MANUFACTURING SYSTEM AND METHOD FOR MANUFACTURING A STATOR WITH STABILLERS

Description

[0001] The invention relates to a manufacturing system for producing a stator for an electric machine, in particular an electric motor, wherein the stator comprises a base body and a plurality of bent or straight conductors. The invention further relates to a method for producing a stator for an electric machine, in particular an electric motor, wherein the stator comprises a base body and a plurality of straight or bent conductors.

[0002] Electrical machines, such as electric motors, commonly feature a stator with a coil winding. Traditionally, the coil winding is produced by winding a wire. However, such winding methods are technically complex and subject to limitations. Furthermore, the fill factor (the area covered by the wire in a wound cross-section) is limited in wound coils.

[0003] The coils of stators in electrical machines can alternatively be formed by interconnected rod conductors inserted into a stator body. Particularly in the field of electrically driven (or powered) motor vehicles, electric motors with stators featuring rod conductors are increasingly used. To connect two rod conductors, their free ends are typically welded together. Before welding, the rod conductors are usually bent so that the free ends of the two conductors to be welded are brought close together. Furthermore, the free ends of the rod conductors are usually spread out radially before welding so that rod conductors not being welded together do not touch each other. According to the current state of the art, handling and fixing the stator with the rod conductors is very complex.

[0004] From WO 2019 / 040958 A1 a manufacturing system with a holding device for manufacturing a stator of an electric machine with rod conductors is known. Object of the invention

[0005] The invention is based on the objective of providing a manufacturing system and a manufacturing process for the accelerated and cost-effective production of stators with rod conductors. Brief description of the invention

[0006] This problem is solved by a manufacturing system for producing a stator for an electric machine according to claim 2.

[0007] According to the invention, the holding device serves to handle the stator and fix it to the individual machines of the production system. During machining of a stator on the machines of the production system, the stator is generally not removed from the holding device but remains held in it. The production system allows the stator to be manufactured without having to provide special fixtures for the type of stator being produced on each individual machine. The holding device thus forms an intermediate element for connecting the stator to the individual machines. The fixtures on the machines can therefore be designed more simply and cost-effectively, as they only need to be adapted to the holding device. The holding device also speeds up the process of attaching the stator to the individual machines.In particular, it is not necessary to laboriously fix the base body and the rod ladder to each of the machines. The holding device can have a set of coupling elements for securing it to the machines. Each machine typically has a set of corresponding feedback elements. For different types of stators, especially those with different dimensions (e.g., length and diameter), the feedback elements on the machines of the production system remain identical; only different holding devices (which are specifically adapted to the respective type of stator, e.g., with regard to length and diameter) are provided. The bending, spreading, and welding machine can therefore be used to manufacture different types of stators without modification. The holding device can also be used universally outside the production system for handling the stator.

[0008] The holding device has at least one set of fingers. These fingers are used to engage between the pole sections at a first end face of the base body. When the fingers engage between the pole sections, they typically overlap the base body, at least partially. The fingers of the first set can therefore fix the base body in at least one direction. By engaging between the pole sections, the fingers can fix and align them. Typically, the fingers rest against the pole sections when they engage between them.

[0009] The fingers of the holding device are generally movable in the radial direction between an open (radially outward extended) and a closed (radially inward extended) position. In the open position, the stator can be inserted into and removed from the holding device. The fingers typically have at least one shoulder, preferably two, for radially clamping the ladder. This allows for particularly precise alignment of the ladder.

[0010] The bending machine is used to bend the free ends of the pole ladders so that the free ends of at least two pole ladders to be welded together are brought close together. The spreading machine is used to spread the free ends of the pole ladders radially. Spreading prevents the ends of pole ladders that are not to be welded together, or that are already welded, from touching each other. The welding machine is used to weld the free ends of at least two pole ladders at a time. Typically, between two and six pole ladders, and in special cases more, are welded together. The welding machine may include a laser welding unit. The production system is typically configured to apply the aforementioned machines to a stator to be manufactured in this sequence. Alternatively, the production system may be configured, in particular, to apply the spreading machine before the bending machine.

[0011] The conductors are arranged in the stator's core body in several ring-shaped layers or concentric rings. The core body is typically designed as a laminated core. The conductors can be welded at least partially at both ends (on both sides of the core body). In this case, the conductors are usually (originally) straight. Straight conductors can also serve for electrical contact with the stator. Alternatively, the conductors can be bent at least partially in a U-shape, similar to a hairpin. Thus, on one side of the core body, the U-shaped section creates a connection between the usually straight longitudinal sections of the conductors that extend through the core body.

