METHOD AND DEVICE FOR MULTI-LAYER INSERT OF A COIL MAT INTO A COMPONENT OF AN ELECTRICAL MACHINE

Description

[0001] The invention relates to a method for inserting a multi-layered coil mat into inwardly open receiving grooves of a component of an electric machine that is at least partially annular. The invention further relates to a device for inserting a multi-layered coil mat into inwardly open receiving grooves of a component of an electric machine that is at least partially annular.

[0002] The invention lies in the field of electrical machines such as electric motors or generators. At least one component of such an electrical machine, such as a stator or a rotor, has a coil winding. In a method for manufacturing a component with such a coil winding, the coil winding is prefabricated outside the component and then inserted into the component.

[0003] For example, a wave winding is prefabricated outside the component, such as a stator, e.g. as a linear coil.

[0004] Examples of such a linear coil or coil mat are explained in DE 10 2017 104 932, DE 103 28 955 B4, DE 11 2006 000 742 A1, and DE 10 2016 222 818 A1. The individual wires can be interwoven, as shown in DE 10 2017 104 932, stacked individually on top of each other, as shown in DE 103 28 955 B4, or a conductor exchange can be provided, as explained in DE 11 2006 000 742 A1. The coil mat can also have a variable slot spacing, so that straight wire sections of the coil mat have different wire spacings to each other in different sections, as explained in DE 10 2016 222 818 A1.

[0005] DE 10 2016 222 818 A1 discloses: A method for inserting a coil mat in multiple layers into inwardly open receiving grooves of a component of an electrical machine that is at least partially ring-shaped, comprising: a) providing a coil mat that has straight wire sections and winding heads connecting straight wire sections, such that a first longitudinal section of the coil mat, designated for forming a first layer of the coil mat in the component, has first straight wire sections spaced apart by a first wire spacing, and a second longitudinal section of the coil mat, designated for forming a second layer of the coil mat in the component, has second straight wire sections spaced apart by a different second wire spacing.

[0006] An example of a device and a method for inserting a coil mat into receiving slots of a stator is known from EP 1 639 688 B1. Further examples can be found in WO 2016 / 021674 A1, US 9 071 115 B2 and DE 10 2016 111 478 A1.

[0007] US 9 071 115 B2 and DE 10 2016 113 894 A1 describe the insertion of a coil winding using an insertion mandrel. US 9 071 115 B2 describes a

[0008] The coil mat is first rolled onto the joining mandrel, which is then inserted into the component and subsequently transferred into the grooves of the component.

[0009] From DE 10 2016 113 894 A1, a joining tool in the form of a joining mandrel with movable guide plates is known to those skilled in the art. The joining tool is used together with gripping units provided outside the joining tool. In a state where the coil mat is applied to the joining tool, which is still axially offset from the stator, the coil mat is compressed on the joining tool to a smaller diameter than the inner diameter of the stator by means of a radial motor. Gripping elements provided on the gripping units are moved radially inwards, which serves to hold the wires of the coil mat radially on the outside and press them inwards. This allows the radial motor to be retracted, since the gripping units ultimately perform a holding function. The gripping takes place at two axial ends of the wires of the coil mat. The joining tool with the coil mat thus held in compression is inserted axially into the stator.The coil mat is then transferred into the stator slots by means of elements located outside the joining tool that engage radially from the inside at the axial ends of the coil mat. These elements are moved radially outwards from the joining tool. According to another embodiment, the compression on the joining tool can also be performed by gripping units provided in addition to the joining tool, instead of by a radial motor.

[0010] According to this, DE 10 2016 113 894 A1 already discloses a method for inserting a coil mat in multiple layers into inwardly open receiving grooves of a component of an electrical machine that is at least partially ring-shaped, comprising: a) Providing a coil mat comprising straight wire sections and winding heads connecting straight wire sections, b) Applying the coil mat (10) to a joining tool (14) which is provided on an outer circumferential area (64) with positionally adjustable guide plates, between which outwardly open joining tool grooves are formed, wherein the straight wire sections are inserted into the joining tool grooves, f) Inserting the joining tool into the component and aligning the joining tool grooves with the receiving grooves, g) Transferring the straight wire sections from the joining tool grooves into the receiving grooves, here with gripping units provided in addition to the joining tool.

[0011] Based on the prior art of DE 10 2016 113 894 A1, the object of the invention is to provide a method and a device with which a coil winding can be inserted into a component of an electrical machine that is at least partially ring-shaped in such a way that voltages in wires of the coil mat are reduced and that the insertion can be carried out in a more reliable process with increased reliability and a lower risk of damage to wires or their insulation.

[0012] To solve this problem, the invention provides a method according to claim 1 and a device according to the subsidiary claim.

[0013] Advantageous embodiments are the subject of the dependent claims.

[0014] According to one aspect thereof, the invention provides a method for inserting a coil mat in multiple layers into inwardly open receiving grooves of a component of an electrical machine that is at least partially ring-shaped, comprising:a) Providing a coil mat comprising straight wire sections and winding heads connecting straight wire sections, such that a first length section of the coil mat, intended to form a first layer of the coil mat in the component, has first straight wire sections spaced apart by a first wire spacing, and a second length section of the coil mat, intended to form a second layer of the coil mat in the component, has second straight wire sections spaced apart by a different second wire spacing; b) Winding the first length section of the coil mat onto a joining tool, which is provided on an outer circumferential region with positionally adjustable gripping elements, between which outwardly open joining tool grooves are formed, wherein the first straight wire sections are inserted into the joining tool grooves.c) Adjusting the slot spacing of the joining tool slots to accommodate the second wire spacing; d) Winding the second length section of the coil mat, inserting the second straight wire sections into the joining tool slots, and then retracting the joining tool to a smaller outer diameter, allowing it to penetrate the component; f) Inserting the joining tool into the component and aligning the joining tool slots with the receiving slots; g) Transferring the straight wire sections from the joining tool slots into the receiving slots.

[0015] The term "coil mat" refers to a mat-like arrangement of at least one conductor, preferably several conductors, which can be inserted as a prefabricated coil winding into a component of an electrical machine, such as a stator, to form the coil winding of that component. The coil mat can be formed from individual wires that are interwoven, stacked, or plugged into one another. The coil mat can also be composed of several individual mats or partial mats arranged one above the other or one behind the other to form the coil mat.

[0016] In particular, a distributed wave winding is to be formed for an electric machine or a generator.

[0017] For this purpose, a coil mat is first provided in order to insert it into the component.

[0018] A coil mat can be formed, for example, by a single or multi-part linear coil. A coil mat can also be composed of several sub-mats.

[0019] A coil mat consists of several straight wire segments designed for insertion into slots in a component, such as the stator slots of a stator. For example, a coil mat might be formed from several individual, S-shaped, insulated copper bars. The straight wire segments are connected via winding heads. In the winding head, the wire jumps a corresponding number of slots. This jump is often referred to as a coil step. Identical coil steps can be used within a single mat; however, different coil steps on one or both sides are also possible, depending on the desired electrical configuration.

[0020] Such S-shaped bent copper rods or other wires, which can also have different head geometries and coil jumps, together form the coil or coil mat. In one embodiment, a coil mat is designed so that it later has the same number of conductors in each slot of the component, particularly in the stator. In a linear state of the coil mat, the straight wire segments of those wires that will later be located in the same slot can lie on top of each other.

[0021] The coil mat can be continuous, so that the length sections are subsections of the continuous coil mat. Alternatively, the coil mat can be formed from sub-mats. In this case, one or more of the sub-mats can each have the first and second length sections. In another embodiment, the first length section can be formed on a first sub-mat and the second length section on a second sub-mat. The coil mat or its sub-mats can, for example, be formed from wave-wound wires that are bent in a wave-like shape as a flat winding in a plane and have alternating first and second winding heads with different bending directions. The coil mat or its sub-mats can also be formed, for example, by sword winding, in which preferably several parallel wires are wound onto a winding core shaped, for example, like a sword.A coil mat (or its sub-mats) can also be constructed from so-called hairpins, whereby winding heads are formed on one side by bending and wire ends are connected to each other on the other side by a suitable joining technique, such as welding.

