] In Fig. Figure 2 shows an exemplary sealing device 13 which has a sealing element 14, in particular a core seal, which seals the opening 5 of the component 2. This prevents an aberrant flow through the opening 5, i.e. along the central axis 4, so that the flow or the pressure difference that is present at the different ends of the channels 3, i.e. between the inlet opening 8 and the suction opening 10 or between the inlet side 7 and the suction side 9, is better utilized in order to consequently generate a flow of the liquid only through the channel 3.

[0030] Fig. Figure 3 shows a further embodiment of the device 1, in which a sealing element 15 is depicted that is designed to seal the component 2 and leave open only the channel 3 into which liquid is currently to be introduced. In other words, the negative pressure generated by the gas flow 12 acts only on the channel 3 that is currently open by the sealing element 15, so that all other channels 3 and, optionally, also the opening 5 are sealed off. This allows the gas flow 12 to be used particularly efficiently to generate the negative pressure. The sealing element 15 can be used in combination with the sealing element 14.

[0031] The sealing element 15 can be adjustable, in particular movably arranged, so that the sealing element 15 can be positioned relative to the component 2, or vice versa, such that the opening in the sealing element 15 corresponds to the channel 3 into which liquid is to be introduced. In addition to the possibility of opening a single channel 3 to introduce the liquid into it by means of negative pressure, the sealing element 15 can also open a number of circumferentially adjacent channels 3 as a channel area. For example, the design of the sealing element 15 can provide that it has exactly one through-opening that corresponds to a channel 3. If the channel 3 is filled with liquid, the sealing element 15 can be rotated further, for example about the central axis 4, to open the circumferentially adjacent channel 3 so that liquid can be drawn into it.Alternatively or in addition to sealing the suction openings 10, it can also be provided that the sealing element 15 is arranged on the insertion side 7 and covers all insertion openings 8 into which no liquid is currently to be introduced, i.e. that the sealing element 15 then only releases the insertion openings 8 into which liquid is currently to be introduced.

[0032] Fig. Figure 4 shows a further embodiment of a device 1 in which the liquid is to be drawn "upwards" from a liquid reservoir 16. In other words, the component 2 is arranged above the surface of the liquid reservoir 16 so that the inlet side 7 or the inlet openings 8 of the channels 3 face the surface of the liquid. It is shown, purely by way of example, that liquid can be drawn in simultaneously via several channels 3, in particular all channels 3, namely due to the gas flow 12 generated by the flow-generating device 11. Alternatively, a sealing element 15 can be used according to Fig. 3 is provided to selectively release suction openings 10. The gas flow 12 is again generated, as already described with reference to the preceding embodiments, along the suction side 9, for example transversely to the suction openings 10 of the channels 3, in order to create a negative pressure that draws the liquid from the liquid reservoir 16 on the injection side 7 into the injection openings 8 and from there through the channels 3 towards the suction side 9.

[0033] In Fig.Figure 4 further shows that the previously described sealing element 14 is used to seal the opening 5 of component 2, so that the liquid can only be drawn in through channels 3. Additionally, another sealing element 17 is provided that seals an outer surface 18 of component 2 against the environment, so that the liquid cannot flow past component 2. The sealing element 17 can, for example, seal the liquid reservoir 16 from above. The sealing elements 14, 15, and 17 can be used alone or in any combination in all embodiments.

[0034] As already described, component 2 can specifically be configured as a stator for an electric machine. This means that at least one insulating device, in particular insulating paper, and at least one conductor element are arranged in each of the channels 3. Resin material can be drawn into the channels 3 as a liquid, or a vacuum can be created by the gas flow 12, which facilitates the introduction of the liquid. Once the channels 3 are filled with the liquid, the liquid, and in particular the resin material, can then be cured, especially by applying heat.

[0035] As described, the device 1 can be used to manufacture component 2 according to the method described herein. All advantages, details, and features described in relation to the device 1 and / or component 2 are fully transferable to the method and vice versa.

[0036] The advantages, details and features shown in the individual embodiments can be combined, interchanged and transferred to one another as desired. REFERENCE MARK LIST 1 Device 2 components 3-channel 4 Central axis 5 Opening 6 Insertion device 7 Insertion side 8 insertion opening 9 Suction side 10 Suction opening 11 Flow generating device 12 Gas flow 13 Sealing device 14, 15 Sealing element 16 Liquid reservoir 17 Sealing element 18 outdoor area

Claims

[1] Method for manufacturing a component (2), in particular a component (2) for an electric machine, wherein a liquid, in particular a resin material, is introduced from an insertion side (7) of the component (2) into at least one channel (3) of the component (2), in particular a groove in a sheet metal stack of the component (2), characterized by , that at a suction opening (10) of the channel (3), which is arranged on a suction side (9) of the at least one channel (3) opposite the injection side (7), a gas flow (12) is generated transverse to the suction opening (10) and the injection of the liquid is at least supported by the gas flow (12). [2] Method according to claim 1, characterized by , that by means of the gas flow (12) a vacuum is created on the suction side (9) and the liquid is drawn from the injection side (7) to the suction side (9). [3] Method according to claim 1 or 2, characterized by, that the liquid is poured, in particular dripped, into the channel (3) from the inlet side (7). [4] Method according to claim 1 or 2, characterized by , that the component (2) is positioned with the insertion side (7) above or on a surface of the liquid and the liquid is drawn into an insertion opening (8) of the channel (3) arranged on the insertion side (7) in the direction of the suction side (9). [5] Method according to any of the preceding claims, characterized by , that at least one section of the component (2) is sealed, in particular a core area arranged radially adjacent to the at least one channel (3) and / or at least one suction opening (10) of at least one further channel (3) and / or at least one insertion opening (8) of at least one further channel (3) and / or at least one outer surface (18) of the component (2) towards the environment. [6] Method according to any of the preceding claims, characterized by, that at least one sealing element (14, 15, 17) is changed in its position between two process steps, in particular between the introduction of liquid into two different channels (3). [7] Method according to any of the preceding claims, characterized by , that the channel (3) of the component (2) is arranged at a defined angle, in particular perpendicular, to the gas flow (12) and / or parallel to a direction of gravity. [8] Method according to any of the preceding claims, characterized by , that the component (2) is designed as a stator lamination stack, wherein resin material is introduced into at least one stator slot which accommodates at least one insulating element, in particular insulating paper, and / or at least one conductor element. [9] Component (2), in particular a component (2) for an electric machine, characterized by , that the component (2) is manufactured by a method according to one of the preceding claims. [10] Device (1) for manufacturing a component (2), in particular a component (2) for an electric machine, wherein the device is designed to introduce a liquid, in particular a resin material, from an insertion side (7) of the component (2) into at least one channel (3) of the component (2), in particular a groove in a sheet metal stack of the component (2), characterized by , that the device (1) is designed to generate a gas flow (12) transverse to the suction opening (10) at a suction opening (10) of the channel (3), which is arranged on a suction side (9) opposite the injection side (7) of the at least one channel (3), and to at least support the injection of the liquid by the gas flow (12).

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