[0012] The manufacturing system according to the invention is particularly suitable for carrying out a manufacturing process according to the invention described below. Preferably, the manufacturing system according to the invention is used to carry out a manufacturing process according to the invention described below.

[0013] According to the invention, the manufacturing system further comprises a loading and unloading station for the holding device. The loading and unloading station can facilitate the integration of the manufacturing system with other equipment. The loading and unloading station can be used to insert the pre-assembled components (base body and conductor) of the stator into the holding device and to remove the machined stator from the holding device. Alternatively, the loading and unloading station can be used to feed holding devices (with stators) in and out. The holding device can typically also be fixed at the loading and unloading station.

[0014] A particularly preferred embodiment of the manufacturing system is one in which the holding device has a uniform interface for attaching it to the bending machine, the spreading machine, and the welding machine. This allows the holding device to be of a particularly simple design; in particular, no special interfaces individually tailored to each machine are required. The bending machine, the spreading machine, and the welding machine each have a receiving device that is complementary to the interface of the holding device. Optionally, the loading and unloading station can also have a receiving device that is complementary to the interface of the holding device, so that the holding device can be attached to the loading and unloading station via the uniform interface.

[0015] The manufacturing system preferably further includes a handling device for transferring the holding device to the bending machine, the spreading machine, and the welding machine, particularly wherein the holding device has a coupling section, preferably a quick-change coupling section, for the handling device. Optionally, the handling device also serves to transfer the holding device to the loading and unloading station. The handling device allows for further automation of the stator manufacturing process within the manufacturing system. The handling device may include a rotary table. A gripper for the holding device is preferably arranged on the rotary table.

[0016] In a particularly advantageous embodiment of the manufacturing system, the holding device comprises a first component of a centering clamping system, in particular a zero-point clamping system, and the bending machine, the spreading machine, and the welding machine each have a complementary component of the centering clamping system. Optionally, the loading and unloading station may also have a complementary component of the centering clamping system. A centering clamping system allows for particularly precise fixation of the holding device to the machines.

[0017] A preferred embodiment of the manufacturing system is characterized in that the holding device has a centering element for radially aligning the fingers of the first set. The centering element can improve the positioning accuracy of the stator; in particular, the centering element can ensure that the fingers are each retracted radially inwards to the same extent. The centering element can be designed as a disk centrally located in the holding device. In the clamped state (with the holding device closed, i.e., fingers retracted radially inwards), the rod elements of the innermost radial layer also bear against the centering element, typically directly. The centering element then also significantly increases the alignment accuracy of the free ends of the rod elements. The fingers of the first set can engage a circumferential groove in the centering element from the radial outside to bear against it.

[0018] Another advantageous embodiment of the manufacturing system is one in which each finger has an elastic element between its engagement section and drive section. In other words, the engagement section and drive section of each finger are connected via an elastic element. Fingers with an elastic element are particularly suitable for bracing the ladder. Specifically, the drive section of the fingers can be actuated by displacement control. The engagement sections of the fingers are then kinematically decoupled from the drive section by the elastic elements. The elastic element makes it possible, in particular, to displace the engagement section towards the drive section under increasing force. The elastic element can be designed as a spring, especially a cylindrical helical spring.

[0019] The manufacturing system is characterized in that the holding device has a first rotatable slotted disk for moving the fingers of the first set. A common drive for all fingers of the first set can be provided via the first slotted disk. The fingers typically engage with pins in slots of the first slotted disk. The first slotted disk can be driven by a control slide. The control slide has a locking mechanism that prevents movement of the control slide when it is not actuated. An actuating element for the locking mechanism is provided at a loading and unloading station. This allows the locking mechanism to be unlocked when the holding device is connected to the loading and unloading station, particularly via a standardized interface.

[0020] A particularly preferred embodiment of the manufacturing system is one in which the holding device has a second set of fingers for engaging between the rod ladders on a second end face of the base body.

[0021] When the fingers of the second set engage between the rods, they typically overlap the base body, at least partially, on the second end face opposite the first. The fingers of the second set can therefore fix the base body in a second direction. Together, the fingers of the first and second sets can completely fix the base body, particularly along its axis. The fingers of the second set can be designed like the fingers of the first set; in particular, the fingers of the second set can also have two sections that are resiliently supported against each other. In an advantageous embodiment, the holding device includes a second rotatable grooved disk for moving the fingers of the second set. A common drive for all fingers of the second set can be provided via this second grooved disk.The fingers typically engage with pins in grooves of the second slotted disc.