[0022] Different distances between the straight wire sections are provided along varying lengths. This allows the distances to be adjusted to the different radial positions of the first and second wire sections within a groove, corresponding to the different circumferential distances of the grooves. This prevents tension in the wires of the coil mats caused by varying circumferential distances due to differing radial positions. Furthermore, the joining tool can also be adapted to the different distances between the straight wire sections. This ensures that the wires can be handled with minimal stress during transfer.

[0023] To wind up the coil mat, the joining grooves of the joining tool are modified to adapt the joining tool to the wire spacing.

[0024] Preferably the method comprises: u) using a joining tool with segment-like gripping elements that are radially displaceable, and radially adjusting the gripping elements to change the groove width, outer circumference and groove spacing.

[0025] Preferably the method comprises: v) changing the diameter of the joining tool at the outer circumference to change the groove spacing.

[0026] Preferably the method comprises: w) adjusting a distance of a rotation axis of the joining tool to a section of the coil mat yet to be wound up, depending on a change in the diameter of the outer circumferential area.

[0027] Preferably the method comprises the step: e1) fixing at least one area of ​​the coil mat in the joining tool by reducing the groove width of at least some or all of the joining tool grooves in order to hold wire sections inserted therein.

[0028] Preferably the method comprises the step: e2) Detaching the coil mat from the joining tool by increasing the groove width in order to release wire sections held therein.

[0029] According to a preferred embodiment, step e1) comprises step: e1.1) reducing the groove widths for clamping wire sections between the gripping elements.

[0030] According to a preferred embodiment, step e1) comprises step: e1.2) reducing the groove widths for positive locking of wire sections behind projections on gripping elements at the opening of the guide tool grooves.

[0031] According to a preferred embodiment, step e1) comprises step: e.1.3) Reducing the groove widths by performing at least one of steps u), v) and / or w) and reducing the diameter of the outer circumference of the joining tool by more than 1%.

[0032] According to a preferred embodiment, step e2) comprises the step of: increasing the groove widths by performing at least one of steps u), v) and / or w) and increasing the diameter of the outer circumference by more than 1%.

[0033] It is preferred that step e1) is performed before and / or during step f) and that step e2) is performed after step f) and before and / or during step g).

[0034] It is preferred that step a) comprises the step: a1) providing the coil mat on a linearly extending comb-like transfer tool such that one or more coil mat layers of a coil mat or of several sub-mats are held on a comb structure with straight wire sections positioned between the teeth of the comb structure.

[0035] It is preferred that step a) includes step: a2) providing the coil mat such that a first straight wire section at the end of the first length section and a second straight wire section at the beginning of the second length section are spaced apart by a transition wire spacing whose value lies between the first wire spacing and the second wire spacing.

[0036] It is preferred that step a) includes step: a3) providing the coil mat such that the first straight wire section at the end of the first length section and the second straight wire section at the beginning of the second length section are spaced apart by a transition wire spacing whose value corresponds to the mean of the first wire spacing and the second wire spacing plus / minus 10%.

[0037] It is preferred that step a) includes step: a4) providing the coil mat such that the first wire spacing corresponds to the wire spacing of the first straight wire sections when used as intended in the component and that the second wire spacing corresponds to the wire spacing of the second straight wire sections when used as intended in the component.

[0038] It is preferred that step b) includes the step: b1) Adjusting the slot spacing of the joining tool slots to the first wire spacing.

[0039] It is preferred that step b) includes step: b2) rolling the joining tool with its circular outer circumference over the linearly laid out or linearly moving coil mat.

[0040] It is preferred that step b) includes the step: b3) rolling the joining tool with its circular outer circumference over the linear transfer tool moving linearly relative to the joining tool according to step a1).

[0041] It is preferred that step b) includes step: b4) adjusting the distance of the outer circumference to the linear transfer tool according to step a1) by changing the distance of the axis of rotation of the joining tool to the linear transfer tool.

[0042] It is preferred that step b) includes step: b5.1 radially moving the first wire sections into the joining tool grooves.

[0043] It is preferred that step b) includes step: b5.2 Adjusting the groove width to allow for skewed threading of the first wire sections and inserting the first wire sections by rolling without radially moving the first wire sections.

[0044] It is preferred that step d) includes the step: d1) Adjusting the slot spacing of the joining tool slots to the second wire spacing.

[0045] It is preferred that step d) includes step: d2) rolling the joining tool with its circular outer circumference over the linearly laid or linearly moving coil mat.

[0046] It is preferred that step d) includes the step: d3) rolling the joining tool with its circular outer circumference over the linear transfer tool moving linearly relative to the joining tool according to step a1).

[0047] It is preferred that step d) includes step: d4) Adjusting the distance of the outer circumference to the linear transfer tool according to step a1) by changing the distance of the axis of rotation of the joining tool to the linear transfer tool.

[0048] It is preferred that step d) includes step: d5.1 radially moving the second wire sections into the joining tool grooves.

[0049] It is preferred that step d) includes the step: d5.2 Adjusting the groove width to allow for skewed threading of the second wire sections and inserting the second wire sections by rolling without radially moving the second wire sections.

[0050] It is preferred that step c) includes the step: c1) changing the slot spacing to match the transition wire spacing according to step a2) or a3) and then changing the slot spacing to match the second wire spacing.

[0051] It is preferred that step c) includes step: c2) changing the slot spacing while stopping a relative linear movement between joining tool and coil mat.

[0052] It is preferred that step c) includes step: c3) changing the slot spacing during a continuous relative linear movement between joining tool and coil mat.

[0053] It is preferred that step c) includes step: c4) changing the slot spacing depending on the geometry of the coil mat.

[0054] According to a further aspect, the invention provides a device for inserting a coil mat in multiple layers into inwardly open receiving grooves of a component of an electrical machine that is at least partially annular in shape, comprising: a coil mat supply device for supplying a coil mat, which has straight wire sections and winding heads that connect straight wire sections, such that a first longitudinal section of the coil mat, defined for forming a first layer of the coil mat in the component, has first straight wire sections spaced apart by a first wire spacing, and a second longitudinal section of the coil mat, defined for forming a second layer of the coil mat in the component, has second straight wire sections spaced apart by a different second wire spacing. A joining tool rotatable about an axis of rotation relative to the coil mat and / or the component, which is provided on an outer circumferential area with position-adjustable gripping elements between which outwardly open joining tool grooves are formed, a winding device for winding the coil mat onto the joining tool such that the straight wire sections are inserted into the joining tool grooves, a transfer device for inserting the joining tool into the component, aligning the joining tool grooves with the receiving grooves and transferring the straight wire sections from the joining tool grooves into the receiving grooves, and a control system configured for this purpose.to change the groove spacing of the joining tool slots between the winding of the first longitudinal section onto the joining tool and the winding of the second longitudinal section onto the joining tool to adapt to the second wire spacing, and to retract the joining tool to a smaller diameter after winding, allowing the joining tool to plunge into the component in order to then transfer the straight wire sections into the receiving slots.

[0055] It is preferred that the joining tool has segment-like gripping elements which are radially displaceable and that the control is configured to adjust the gripping elements radially in order to change the groove width, outer circumference and groove spacing.

[0056] It is preferred that the diameter of the joining tool is variable at the outer circumference in order to change the groove spacing.

[0057] Preferably, the device comprises a joining tool movement device for moving the axis of rotation of the joining tool relative to the coil mat, wherein the control is configured to adjust the distance of the axis of rotation of the joining tool to a section of the coil mat yet to be wound up depending on a change in the diameter of the outer circumferential area.

[0058] It is preferred that the control is configured to reduce the groove width of at least some or all of the joining tool grooves in order to fix at least one area of ​​the coil mat in the joining tool in order to hold wire sections inserted therein and / or to increase the groove width in order to release the coil mat in order to release wire sections held therein.

[0059] It is preferred that the control system be configured to reduce the groove widths for clamping wire sections between the gripping elements.

[0060] It is preferred that at least some of the gripping elements each have at least one projection that narrows the associated joining tool groove in the opening area and that the control system is configured to reduce the groove widths for positive locking of wire sections behind the projections of the gripping elements.

[0061] It is preferred that the adjustment range of the diameter of the outer circumference of the joining tool is more than 1% of the diameter in order to cause the wire sections to jam and release between the gripping elements.

[0062] It is preferred that the control system is configured to hold the wire sections in place by reducing the size of the groove before and during the transfer of the joining tool into the component.

[0063] It is preferred that the coil mat supply device has a linearly extending comb-like transfer tool for holding one or more coil mat layers of a coil mat or several partial mats on a comb structure with straight wire sections positioned between the teeth of the comb structure, wherein the comb-like transfer tool is movable linearly in the direction of its extension relative to the joining tool.

[0064] Preferably, a device is provided comprising a data processing unit with a computer program product or computer program loaded therein, comprising machine-readable control instructions that cause the device (40) to carry out the steps of the method according to an embodiment described above.

[0065] According to another aspect, the invention relates to a computer program product or computer program comprising machine-readable control instructions which, when loaded into the data processing unit of the device of one of the preceding embodiments, cause the device to carry out the steps of the method according to an embodiment described above.

[0066] Exemplary embodiments of the invention are explained in more detail below with reference to the accompanying drawings. These show: Fig. 1 a top view of an example of a coil mat; Fig. 2 a schematic representation of a transfer tool and a joining tool to illustrate a step in a method for inserting a coil mat in multiple layers into receiving grooves of a component of an electrical machine; Fig. 3 a schematic axial view of an embodiment of such a component of an electrical machine with receiving grooves and a coil mat inserted therein, wherein the coil mat is formed entirely from a single mat that is inserted in multiple layers, so that it occupies a first to third winding layer in the component; Fig. 4 a view comparable to the Fig. 3 , wherein the coil winding is formed from a coil mat which is formed from a first to third sub-mat, each sub-mat forming one of the first to third winding layers; Fig. 5 a view comparable to the Fig. 3, wherein the coil winding is formed from a coil mat which is formed from a first and a second sub-mat, each sub-mat having different longitudinal sections and thus occupying a different winding position; Fig. 6 a view comparable to the Figs. 3 to 5 , wherein the coil mat is formed from a first to third sub-mat, each sub-mat having different longitudinal sections and occupying different winding positions; Fig. 7 a view comparable to the Figs. 3 to 6, wherein the coil mat is formed from a first to fourth sub-mat, each occupying different winding positions within the component; Fig. 8 a schematic view of a partial area of ​​the coil mat, showing a half-winding in a first winding position in the component compared to a half-winding in a third winding position in the component to illustrate different circumferential distances; Fig. 9 a schematic representation of a joining tool and a component in a second step of the method; Fig. 10 a view comparable to the Fig. 9in a third step of the method; Fig. 11 an example of the transfer tool and an example of a rigid joining tool to illustrate a problem with the method; Fig. 12 another example of the transfer tool and an example of an adjustable joining tool to illustrate a further problem with the method; Fig. 13 an example of a transfer tool and an adjustable joining tool in a first step of an embodiment of the method according to the invention; Fig. 14 the arrangement of Fig. 13 in a further step of the process; Fig. 15 the arrangement of Fig. 14 in a further step of the process; Fig. 16 the arrangement of Fig. 14 in a further step of the process; Fig. 17 the arrangement of Fig. 15 in a further step of the process; Fig. 18 an arrangement comparable to the Figs. 13 to 17according to a further embodiment of the method and a device for carrying out the method according to the invention; Figs. 19 and 20 the adjustable joining tool in two settings to illustrate further process steps according to further embodiments of the method according to the invention; and Fig. 21 a partial area of ​​a further joining tool to illustrate a further embodiment of the method according to the invention.

[0067] The following describes exemplary embodiments of methods and devices 40 for the multi-layered insertion of a coil mat 10 into inwardly open receiving grooves 24 of a component 16 of an electric machine that is at least partially annular in shape. These methods and devices allow the insertion of coil mats 10 that are held in the component 16, for example a stator 20, with low internal stresses, while simultaneously providing a uniformly high winding head 38. For this purpose, different head geometries of the winding heads 38 are provided in different length sections 60-1, 60-2, 60-3, and possibly in transition regions 30 between them. These geometries hold straight wire sections 36-1, 36-2, 36-3 at the appropriate wire spacing relative to each other. Fig. 1 An example of a coil mat 10 for forming a coil winding 18 of a component 16 of an electrical machine is shown. Fig. 2shows a transfer tool 12 and a joining tool 14 for inserting the coil mat 10 into the component 16.

[0068] The Figs. 3 to 7 show different embodiments of a component 16, which is at least partially ring-shaped and is provided with a coil winding 18 formed by a coil mat 10.

[0069] Component 16 is, for example, a stator 20 of an electric machine, such as in particular an electric motor or generator, and more specifically an electric motor which can be used as a traction motor in a motor vehicle and has a rated power between 10 kW and 400 kW.

[0070] The stator 20 has a ring-shaped housing 22, which is designed, for example, as a laminated core, with inwardly open receiving grooves 24 on an inner circumference for receiving the coil winding 18.

[0071] For this purpose, the spool mat 10 is inserted in multiple layers into the receiving grooves 24.

[0072] In the Figs. 3 to 7 In the illustrated embodiments, the coil winding 18 in component 16 is shown with a first winding layer 26-1, a second winding layer 26-2 and a third winding layer 26-3; more or fewer winding layers may also be provided.

[0073] The coil mat 10 can be used as shown in Fig. 3 shown to be formed entirely from a single mat, which is inserted into component 16 in several layers.

[0074] At the in Fig. 3 In the illustrated embodiment, the coil mat 10, designed as a single mat, is inserted in multiple layers, so that this coil mat 10, designed as a single mat, occupies the first winding layer 26-1, the second winding layer 26-2 and the third winding layer 26-3.

[0075] At the in Fig. 4In the illustrated embodiment, the coil mat 10 is formed from a first partial mat 28-1, a second partial mat 28-2, and a third partial mat 28-3, wherein the first partial mat 28-1 occupies the first winding layer 26-1, the second partial mat 28-2 occupies the second winding layer 26-2, and the third partial mat 28-3 occupies the third winding layer 26-3. Thus, a coil mat 10 consisting of several partial mats 28-1, 28-2, 28-3 is shown here, without any layer transition 32.

[0076] At the in Fig. 5 In the illustrated embodiment, the coil mat 10 is formed from a first partial mat 28-1 and a second partial mat 28-2, wherein the partial mats 28-1 and 28-2 each occupy different winding layers 26-1, 26-2 and 26-3. A layer change 32 occurs within the coil mat 10 at transition areas 30.

[0077] Fig. 6Figure 1 shows a further embodiment of the stator 20, wherein the coil winding 18 is formed from a coil mat 10, wherein in this embodiment the coil mat 10 is provided a first sub-mat 28-1, a second sub-mat 28-2 and a third sub-mat 28-3. In these sub-mats 28-1, 28-2, 28-3, a change in the position of the individual sub-mats 28-1, 28-2, 28-3 from one winding position 26-1, 26-2, 26-3 to another winding position 26-2, 26-3, 26-1 also occurs in transition regions 30.

[0078] The construction of the coil mat 10 according to the exemplary embodiment of is comparable to this. Fig. 7 However, the coil mat 10 does not consist of only three sub-mats 28-1, 28-2, 28-3, but of more sub-mats. For example, in addition to the first to third sub-mats 28-1 to 28-3, a fourth sub-mat 28-4 is provided.

[0079] The structure and manufacture of the individual coil mats 10 can vary. For example, the coil mat 10 and its sub-mats are formed from wave-wound wires, as described and shown in detail in the international patent applications with the international file numbers PCT / DE 2019 / 100178 and PCT / DE 2019 / 100179. Other embodiments of the coil mat 10 are manufactured by sword winding, for example by the method explained and shown in more detail in WO 2019 / 020148 A1, and are provided by a corresponding coil mat manufacturing device (not shown here).

[0080] As in Fig. 1 As shown, the coil winding 18, designed as a wave winding, is prefabricated outside the component 16, for example as a linear coil - example of a coil mat 10.