[0022] In a manufacturing system whose holding device has a first and a second slotted disk, it is preferably provided that the two slotted disks can be driven via a common control slide. This simplifies the opening and closing of the holding device.

[0023] The control slide is provided with a locking device that prevents movement of the control slide in its unactuated state. If the aforementioned production system also includes a loading and unloading station, an actuating element for the locking device may be provided at the loading and unloading station. This actuating element can move the locking device into an actuated state when the holding device at the loading and unloading station is locked in place. In particular, the actuating element may automatically move the locking device into the actuated position when the holding device at the loading and unloading station is locked. In the actuated state of the locking device, the control slide can be moved. Conversely, if the holding device is detached from the loading and unloading station, the locking device prevents the holding device from opening (unintentionally).

[0024] A particularly preferred embodiment of the manufacturing system is characterized in that the bending machine, the spreading machine, and the welding machine form a first production circuit for one revolution of the holding device; that the manufacturing system includes a further spreading machine, a further welding machine, and a further holding device for a stator; and that the bending machine, the further spreading machine, and the further welding machine form a second production circuit for one revolution of the further holding device. In other words, in the first production circuit, the holding device rotates between the bending machine, the spreading machine, and the welding machine, and in the second production circuit, the further holding device rotates between the bending machine, the further spreading machine, and the further welding machine. The bending machine is thus part of both production circuits.The bending machine is usually very expensive compared to the other machines. Therefore, costs can be saved by using a single bending machine in two production circuits. The cycle time of the bending machine is usually significantly shorter than the cycle time of the welding machines. Therefore, by using two welding machines with one bending machine, the bending machine can be utilized more efficiently. If present, the handling device and the loading / unloading station are also part of the first production circuit. Preferably, the production system includes another handling device and / or another loading / unloading station, which are part of the second production circuit. The additional spreading machine, the additional welding machine, and the additional holding device, as well as any other equipment, are also part of the second production circuit.The additional handling device and / or the additional loading and unloading station are typically designed like the (first) spreading machine, the (first) welding machine, the (first) holding device, the (first) handling device, and / or the (first) loading and unloading station. The additional handling device is generally used to move the additional holding device to the bending machine, the additional spreading machine, and the additional welding machine, as well as, if applicable, the additional loading and unloading station. The additional spreading machine, the additional welding machine, the additional holding device, and, if applicable, the additional loading and unloading station are advantageously arranged symmetrically (mirror-)image to the bending machine. This simplifies the circulation of the holding devices within their respective production circuits.

[0025] In a preferred embodiment of the manufacturing system, the system features a common platform on which its components are arranged. This simplifies the transport of the system. Furthermore, the common platform allows the system to be easily integrated into a higher-level production line. Holding device according to the invention

[0026] The invention also includes a holding device according to claim 1.

[0027] According to the invention, a holding device for a stator is provided, comprising a base body and a plurality of curved and / or straight rod sections. The holding device has at least a first set of fingers for engaging between the rod sections on a first end face of the base body.

[0028] The holding device can have a uniform interface for attaching the holding device to machines of a manufacturing system, in particular to the bending machine, the spreading machine, and the welding machine, as well as optionally to the loading and unloading station of a manufacturing system according to the invention as described above. The holding device can alternatively or additionally have a coupling section, preferably a quick-change coupling section, particularly for a handling device. The holding device can have a first component of a centering clamping system, in particular a zero-point clamping system. Preferably, the holding device has a centering element for radial contact of the fingers of the first set. The fingers of the first set can each have an elastic element between an engagement section and a drive section of the respective finger.Advantageously, the holding device includes a first rotatable grooved disk for moving the fingers of the first set. The holding device can have a second set of fingers for engaging between the rods on a second end face of the base body. A particularly preferred embodiment includes a second rotatable grooved disk for moving the fingers of the second set. Most preferably, the two grooved disks are actuated via a common control slide. The control slide can have a locking mechanism that prevents movement of the control slide when it is not actuated.