[0081] The coil mat 10 has several conductors in the form of bent wires. In particular, the coil mat 10 has several individual S-shaped bent insulated copper bars that form the wires 34. The copper bars are preferably designed with a non-circular profile and, for example, with a rectangular profile, as is the case, for example, in Fig. 2 can be seen.

[0082] As in Fig. 1 As shown, the coil mat has 10 straight wire sections 36 and winding heads 38. A winding head 38 connects two straight wire sections 36 such that they are a certain distance apart. For example, a wire 34 jumps several slots, for example five slots, when passing through a winding head 38.

[0083] The respective straight wire section 36 is thus later located in one of the receiving slots 24. In a winding head 38, the wire 34 jumps a corresponding number of receiving slots 24. This jump is often referred to as a coil jump. It is possible to provide a coil mat 10 in which the same coil jumps are used. In other embodiments, the coil mat 10 also has different coil jumps on one or both sides, depending on the desired electrical connection.

[0084] The individual wires 84, formed, for example, from S-shaped bent copper rods, which can also be designed differently in the winding head geometry of the winding head 38 and in the coil jump, together form the coil mat 10. It is preferred that the coil mat 10 is designed such that it can later be used in the component 16 - see, for example, the Figs. 3 to 7- has the same number of conductors in each slot 24. In one configuration of the coil mat 10, the straight wire sections 36, which are later located in the same slot, lie on top of each other in the linear state.

[0085] Fig. 2Figure 40 shows a device 40 for inserting a multi-layered coil mat 10 into the inwardly open receiving grooves 24 of the component 16. The device 40 comprises a coil mat supply device 42 for supplying the coil mat 10 and an insertion tool 14 for inserting the coil mat 10 into the component 16. Furthermore, the device 40 includes a control unit 46 for controlling the movement sequences. In some embodiments, the coil mat supply device 42 has a linear transfer tool 12. The transfer tool 12 extends, for example, linearly and is comb-like in design, serving to hold one or more layers of the coil mat 10. For example, the partial mats 28-1, 28-2, 28-3 can be held on it. For this purpose, the transfer tool 12 has a comb structure 50 with teeth 52 and transfer tool grooves 54 formed between them.

[0086] The joining tool 14 is movable relative to the transfer tool 12 by means of a joining tool movement device 56, which is only schematically indicated in the figures and may be formed, for example, by a robot arm or the like, so that the joining tool 14 can be rolled over the transfer tool 12. Joining tool grooves 58 are provided on an outer circumference of the joining tool 14 for receiving the straight wire sections 36 of the coil mat 10. In alternative embodiments, however, a linear movement can also be carried out by the transfer tool 12.

[0087] As in Fig. 2As shown, the transfer tool 12 with transfer tool grooves 54 is used to receive the coil mat 10. The transfer tool grooves 54 have a groove spacing A20 corresponding to a wire spacing A20 between two adjacent straight wire sections 36. For the transfer, the rotary joining tool 14 rolls on the transfer tool 12, thereby transferring the coil mat 10 from the transfer tool 12 to the joining tool 14. During the rolling motion, the transfer tool 12 is moved linearly relative to the joining tool. This can be achieved, for example, by means of the joining tool movement device 56.

[0088] As in Fig. 2 To ensure reliable transfer, it is advantageous that the groove spacing A20 between the transfer tool grooves 54 and the joining tool grooves 58 of the joining tool 14 matches. Fig. 2For clarity, a linear coil mat 10 with two wires 34 stacked on top of each other is shown.

[0089] The coil mat 10 is transferred into the joining tool 14 to form a rotary coil winding 18 with two wraps, so that four straight wire sections 36 are accommodated per joining tool groove 14. This is only one example; the coil mat 10 can also have more or fewer conductors per groove. Similarly, depending on the coil mat 10 and the number of wraps, different numbers of wires 34 per groove are possible in the joining tool 14.

[0090] For illustrative purposes, the joining tool 14, which can also be called a joining mandrel, was intentionally drawn with very few joining tool grooves 58 in order to more clearly demonstrate the effect of a changing groove spacing depending on the radial position of the wires 34 in the joining tool groove 48. It can be seen that the groove spacing A20, A21, A22 changes when the wire is positioned deeper in the rotary joining tool 14. If the wires 34 are located relatively far out in the joining tool 14, the resulting groove spacing of A21 at this position is almost identical to A20. A20 here is the groove spacing at the outer circumference of the joining tool 14.

[0091] However, with multiple wraps of the coil mat 10 or its layers or partial mats 28-1, 28-2, 28-3, wires 34 also lie significantly deeper in the joining tool groove 58, resulting in a significantly smaller groove spacing A22.

[0092] If the distances between linearly or circumferentially adjacent straight wire sections 36 were changed during their pickup, the winding heads 38, which connect the wire sections 36, would deform. The forces required for this deformation would be introduced into the straight wire sections 36 via the lateral groove surfaces of the joining tool 14 during the sliding movement, which could lead to damage to the wire insulation.

[0093] In Fig. 8The figure illustrates the change in the positions of the straight wire sections 36 depending on the winding position 26-1, 26-2, 26-3. On the left, a winding head 38 is shown with the first straight wire sections 36-1 connected to it, which are located in the stator 20 in the first winding position 26-1. On the right, a winding head 38 is shown with the third straight wire sections 36-3, which are located in the third winding position 26-3. In the first winding position 26-1, the first straight wire sections 36-1 have an exemplary spacing of 32 mm, while the third straight wire sections 36-3 have, for example, a spacing of 29 mm from each other in the third winding position 26-3.

[0094] So that the winding heads 38 are in the Figs. 3 to 7 The coil mat 10 of the depicted inserted state does not deform and is not under tension. Fig. 1The coil mat comprises a first length section 60-1, a second length section 60-2, and a third length section 60-3. In the first length section 60-1, the first straight wire sections 36-1 are provided with a first wire spacing between them; in the second length section 60-2, the second straight wire sections 36-2 are provided with a different second wire spacing between them; and in the third length section 60-3, third straight wire sections 36-3 are provided with a different third wire spacing between them. The winding heads 38 are already shaped during manufacturing such that the wire sections 36-1, 36-2, 36-3 in the different length sections 60-1, 60-2, 60-3 have the different wire spacings between them. Different wire spacings may also be provided in the transition areas 30. Depending on the design of the coil mat, as shown in the Figs. 3 to 7It emerges that a single mat with the three length sections 60-1, 60-2, 60-3 is provided, that - as in Fig. 4 - different partial mats 28-1, 28-2, 28-3 of the coil mat 10 have the different length sections 60-1, 60-2, 60-3, or that different partial mats 28-1, 28-2, 28-3 have one or more or all of the different length sections 60-1, 60-2, 60-3 with the different wire spacings between the straight wire sections 36-1, 36-2, 36-3 according to the winding position 26-1, 26-2, 26-3 to be taken.

[0095] Depending on the design of the coil winding 18, the coil mat 10 can be transferred according to the exemplary embodiments of the Figs. 3 to 7 a single mat be wound up as a coil mat 10 to achieve the configuration according to Fig. 3to form. In the joining tool 14 itself, several linear submats 28-1, 28-2, 28-3 can also be stacked and wound on top of each other. Several individual linear submats 28-1, 28-2, 28-3 can also be placed simultaneously on a transfer tool 12, with their beginnings at the same point (as for forming the configuration according to Fig. 3 ) or can also be located in different places - for example, to form spirally inserted partial mats 28-1, 28-2, 28-3, 28-4 or partial coils according to the configurations of the Figs. 5 to 7. Fig. 3 This shows a layered coil mat 10, formed from a single coil. Fig. 4 This shows a layered coil mat 10, formed from layered partial mats 28-1, 28-2, 28-3. Figs. 5 to 7 show a multi-layered coil mat 10, formed from spirally inserted partial mats 28-1, 28-2, 28-3, 28-4, wherein in Fig. 5a first and a second partial mat 28-1, 28-2 are provided, in Fig. 6 a first to third partial mat 28-1 to 28-3 are provided and in Fig. 7 A first to fourth partial mat 28-1 to 28-4 are provided.