[0029] The holding device according to the invention has further features of the holding device of the manufacturing system described above. By means of the holding device according to the invention, the advantages described above can also be utilized outside of the manufacturing system according to the invention. Manufacturing process according to the invention

[0030] The invention also encompasses a method according to claim 14 for manufacturing a stator for an electric machine, in particular an electric motor, wherein the stator comprises a base body and a plurality of straight and / or bent conductor bars. The method is carried out using a manufacturing system according to the invention as described above. The method comprises the steps a) Securing, in particular clamping, the base body and the pole sections in a holding device, wherein fingers of the holding device engage between the pole sections, b1) Moving the holding device to a bending machine and bending the free ends of the pole sections, b2) Moving the holding device to a spreading machine and spreading the free ends in a radial direction, c) Moving the holding device to a welding machine and welding the free ends of at least two pole sections together, d) Releasing the stator in the holding device, whereby the fingers are released from engagement between the pole sections, and removing the stator from the holding device.

[0031] During steps b1), b2), and c), the stator remains fixed in the holding device. Substeps b1) and b2) can be performed in any order. Depending on the type of stator, it may be advantageous to perform substep b1) first and then substep b2), or vice versa. Otherwise, the steps of the procedure are performed in the specified order. In particular, step a) is performed before the first substep b1) or b2). Steps c) and d) are performed in the specified order after the last substep b1) or b2). To position the stator for the manufacturing operations in steps b1), b2), and c), the holding device can be fixed to the respective machines. This eliminates the need for time-consuming and complex fixtures that would otherwise be required to fix the stator directly to each machine.Furthermore, the engagement of the fingers of the holding device ensures that the pole ladder does not unintentionally shift relative to the base body during the further course of the process.

[0032] Preferably, steps a) and d) are performed at a loading and unloading station, and the holding device is moved to the loading and unloading station between steps c) and d). The loading and unloading station can facilitate the integration of the production system with other equipment. The holding device is typically fixed at the loading and unloading station for the execution of steps a) and d). This simplifies the execution of steps a) and d).

[0033] Further advantages of the invention will become apparent from the description and the drawing. According to the invention, the features mentioned above and those further elaborated can be used individually or in combination within the scope of the claims. The embodiments shown and described are not to be understood as an exhaustive list, but rather serve as examples for illustrating the invention. Detailed description of the invention and drawing

[0034] The invention is illustrated in the drawing and explained in more detail with reference to exemplary embodiments. The drawing shows: Fig. 1 a manufacturing system according to the invention with a bending machine, which is part of two production circuits, each with a spreading machine, a welding machine, a loading and unloading station and a handling device, wherein a holding device according to the invention for a stator is provided for each of the production circuits, in a schematic view; Fig. 2a a stator with straight and curved rod conductors, in a schematic perspective view; Fig. 2b the stator of Fig. 2a in a schematic top view of a first end face; Fig. 2c a holding device according to the invention with a first set of fingers for holding a stator, wherein the fingers are in an open position, in a schematic top view; Fig. 2d the holding device of Fig. 2c, wherein the fingers are in a closed position, in a schematic top view; Fig. 3a a holding device according to the invention with a first set of fingers which have an elastic element between an engagement section and a drive section, wherein a first grooved disk interacts with the engagement sections, in a schematic partial section; Fig. 3b the holding device of Fig. 3a further comprising a second set of fingers which are movable by means of a second grooved disk, in a schematic cross-section; Fig. 4a a holding device according to the invention with a stator, wherein first components of a centering clamping system form a uniform interface of the holding device, in a schematic perspective view; Fig. 4b a first component and a complementary component of the centering clamping system of the holding device of Fig. 4a, in a schematic side view; Fig. 4c the holding device of Fig. 4a in a schematic sectional view looking at a first slotted disk; Fig. 5a a handling device for a manufacturing system according to Fig. 1 and a holding device according to the invention with a coupling section for the handling device, in a schematic perspective view; Fig. 5 holding device according to Fig. 5a , comprising a control slide for jointly actuating two slotted disks, in a schematic cross-section; Fig. 6 a flow diagram of a method according to the invention for manufacturing stators using one of the manufacturing circuits of the manufacturing system of Fig. 1 .

[0035] Figure 1 shows an embodiment of a manufacturing system according to the invention. 1. Manufacturing system 1 has two manufacturing cycles. 42, 46 set up. Each of the production circles 42, 46 is used for manufacturing stators (see...). Figure 2a, 2b) for electrical machines such as electric motors.

[0036] In Figure 2a is a stator 2 shown in a perspective view. Stator 2 has a base body. 3 The base body 3 is formed with a laminated core. The stator 2 also has a plurality of rod conductors 4. Some of the rod conductors 4 are curved. 4a and partly as a staff leader 4b trained. Free ends 6 of the pole ladder 4 protrude beyond a first end face. 11 of the base body 3. The curved rod ladders 4a each have a connecting section. 48on, which is arranged above a second end face 36 of the base body 3. The curved rod ladders 4a each have two free ends 6, which are arranged on the first end face 11 of the base body 3, facing away from the connecting sections 48. The free ends 6 of the curved rod ladders 4a are connected to the respective connecting section 48 via straight longitudinal sections of the rod ladders 4a that are incorporated into the base body 3. In the following, reference is made to the rod ladders 4 without further distinction. The manufacturing system 1 of Figure 1 It is used in particular for welding the free ends 6 of the pole ladder 4, after the free ends 6 to be welded together have been brought closer together by bending the pole ladder 4.

[0037] Figure 2b The figure shows the stator 2 in a top view of the first end face 11. The rod conductors 4 are arranged here in four ring-shaped layers. 12a-12darranged. Depending on the type of stator, fewer or more than four annular layers may be provided, in particular up to ten annular layers (not shown in detail). Here, the annular layers 12a-12d are arranged as concentric rings. In the radial direction, the rod conductors 4 of the four layers 12a-12d follow one another; in other words, they are arranged at the same (angular) positions in the circumferential direction.

[0038] Manufacturing system 1 (see Figure 1 ) includes a bending machine 5. Bending machine 5 is used to bend the free ends 6 of the pole ladder 4 so that they are brought close together for welding. Bending machine 5 is part of the two production circuits 42 and 46.

[0039] Manufacturing system 1 also includes a spreading machine for the first manufacturing cycle 42. 7, a welding machine 8, a loading and unloading station 17 and a handling device 20.For the second production circuit 46, production system 1 also includes another spreading machine. 43, another welding machine 44, another loading and unloading station 48 and another handling device 47. The manufacturing system 1 comprises a holding device according to the invention. 9, which circulates in the first production circuit 42. The production system 1 further comprises another holding device according to the invention. 45, which circulates in the second production circle 46. The aforementioned components of production system 1 are on a common platform. 49The components of the two production circles 42 and 46 (apart from the holding devices 9 and 45) are arranged in a mirror-symmetrical manner with respect to a vertical mirror plane running through the bending machine 5. The other components 43, 44, 45, 47, and 48 belonging to the second production circle 46 are identical in construction to the components 7, 8, 9, 20, and 17 of the first production circle 42.

[0040] The stators 2 to be manufactured are fixed in the holding devices 9, 45. Using the holding devices 9, 45, the stators 2 are transported between the individual machines of the production circuits 42, 46 and attached to the machines. The handling devices 20, 47 are used to transport the holding devices 9, 45.

[0041] During a production run in one of the production circuits 42 or 46, the individual parts (base body 3, rod ladder 4) of the stator 2 are first inserted into the holding device 9 or 45 attached to the loading and unloading station 20 or 48 (e.g., using a portal system not shown in detail) and fixed in the holding device 9, 45. The handling device 20 or 47 then moves the holding device 9, 45 with the stator 2 to the bending machine 5. The bending machine 5 bends the free ends 6 of the rod ladder 4, particularly in an azimuthal direction, so that they are brought close together, especially in pairs or in groups of more than two free ends 6. The handling device 20, 47 then moves the holding device 9, 43 with the stator 2 to the spreading machine 7 or 43. The spreading machine 7, 43 spreads the free ends 6 of the pole ladder 4 apart in a radial direction, so that free ends 6 that are not to be welded together do not touch each other.Alternatively, it can be provided that the free ends 6 are first spread apart radially using the spreading machine 7 or 43 and then bent using the bending machine 5. In this case, the handling device 20 or 47 first moves the holding device 9 or 45 to the spreading machine 7 or 43 and then to the bending machine 5.

[0042] The handling device 20, 47 then transports the holding device 9, 45 with the stator 2 to the welding machine 8 or 44. The welding machine 8, 44 welds the free ends 6 of the pole ladder 4 together in pairs. Alternatively, it can be provided that the free ends 6 of more than two pole ladders 4 are welded together. The handling device 20, 47 then transports the holding device 9, 45 with the stator 2 back to the loading and unloading station 17, 48. The processed stator 2 is removed from the holding device 9, 45 there.

[0043] Alternatively, it would be conceivable to clamp the stator 2 to be manufactured outside of production system 1 in the holding device 9 or 45 and then feed the holding device 9 or 45 into production circuit 42 or 46 via the loading and unloading station 7 or 48. After the production run, the holding device 9 or 45 with the stator 2 could be removed from production circuit 42 or 46 via the loading and unloading station 7 or 48. Finally, the stator 2 could be released from the holding device 9 or 45 outside of production system 1.