[0096] In the Fig. 9 and 10The joining tool 14 is shown before and after the transfer of the coil mat 10 from the joining tool 14 into the component 16. For this purpose, the joining tool 14 was axially moved from the transfer tool 12 into the interior of the component 16 by the joining tool movement device 56. The joining tool 14 is immersed in the prepared stator 20, and the coil winding 18 is transferred from the joining tool 14 into the stator 20 by a predominantly radial movement of the individual wire sections 36-1, 36-2. This transfer can be effected by gripper elements (not shown) or a cam guide (also not shown), as described and shown in the aforementioned prior art.Preferred embodiments of the device 40 according to the invention utilize for this step transmission techniques as described and shown in detail in DE 10 2016 111 478 A1, with the modifications and differences explained in more detail below.

[0097] The radial transmission can be carried out for all wire sections 36, 36-1, 36-2, 36-3 simultaneously, or section by section or one after the other.

[0098] Preferably, the joining tool has a number of joining tool slots 58 corresponding to the number of receiving slots 24 in the stator 20. Thus, the joining tool 14 has the same number of slots at the same location as the stator 20. In order to transfer the straight wire section 36, 36-1, 36-2, 36-3, which is located in the joining tool slot 58, appropriately into the receiving slot 24 of the stator 20, it is advantageous if the straight wire section 36-1, 36-2, 36-3 included here is guided tightly by the joining tool 14 in order to transfer the wire 34 into the tightly toleranced receiving slots 24.

[0099] For the in Fig. 2When winding the coil mat 10 onto the joining tool 14, the clearance in the joining tool slots 58 should be as large as possible so that the straight wire sections 36 can be transferred from the transfer tool 12 to the joining tool 14 without deformation or risk of damaging their insulation. However, for transferring the coil winding 18 from the joining tool 14 into the receiving slots 24, the clearance in the joining tool should be as small as possible so that the straight wire sections 36 can be transferred precisely from the joining tool 14 to the stator.

[0100] Furthermore, the spacing between the straight wire sections 36-1, 36-2, 36-3 should be defined as closely as possible to the circumferential spacing they occupy when installed in the stator 20. This results in different wire spacings between the straight wire sections 36-1, 36-2, 36-3 in the different length sections 60-1, 60-2, 60-3, which further complicates the transfer of the coil mat 10 from the transfer tool 12 to the joining tool 14 and the transfer from the joining tool 14 into the stator 20.

[0101] Previously known transfer methods for transferring a coil mat 10 onto a joining tool 14, for example, a joining mandrel, require a coil mat with a constant spacing between straight wire sections along its entire length to allow the wires to be picked up by the transfer tool 12 without damage. However, in previously known transfer methods, the coil mat 10 assumes different wire spacings in the joining tool depending on its position and, in particular, during multiple rotations. The coil mat 10 must therefore be reshaped in the joining tool 14, which involves reshaping the winding heads and thus changing the winding head height, and carries the risk of damaging the wire insulation.

[0102] The following describes the special features of a method and a device 40 which transfers a coil mat 10 with previously produced differently shaped wire sections into the joining tool 14 without changing the distance between the different wire sections 36-1, 36-2, 36-3, thus eliminating the need to reshape the winding head 38 when transferring or positioning the coil mat 10 into the different layers in the joining tool 14. This results in a more wire-friendly transfer method with the additional possibility of achieving a uniform winding head height across all winding layers 26-1, 26-2, 26-3 in the joined state.

[0103] For this purpose, the coil mat 10 is pre-produced with wire spacings that will later be found in the stator 20. Accordingly, such a coil mat 10 is provided. In the method and in the device 40, the wire spacing of the coil mat 10 is not adapted to the joining tool 14, but rather the joining tool 14 is adapted to the respective wire spacing in the different length sections 60-1, 60-2, 60-3.

[0104] With embodiments of the inventive method, it is possible to transfer a linear coil mat 10 with several turns onto a joining tool 14 designed as a joining mandrel without having to change the wire spacing during this transfer. This eliminates the need for head forming and thus also eliminates the need for force application to the wire 34 during the sliding movement of the wire 34 in the joining tool grooves 58. This minimizes the risk of insulation damage.

[0105] In embodiments of the method, it is provided that the joining tool 14, rather than a multi-layered coil mat 10 adapting to the corresponding radial winding layer during the winding of the layers, adapts to the coil mat 10. The coil mat 10 is manufactured beforehand with the advantageously provided different wire spacings for each subsequent winding layer 26-1, 26-2, 26-3.

[0106] In embodiments of the method and the device 40, the transfer to the joining tool 14 without changing the wire spacing is possible because the joining tool 14, within the transfer of the coil mat 10, adjusts itself to the spacing of the joining tool grooves 58 by adjusting to the respective appropriate wire spacing. In one embodiment, the linear transfer tool 12 is provided, the comb structure 50 of which is also adapted to the different wire spacings in the different length sections 60-1, 60-2, 60-3.

[0107] When using the linear transfer tool 12, the embodiments of the method and the device 40 provide for the additional correction of the distance between the joining tool 14 and the linear transfer tool 12. The wire spacings in the different length sections 60-1, 60-2, 60-3, when the coil mat 10 is still linearly configured (for example, when mounted in the transfer tool 12), can be identical to the later wire spacings in the stator 20, but they do not necessarily have to correspond to the later wire spacing in the stator 20. For example, the wire spacings in the linear state can also be adjusted to a different radial position in the joining tool 14.

[0108] Advantages of embodiments of the method and the device 40 include a reduction in the risk of insulation damage to the wires 34 during winding onto the joining tool 14, a more uniform winding head 38 in the stator 20 due to the already suitable different wire spacings in the linear coil mat 20, and ideally also a possible dispensing with the straight transmission tool 12.

[0109] Fig. 11 Figure 1 shows a situation that would arise if a rigid joining tool 14' were used. The wire 34 would then have to be inserted into a very narrow joining tool groove 58 with a groove width B. During transfer, the coil mat 10 has a consistent wire spacing A20 along its entire length, which must later be changed to A21 or A22 in the joining tool 44 by additional forming when the previously wound layers are transferred to a position radially closer to the center. Fig. 12 In contrast, a joining tool 14 with gripping elements 68 in the form of segments 62 is shown, which are adjustable in the radial direction within the joining tool 14. By adjusting the segments 62 in the radial direction, the groove width of the joining tool grooves 58 can be adjusted. Fig. 13 The joining tool 14 is slightly raised to increase the groove width from B to B1. Considering the function of the radially adjustable joining tool 14 in Fig. 11 More precisely, it can be seen that not only does the groove width of the joining tool grooves 58 change, but also, depending on this, the outer diameter of an outer circumferential area 64 of the joining tool 14 having the joining tool grooves 58 changes. Furthermore, the wound coil mat 10 is no longer wound onto the diameter of Fig. 11 compressed, but only as far as necessary, in the example shown to the wire spacing A31 and A32.

[0110] In Fig. 13 and Fig. 14The start and end of the transfer process for the winding layer that will later be radially inner in component 16 can be identified, here, for example, the second winding layer 26-2. It can be seen that the coil mat 10 is positioned in the joining tool 14 with a wire spacing A31, while the joining tool 14, due to geometric constraints, has a slot spacing A30 on its outer circumferential area 64. With a very narrow slot clearance, this could lead to problems; however, the slot width B1 is sufficiently large due to the way the joining tool 14 moves up and down, so that even a longitudinal section 60-2 of the coil mat 10 with a slightly smaller wire spacing A31 can be accommodated without damage. Fig. 14 The second winding layer 26-2 has been taken up, and the taking up of the next resulting winding layer - here e.g. the first winding layer 26-1 - into the joining tool 14 starts.