[0044] Figure 2c Figure 1 shows a holding device 9 according to the invention with a stator 2 in a top view. The holding device 9 has a centering element. 26 The centering element 26 is arranged radially within the free ends 6 of the pole ladder 4. In other words, the free ends 6 of the pole ladder 4 protrude through a space between the centering element 26 and a body. 50the holding device 9.

[0045] The holding device 9 has a first set of fingers 10. The fingers 10 are slidably mounted in the holding device 9. Figure 2c The fingers 10 are in a radially outward extended position, in which the holding device 9 is open.

[0046] Figure 2d shows the arrangement of Figure 2c , wherein the fingers 10 of the holding device 9 are now in a radially inwardly retracted position, in which the holding device 9 is closed. In the closed position, the fingers 10 engage with their radially inward end face on the first end face 11 of the base body 3 of the stator 2 (cf. Figure 2a ) between the rod ladders 4. In the closed position, the fingers 10 rest against the centering element 26. The rod ladders 4 are clamped between the fingers 10. Furthermore, the rod ladders 4 are in the radially innermost position 12a (see figure). Fig. 2b) at the centering element 26.

[0047] Figure 3a Figure 1 shows a section of the holding device 9 in a sectional view. One of the fingers 10 of the first set can be seen. Finger 10 has an engagement section. 30 and a drive section 31 The engagement section 30 and the drive section 31 are connected via an elastic element. 29, Here, a cylindrical helical spring is coupled together. The holding device 9 is located in Figure 3a In the closed position. The engagement section 30 of the finger 10 is recessed radially inwards. The finger 10 engages with its engagement section 30 in a circumferential groove formed on the centering element 26. 28 a.

[0048] The drive section 31 serves to move the engagement section 30 between the closed position and the open position (not shown here). The finger 10 has a pin 33 on the drive section 31. The pin 33 engages in a spirally extending groove. 34 a first grooved disk 32, see also Figure 4c . The grooved disc 32 is rotatably mounted in the holding device 9. When the grooved disc 32 is rotated, the drive section 31 is displaced radially. The movement of the drive section 31 is transmitted to the engagement section 30 via the elastic element 29. When the engagement section 30 rests against the centering element 26, the drive section 31 can be advanced further radially inwards by increasing spring force of the elastic element 29. In this way, the engagement section 30 can be pre-tensioned against the centering element 26 or the pole sections 4 to be clamped.

[0049] Figure 3b shows an opposite Figure 3a A larger section of the holding device 9 in a sectional view. It can be seen that the centering element 28 is designed in the form of a disc which has the circumferential groove 28 on its circumference.

[0050] The holding device 9 has, in addition to the first set of fingers 10, a second set of fingers. 35 The fingers 35 of the second set serve to engage between the rod ladder 4 on the second end face 36 (cf. Figure 2a ) of the base body 3 of the stator 2. Fingers 10, 35 of both sets are located in Figure 3b in the closed position. Note that no centering element is provided for fingers 35 of the second set.

[0051] The fingers 35 of the second set can be constructed and designed like the fingers 10 of the first set. In particular, each finger 35 has an engagement section 30, a drive section 31, and an intervening elastic element 29. A second grooved disk is required to displace the fingers 35 of the second set. 37 The drive sections 31 of the fingers 35 are rotatably mounted in the holding device 9. Each drive section 31 of the fingers 35 has a pin 33 which (as with the fingers 10 of the first set) engages in a spirally extending groove 34 of the second slotted disk 37. The second slotted disk 37 can be designed to be mirror-symmetrical to the first slotted disk 32.

[0052] Figure 4cFigure 1 shows a horizontal section through the holding device 9. The first grooved disk 32 has several spiral grooves 34 into which several fingers 10 of the first set engage with their pins 33. The pins 33 of the fingers 10 engaging in the same groove 34 are therefore mounted in different radial positions on the drive sections 31. The engagement sections 30 of all fingers 10, however, are identical. The elastic elements 29 of all fingers 10 are also identical to each other.

[0053] Finger 10 each point to a shoulder 15 The shoulder 15 serves to press the rod ladder 4 radially against each other and against the centering element 26. In an alternative not shown, it is also conceivable that the fingers 10 each have two shoulders 15.

[0054] The holding device 9 has a control slide. 38for driving the grooved discs 32, 37. The control slide 38 is linearly movable in the holding device 9. The grooved discs 32 and 37 each engage with a projection. 51 into the control slide 38. By moving the control slide 38, a rotational movement of the grooved disks 32, 37 can be effected.

[0055] In Figure 5b It can be seen that the control valve 38 is a safety device. 39 exhibits. In an unactuated state, the locking device 39 prevents the control slide 38 from moving. In particular, the unactuated locking device 39 prevents the holding device 9 from opening. Unintentional release of the stator 2 from the holding device 9 can thus be prevented. In the unactuated state, a collar can 56 of the safety device 39 in a locking recess 57 the retaining device 9 must be locked in place. The locking device 39 can be moved downwards (with respect to its orientation) for this purpose. Figure 5b ) be biased. In Figure 5b The safety device 39 is shown in an actuated state. In the actuated state of the safety device 39, the control slide 38 can be moved to open or close the holding device 9, thus releasing or clamping the stator 2.

[0056] To bring the safety device 39 into the actuated state (actuated position), the following is required at the loading and unloading station 17 (see below). Figure 1 ) an actuating element 40 Provided. When the holding device 9 is held at the loading and unloading station 17, the actuating element 40 pushes the locking device 39 into the actuated position. The collar 56 of the locking device 39 is thereby released from the detent recess 57. The actuating element 40 can then move the control slide 38 to open or close the holding device 9.

[0057] In Figure 5bIt can also be seen that the holding device 9 has a coupling section. 21, The quick-change coupling section is located here. The holding device 9 can be connected to the handling device 20 by means of the coupling section 21. The handling device 20 can then transport the holding device 9 between machines 5, 7, 8, and 17 of the production system 1.

[0058] Figure 5a Figure 20 shows the handling device 20 and the holding device 9. The handling device 20 has a gripper. 23 for receiving the coupling section 21 of the holding device 9. The gripper 23 is rotatable about a vertical axis via a rotary table 22 and along an arm. 52 The rotary table 22 is movable radially to the rotary table 22. The rotary table 22 is further guided by a guide device. 53 The gripper can be moved horizontally. In addition, it is equipped with a boom. 54 movable in a vertical direction.

[0059] Figure 4aThe holding device 9 is shown in a perspective view. In the Figure 4a In the rear area of ​​the holding device 9, an actuation section of the previously described locking device 39 of the control slide 38 can be seen.

[0060] The holding device 9 has a uniform interface 18 for attaching the holding device 9 to the bending machine 5, the spreading machine 7, the welding machine 8 and the loading and unloading station 17. The standardized interface 18 comprises four coupling elements. 16. The coupling elements 16 are designed as the first components of a centering clamping system, here a zero-point clamping system.

[0061] Figure 4b Figure 1 shows such a first component and a complementary second component of the centering clamping system. The first component is formed by one of the coupling elements 16. The second component is formed by a complementary receptacle. 19The coupling element 16 can be placed onto the complementary receptacle 19. The coupling element 16 has clamping devices 55. By means of the clamping devices 55, the coupling element 16 and the complementary receptacle 19 can be fixed to one another in a defined relative position. For this purpose, the clamping devices 55 are movable radially inwards. In order to be able to detach the coupling element 16 and the receptacle 19 from each other, or in order to be able to place the coupling element 16 onto the receptacle 19, the clamping devices 55 are movable radially outwards. Figure 4b The clamping devices 55 are in the radially outward moved state.

[0062] Four such complementary fixtures 19 are provided on each of the bending machine 5, the spreading machine 7, the welding machine 8 and the loading and unloading station 17, cf. Figure 1, which together form a receiving device complementary to the uniform interface. The four complementary receiving devices 19 are each arranged to receive one of the four corresponding coupling elements 16 of the holding device 9. The holding device 9 can thus be fixed on all machines 5, 7, 8, 17 of the first production circuit 42 of the production system 1 via the same first components of the centering clamping system. The coupling elements 16 therefore together form the uniform interface 18. The same applies to the further holding device 45 and the second production circuit 46.

[0063] Figure 6 shows a flowchart of a process for manufacturing stators 2 with rod ladders 4, cf. Figures 2a, 2b , by means of a manufacturing system, for example manufacturing system 1 according to Figure 1 .

[0064] A first holding device 9 is initially constructed in one step 98provided. In one step 100 A stator 2 is then fixed to the first holding device 9. The stator 2 can be clamped in this way, in particular by engaging fingers 10, 35 of a first and second set radially inwards.

[0065] Fingers 10 and 35 engage between the pole ladder 4. During step 100, the holding device 9 is attached to a loading and unloading station 17.