[0111] So far, this has remained the case - as in Fig. 11As indicated, the joining tool 14' remains unchanged; the first winding layer 26-1 would be picked up with a constant wire spacing (A41 would be identical to A31), and the second winding layer 26-2 would have to be pressed radially inwards into the joining tool 14. Transferring a coil mat 10 with different length sections 60-1, 60-2, each with different wire spacings from the outset, would not be directly possible with a rigid joining tool 14' due to the now significantly different dimensions A30 and A41, and thus because the joining tool grooves 58 would no longer align with the transfer tool grooves 54 during further unwinding. Transfer would theoretically be possible if the circumferential speed at the outer circumferential area 64 of the joining tool 14' were deliberately chosen to be higher than the linear speed of the linear transfer tool 12, so that a slippage is intentionally created.This would work as long as the wire 34 is completely transferred into a joining tool groove 58 before the next wire 34 is transferred into the joining tool groove 58. In practice, however, the necessary angle of movement for transfer is greater than the existing angle between two joining tool grooves 58; thus, wires 34 are usually transferred from several transfer tool grooves 54 simultaneously. This makes the slip-based principle practically unfeasible or leads to wire damage.

[0112] During the Figs. 13 to 17In the embodiment of the device 40 according to the invention, shown using the example of a coil winding 18 with two winding layers 26-1, 26-2, the outer circumference 64 of the joining tool 12 is now changed in its diameter by the control 46 during the transfer process or within a transfer of a coil mat 10, whereby the rolling circumference changes due to the non-obvious geometric change with a constant number of joining tool grooves 58 and thus the distance of the joining tool grooves 58 on the outer circumference 64.

[0113] In one embodiment of the device 40 according to the invention, the distance between the joining tool grooves 58 on the outer diameter is now changed to A40, as shown in Fig. 15This is shown. Simultaneously, the distance between the axis of rotation 66 of the joining tool 14 and the linear transfer tool 12 is corrected to dimension X3 to ensure continued smooth unwinding on the transfer tool 12. Moving the joining tool 14 creates space for the new first winding layer 26-1. The already wound second winding layer 26-2 remains in its position with the wire spacing A31. It is advantageous that, when the joining tool 14 moves, the groove width B1, to which the radially adjustable joining tool 14 was originally set, is also changed to groove width B2.

[0114] In the Figs. 15 to 17The further process of transferring the first winding layer 26-1 of the coil mat 10 is shown. The joining tool 14 has been moved to the slot spacing A40 on its outer circumferential region 64. The second winding layer 26-2 remains in the joining tool 14 with the wire spacing A31. The first winding layer 26-1 occupies the wire spacing A41 in the joining tool 14; the coil mat 10 was previously manufactured to this wire spacing A41. Here again, it should be noted that the geometrically determined new slot spacing A40 present on the outer circumferential region 64 of the joining tool 14 does not necessarily have to correspond exactly to the wire spacing A41 due to the large slot clearance.

[0115] The Fig. 18Figure 40 shows a variant of the method and the device. A large slot clearance is particularly advantageous at the transition between two winding layers 26-1, 26-2 (in the transition region 30). At a jump from one winding layer 26-1 to another winding layer 26-2, a transition wire spacing A51 can be advantageous, which is preferably approximately the average between the wire spacing A31 of one winding layer 26-1 and the wire spacing A41 of the other winding layer 26-2. Depending on the geometry of the coil mat 10, it is also advantageous to design the coil mat 10 with a transition wire spacing as shown in Figure 40. Fig. 18 This is indicated by the wire spacing A51. Here, a transition wire spacing A51 was provided between the wire spacing A31 and the further wire spacing A41. Advantageously, the joining tool 14 is now also set in the transition area 30 with the corresponding diameter and the groove spacing A50 on the outer circumference 64.

[0116] What's next in Fig. 18 As can be seen, advantageously, with each correction of the groove spacing on the outer circumferential region 64 of the joining tool 14, and thus with each change in the outer diameter of the outer circumferential region 64 of the joining tool 14, the distance dimension between the axis of rotation 66 and the transfer tool 12 is corrected. For example, in Fig. 18 According to the setting on the wire spacing A51 and the groove spacing A50, the distance dimension in X5 is corrected to achieve rolling with the smallest possible clearance between the joining tool 14 and the transfer tool 12.

[0117] In one procedure, the joining tool 14 is always adjusted when switching between two different wire spacings during winding. This can be achieved by stopping the relative linear movement between the transfer tool 12 and the joining tool 14 and adjusting the joining tool 14, or by continuously adjusting the joining tool 14 during the relative linear movement.

[0118] The timing of the start and end of the adjustment process also depends on the coil geometry. The movement between position changes does not necessarily have to be linear; it can also be a different movement pattern.

[0119] In Fig. 19A coil mat 10 wound onto the joining tool 14 according to the new transmission principle is now shown. A special feature is that the wire spacing of the length sections 60-1, 60-2 of the coil mat 10 did not change, or only changed insignificantly, during the transmission. Due to the relationship between the slot spacing of the joining tool 14 and the width of the joining tool slots 58, this method results in a relatively large amount of play for the wire 34 in the joining tool slot 58 compared to previously known transmission methods. This would initially appear undesirable and could lead to problems. However, the individual straight wire sections 36-1, 36-2 are each connected by winding heads 38. Because of the winding heads 38, the wires 34 cannot slip past each other and change their positions or order in the joining tool slot 58.

[0120] After the winding process has been completed, as described in Fig. 19As can be seen, the joining tool 14 is then retracted together with the coil winding 18 to a small outer diameter D1. The segments 62 are advantageously designed as segment-like, radially adjustable gripping elements 68 that grasp and hold the wires 34.

[0121] Due to the simultaneous insertion of the gripping elements 68, there is no relative movement between the wire 34 and the side surfaces of the joining tool grooves 58. In order to insert the coil winding 18 from the inside into the receiving grooves 24, the wire spacing of the individual length sections 60-1, 60-2 (of the individual winding layers 26-1, 26-2) must be temporarily reduced during the joining process. This also temporarily deforms the winding heads 38. While this described forming process of the winding heads 28 again involves the application of force via the straight wire sections 36-1, 36-2, there is no relative movement during this force application; that is, the wire sections 36-1, 36-2 remain in their radial position relative to the gripping elements 68. Therefore, this process is significantly gentler on the wire insulation than previously known forming processes during winding.

[0122] In Fig. 20The joining mandrel – joining tool 14 – with its compressed coil winding 18 and reduced wire spacing, now inserted to the small diameter D1, is visible. The previously critical groove clearance caused by the large groove opening B2 has been minimized by reducing the diameter of the outer circumference 64 of the joining tool 14 and the resulting geometric reduction in the groove width for the joining process. With the small diameter D1, the joining tool 14 can then, according to the invention, plunge into the housing 22 to transfer the wire sections 36-1, 36-2 into the receiving grooves 24.

[0123] In a particularly preferred embodiment of the method and the device 40, during the transition from state to state Fig. 19 on the condition of Fig. 20A further process step is carried out. Here, the joining tool 14 is deliberately inserted further at its outer circumference 64 than would be necessary for joining. That is, the outer diameter D1 is intentionally significantly smaller than the inner diameter of the component 16. This significantly smaller reduction does not serve to compensate for tolerances between the joining tool 14 and the housing 22 of the component 16 (e.g., the stator core 20), but rather allows for the targeted creation of an excess of groove width and wire. For example, the groove width of the joining tool grooves 58 is smaller than the width of the straight wire sections 36-1, 36-2. This prevents wires 34 from popping out through frictional engagement. Therefore, further fixing of the coil winding 18 for the process of inserting the joining tool 14 into the component 16 (e.g., plunging the joining tool 14 into the housing 22 of the stator 20) can be dispensed with.In an alternative embodiment of the method and the device 40, it is also possible to deliberately reduce the size of the joining tool grooves 58 at the groove exit in order to additionally secure the wire 34 in the joining tool 14 by means of a small positive fit. For this purpose, for example, projections (not shown) are provided at the groove exit of the joining tool grooves 58. An undercut or a groove narrowing can also be provided at the groove exit.

[0124] This design eliminates the need for additional holding elements that were previously required to secure the coil mat 10 when transferring the joining tool 14 into the component 16. This significantly simplifies the device 40 and the process. The coil mat 10 is now secured simply by extending the gripping elements 68 further.

[0125] To compensate for tolerances in the diameters of component 16 and joining tool 14, a radial adjustment range of approximately 0.1% of the diameter would normally suffice, e.g., 0.2 mm for a diameter of 200 mm. It would therefore be sufficient to set the diameter of the outer circumference 64 of the joining tool 14 0.1% smaller than the inner diameter of component 16. However, in a particularly preferred approach, a diameter reduction of more than 1% is implemented to clamp the wire 34 in the compressed state of the joining tool 14. Thus, the outer circumference 64 of the joining tool 14 is reduced significantly more than would be necessary for the usual tolerances. A larger adjustment range is therefore provided.

[0126] The adjustment preferably takes place after the coil mat 10 has been wound onto the joining tool 14, and thus when no radial movement of straight wire sections 36 occurs in the joining tool grooves 58. Therefore, the adjustment is not critical with regard to the wire insulation.

[0127] The insertion of the joining tool 14 into the component 16 then takes place as shown in Fig. 9As shown, the outer circumference 64 of the joining tool 14 is extended to more than 1%. A smaller adjustment range would suffice to compensate for tolerances and reduce the gap at the transition to the stator 20. However, in preferred embodiments of the method and the device 40, the extension is deliberately chosen to be greater in order to release a coil winding 18 held by friction or positive locking for insertion. Additionally, this movement may allow for the holding of slot insulation paper (not shown). Each receiving slot 24 can be provided with slot insulation paper. If the gripping elements 68 are now extended radially and pressed against the inside of the housing 22, the slot insulation papers can be held in place. The radial transfer then takes place analogously as shown in Fig. 10 reproduced and described above. In Fig. 21Another embodiment of the method and the device 40 for transferring a linear coil mat 10 into a rotary joining tool 14 is shown, without changing the wire spacing in the coil mat 10 during this transfer. Here, the coil mat 10 is again manufactured beforehand, as already explained, with the different wire spacings in the different length sections 60-1, 60-2. The coil mat 10 can be provided here without a linear transfer tool 12. During the transfer, the previously described method is again used, whereby the diameter of the outer circumference 64 of the joining tool 14, and thus the slot spacing between the joining tool slots 58, is adapted to the respective coil geometry within a coil mat 10. The joining tool 14 and the coil winding 18 for a stator 20 with a very large number of slots are shown here.In principle, however, this method is also applicable to stators 20 with a smaller number of slots - as in the previous examples.

[0128] In the method and device 40 according to the embodiment of Fig. 21The linear transfer tool 12 is completely dispensed with. With a suitable geometry of the coil mat 10 and a sufficiently large groove clearance of the joining tool 14, the coil winding 18 with its different winding layers 26-1, 26-2, 26-3 can be wound directly onto the joining tool 14. By moving the joining tool 14 onto the coil mat, the distance between the joining tool grooves 58 of the joining tool 14 is adjusted to the groove spacing that changes during the winding process, as already explained previously with reference to the other embodiments. This allows a coil mat 10 to be wound layer by layer. The wire spacing of the coil mat 10 remains unchanged during this process. To insert the straight wire sections 36-1, 36-2, 36-3, which are provided here in pairs, into the joining tool grooves 58, these grooves are adjusted to a sufficiently large width. The sufficiently large width of the joining tool grooves 58 provides enough space for angled threading.The play between the gripping elements 68 and the individual wires 34 when the joining tool 14 is extended allows for an oblique penetration of the individual layers of the coil mat 10.

[0129] Otherwise, the procedure is carried out as previously discussed using the other examples. Reference symbol list:

[0130] 10 Coil mat 12 Transfer tool 14 Joining tool 14 Rigid joining tool 16 Component 18 Coil winding 20 Stator 22 Housing 24 Receiving slot 26-1 First winding layer 26-2 Second winding layer 26-3 Third winding layer 28-1 First partial mat 28-2 Second partial mat 28-3 Third partial mat 28-4 Fourth partial mat 30 Transition area 32 Layer jump 34 Wire 36 Straight wire section 36-1 First straight wire section 36-2 Second straight wire section 36-3 Third straight wire section 38 Winding head 40 Device 42 Coil mat supply device 46 Control 50 Comb structure 52 Tines 54 Transfer tool slot 56 Joining tool movement device 58 Joining tool groove 60-1 First length section 60-2 Second length section 60-3 Third length section 62 Segment 64 Outer circumference area 66 Rotation axis 68 Gripping element 70 Skewed threading

Claims

1. Method for multi-layer insertion of a coil mat (10) into inwardly open receiving grooves (24) of an at least partially annular component (16) of an electric machine, the method comprising: a) providing a coil mat (10) which has straight wire sections (36, 36-1, 36-2, 36-3) and winding heads (38) which connect straight wire sections (36, 36-1, 36-2, 36-3) such that a first length section (60-1) of the coil mat (10) intended for forming a first layer (26-1) of the coil mat (10) in the component (16) comprises first straight wire sections (36-1) spaced apart by a first wire spacing, and a second length section (60-2) of the coil mat (10) intended for forming a second layer (26-2) of the coil mat (10) in the component (16) comprises second straight wire sections (36-2) spaced apart by a different second wire spacing, b) rolling up the first length section (60-1) of the coil mat (10) onto a joining tool (14) which is provided on an outer peripheral region (64) with gripping elements (68) which can be adjusted in position and between which outwardly open joining tool grooves (58) are formed, the first straight wire sections (36-1) being introduced into the joining tool grooves (58), c) changing the groove spacing of the joining tool grooves (58) to adapt to the second wire spacing, d) rolling up the second length section (60-2) of the coil mat (10) while inserting the second straight wire sections (36-2) into the joining tool grooves (58), and thereafter retracting the joining tool (14) to a smaller outer diameter (D1) with which the joining tool (14) can dive into the component (16); f) inserting the joining tool (14) into the component (16) and aligning the joining tool grooves (58) with the receiving grooves (24), g) transferring the straight wire sections (36, 36-1, 36-2, 36-3) from the joining tool grooves (58) into the receiving grooves (24).

2. Method according to claim 1, characterized by 2.1 using a joining tool (14) with segment-like gripping elements (68) that can be displaced radially, and radially adjusting the gripping elements (68) to change the groove width, the outer circumference, and the groove spacing and / or 2.2 changing the diameter of the joining tool (14) at the outer circumferential region (64) in order to change the groove spacing and / or 2.3 adjusting a distance of a rotational axis (66) of the joining tool (14) to a section of the coil mat (10) still to be rolled up, depending on a change in the diameter of the outer circumferential region (64).

3. Method according to any of the preceding claims, characterized by e1) fixing at least one region of the coil mat (10) in the joining tool (14) by reducing the groove width of at least some or all of the joining tool grooves (58) in order to hold wire sections (36-1, 36-2, 36-3) inserted therein and / or e2) releasing the coil mat (10) from the joining tool (14) by increasing the groove width in order to release wire sections (36-1, 36-2, 36-3) held therein.

4. Method according to claim 3, characterized in that 4.1 step e1) comprises at least one of the following steps: e1.1) reducing the groove widths to clamp wire sections (36-1, 36-2, 36-3) between the gripping elements (68), e1.2) reducing the groove widths to hold wire sections (36-1, 36-2, 36-3) in a form-fitting manner behind projections on gripping elements (68) at the opening of the joining tool grooves (58), e.1.3) reducing the groove widths by performing at least one of the steps of claim 2 and reducing the diameter of the outer circumference of the joining tool (14) by more than 1%, and / or 4.2 that step e2) comprises: increasing the groove widths by performing at least one of the steps of claim 2 and increasing the diameter of the outer circumference by more than 1%, and / or 4.3 that step e1) is performed before and / or during step f) and that step e2) is performed after step f) and before and / or during step g).

5. Method according to any of the preceding claims, characterized in that step a) comprises at least one or more of the steps: a1) providing the coil mat (10) on a linearly extending comb-like transfer tool (12) such that one or more coil mat layers of a coil mat (10) or several partial mats (28-1, 28-2, 28-3, 28-4) are held on a comb structure (50) with straight wire sections (36, 36-1, 36-2, 36-3) positioned between tines (52) of the comb structure (50), a2) providing the coil mat (10) such that a first straight wire section (36-1) is spaced apart at the end of the first longitudinal section (60-1) and a second straight wire section (36-2) is spaced apart at the beginning of the second longitudinal section (60-2) by a transition wire spacing the value of which is between the first wire spacing and the second wire spacing, a3) providing the coil mat (10) such that the first straight wire section (36-1) at the end of the first length section (60-1) and the second straight wire section (36-2) at the beginning of the second length section (60-2) are spaced apart by a transition wire spacing the value of which corresponds to the mean value of the first wire spacing and the second wire spacing plus / minus 10%, a4) providing the coil mat (10) such that the first wire spacing corresponds to the wire spacing of the first straight wire sections (36-1) during their intended use in the component (16) and such that the second wire spacing corresponds to the wire spacing of the second straight wire sections (36-2) during their intended use in the component (16).

6. Method according to any of the preceding claims, characterized in that step b) comprises at least one or more of the following steps: b1) adjusting the groove spacing of the joining tool grooves (58) to the first wire spacing, b2) rolling the joining tool (14) with its circular outer circumference over the linearly spread or linearly moving coil mat (10), b3) rolling the joining tool (14) with its circular outer circumference over the linear transfer tool (12) moving linearly relative to the joining tool (14) in accordance with step a1) of claim 5, b4) adjusting the distance of the outer circumference to the linear transfer tool (12) in accordance with step a1) of claim 5 by changing the distance of the axis of rotation (66) of the joining tool (14) to the linear transfer tool (12), and / or b5) b5.1 radially moving the first wire sections (36-1) into the joining tool grooves (58) or b5.2 adjusting the groove width to allow oblique threading (70) of the first wire sections (36-1) and inserting the first wire sections (36-1) by rolling them without moving them radially, and / or that step d) comprises at least one or more of the following steps: d1) adjusting the groove spacing of the joining tool grooves (58) to the second wire spacing, d2) rolling the joining tool (14) with its circular outer circumference over the linearly spread or linearly moving coil mat (10), d3) rolling the joining tool (14) with its circular outer circumference over the linear transfer tool (12) moving linearly relative to the joining tool (14) in accordance with step a1) of claim 5, d4) adjusting the distance between the outer circumference and the linear transfer tool (12) in accordance with step a1) of claim 5 by changing the distance between the axis of rotation (66) of the joining tool (14) and the linear transfer tool (12), and / or d5) d5.1 radially moving the second wire sections (36-2) into the joining tool grooves (58) or d5.2 adjusting the groove width to allow oblique threading (70) of the second wire sections (36-2) and inserting the second wire sections (36-2) by rolling them without moving them radially.

7. Method according to any of the preceding claims, characterized in that step c) comprises at least one or more of the following steps: c1) changing the groove spacing to adjust to the transition wire spacing according to step a2) or a3) of claim 5 and then changing the groove spacing to adjust to the second wire spacing, c2) changing the groove spacing during a stop of the relative linear movement between the joining tool (14) and the coil mat (10), c3) changing the groove spacing during continuous relative linear movement between the joining tool (14) and the coil mat (10), c4) changing the groove spacing depending on the geometry of the coil mat (10).

8. Device (40) for multi-layer insertion of a coil mat (10) into inwardly open receiving grooves (24) of an at least partially annular component (16) of an electric machine, the device comprising: a coil mat providing device (42) for providing a coil mat (10) which has straight wire sections (36-1, 36-2, 36-3) and winding heads (38) which connect straight wire sections (36-1, 36-2, 36-3) such that a first length section (60-1) of the coil mat (10) intended for forming a first layer (26-1) of the coil mat (10) in the component (16) has first straight wire sections (36-1) spaced apart by a first wire spacing, and a second length section (60-2) of the coil mat (10) intended for forming a second layer (26-2) of the coil mat (10) in the component (16) has second straight wire sections (36-2) spaced apart by a different second wire spacing, a joining tool (14) which is rotatable about an axis of rotation (66) relative to the coil mat (10) and / or the component (16) and is provided at an outer circumferential region (64) with gripping elements (68) which are adjustable in position, between which outwardly open joining tool grooves (58) are formed, a roll-up device for rolling the coil mat (10) onto the joining tool (14) in such a way that the straight wire sections (36-1, 36-2, 36-3) are introduced into the joining tool grooves (58), a transfer device for inserting the joining tool (14) into the component (16), aligning the joining tool grooves (58) with the receiving grooves (24) and transferring the straight wire sections (36-1, 36-2, 36-3) from the joining tool grooves (58) into the receiving grooves (24), and a control unit (46) which is designed to change the groove spacing of the joining tool grooves (58) between rolling-up the first longitudinal section (60-1) onto the joining tool (14) and rolling-up the second longitudinal section (60-2) onto the joining tool (14) for adjustment to the second wire spacing and, after rolling-up, to retract the joining tool (14) to a smaller diameter (D1) with which the joining tool (14) can dive into the component (16) in order to then transfer the straight wire sections (36-1, 36-2, 36-3) into the receiving grooves (24).

9. Device (40) according to claim 8, characterized in that 9.1 the joining tool (14) has segment-like gripping elements (68) which are radially displaceable and in that the control unit (46) is configured to radially adjust the gripping elements (68) in order to change the groove width, the outer circumference, and the groove spacing and / or 9.2 the diameter of the joining tool (14) is variable at the outer circumferential region (64) in order to change the groove spacing and / or characterized 9.3 by a joining tool movement means (56) for moving the axis of rotation (66) of the joining tool (14) relative to the coil mat (10), wherein the control unit (46) is configured to adjust the distance of the axis of rotation (66) of the joining tool (14) to a section of the coil mat (10) still to be rolled up, depending on a change in the diameter of the outer circumferential region (64).

10. Device (40) according to any of claims 8 or 9, characterized in that the control unit (46) is configured to reduce the groove width of at least some or all of the joining tool grooves (58) in order to fix at least one region of the coil mat (10) in the joining tool (14) in order to hold wire sections (36-1, 36-2, 36-3) held therein and / or to increase the groove width for releasing the coil mat (10) in order to release wire sections (36-1, 36-2, 36-3) held therein.

11. Device (40) according to claim 10, characterized in that 11.1 the control unit (46) is configured to reduce the groove widths for clamping wire sections (36-1, 36-2, 36-3) between the gripping elements (68), and / or 11.2 at least some of the gripping elements (68) each have at least one projection which narrows the associated joining tool groove (58) in the opening area, and the control (46) unit is configured to reduce the groove widths for form-fitting retention of wire sections (36-1, 36-2, 36-3) behind the projections of the gripping elements (68), and / or 11.3 that the joining tool (14) is designed according to one of alternatives 9.1 or 9.2 of claim 9 and the adjustment range of the diameter of the outer circumference of the joining tool (14) is more than 1% of the diameter in order to prevent the wire sections (36-1, 36-2, 36-3) from jamming and coming loose between the gripping elements (68) and / or 11.4 that the control unit (46) is designed to cause the wire sections (36-1, 36-2, 36-3) to be held by reducing the size of the groove before and during transfer of the joining tool (14) into the component (16).

12. Device (40) according to any one of claims 8 to 11, characterized in that the coil mat providing device (42) has a linearly extending comb-like transfer tool (12) for holding one or more coil mat layers of a coil mat (10) or of one or more partial mats (28-1, 28-2, 28-3, 28-4) on the comb structure (50) with straight wire sections (36-1, 36-2, 36-3) positioned between tines (52) of the comb structure (50), wherein the comb-like transfer tool (12) is movable linearly relative to the joining tool (14) in the direction of its extension.

13. Device (40) according to any of claims 8 to 12, characterized by a data processing unit with a computer program product or computer program loaded therein, comprising machine-readable control instructions which cause the device (40) to perform the steps of the method according to any one of claims 1 to 7.

14. Computer program product or computer program comprising machine-readable control instructions which when loaded into a data processing unit of the device (40) according to claim 13 cause the device (40) to perform the steps of the method according to one of claims 1 to 7.