[0066] The holding device 9 is then connected to the stator 2 in one step. 102 by means of a handling device 20 to a bending machine 5. There, in one step 104 The free ends 6 of the pole ladder 4 are bent so that the free ends 6 to be welded together are brought closer together.

[0067] The holding device 9 is then connected to the stator 2 in one step. 106The free ends 6 are transferred to a spreading machine 7 by means of the handling device 20. There, they are separated in one step. 108 spread out in a radial direction.

[0068] In one variant of the procedure, which is not described in detail, steps 106 and 108 can be performed before steps 102 and 104. In this variant, steps 106 and 108 follow step 100; steps 102 and 104 follow these.

[0069] The holding device 9 is then connected to the stator 2 in one step. 110 The free ends 6 are transferred to a welding machine 8 by means of the handling device 20. There, they are welded in one step. 112 Welded together in pairs or in groups of several.

[0070] Now the holding device 9 is connected to the stator 2 in one step 114The stator 2 is transported back to the loading and unloading station 17 by means of the handling device 20. The holding device 9 is attached to the loading and unloading station 17. During steps 102 to 114 inclusive, the stator 2 is always fixed in the holding device 9. Then, in one step, the stator 2 is 116 The stator 2 is released in the holding device 9 by disengaging the fingers 10, 35 radially outwards so that they no longer engage between the rod ladder 4. Finally, the stator 2 is released in one step. 118 removed from the holding device 9.

[0071] Then, using the same holding device 9, further process runs 100 to 118 can be carried out using the steps described above to manufacture further identical stators 2. This is in Figure 6 Indicated by the solid arrow from step 118 to step 100.

[0072] Parallel to the production cycles of the holding device 9 in the first production circuit 42, corresponding production cycles with another holding device 45 can be carried out in a second production circuit 46 with the bending machine 5, another spreading machine 43, another welding machine 44, another loading and unloading station 48, and another handling device 47. The production circuits 42 and 46 are time-staggered relative to each other, so that the bending machine 5 can be used in both production circuits 42 and 46. The holding devices 9 and 45 are typically identical in design and intended for the same type of stator 2.

[0073] After one or more passes with the first holding device 9, the holding device 9 can be removed in one step. 120 can be replaced with a second holding device for a different type of stator, see dashed arrow below. Figure 6The other type of stator may, in particular, have a different size than the first type of stator 2. Accordingly, the second holding device may differ in the size of its receptacle for the stator from the first holding device 9. In contrast, the interfaces 18 for connecting the holding devices to the machines 5, 7, 8, 17 of the production system 1 are identical for the first holding device 9 and the second holding device for the stator of the other type. Therefore, when changing the type of stator to be manufactured, the effort required to reconfigure the production system 1 with regard to the fastening mechanisms can be avoided or at least reduced.

[0074] By replacing the first holding device 9 circulating in the first production circle 42 with a second holding device for a different type of stator, the further first holding device 47 circulating in the second production circle 46 can also be replaced with a further second holding device for a different type of stator, whereby the further second holding device for the second production circle 46 is typically identical in construction to the second holding device for the first production circle 42. Reference symbol list:

[0075] Manufacturing system 1 Stator 2 Base body 3 Curved pole ladder 4a Straight pole ladder 4b Pole ladder 4 Bending machine 5 Free ends 6 Spreader machine 7 Welding machine 8 Holding device 9 First set of fingers 10 First end face 11 Ring-shaped layers 12a-12d Shoulder 15 Coupling elements 16 Loading and unloading station 17 Uniform interface 18 Complementary holder 19 Handling device 20 Coupling section 21 Rotary table 22 Gripper 23 Centering element 26 Circumferential groove 28 Elastic element 29 Engagement section 30 Drive section 31 First slotted disc 32 Pin 33 Groove 34 Second set of fingers 35 Second end face 36 Second slotted disc 37 Control slide 38 Locking device 39 Actuating element 40 First manufacturing circuit 42 Further spreading machine 43 Further welding machine 44 Further holding device 45 Second manufacturing circuit 46 Additional handling device 47 Additional loading and unloading station 48 Platform 49 Body 50 Extension 51 Arm 52 Guide device 53 Boom 54 Clamping device 55Collar 56 Locking recess 57 Providing 98 of a first holding device Securing 100 of a stator in the holding device Moving 102 of the holding device to a bending machine Bending 104 of free ends Moving 106 of the holding device to a spreading machine Spreading 108 of the free ends Moving 110 of the holding device to a welding machine Welding 112 of the free ends Moving 114 of the holding device to a loading and unloading station Releasing 116 of the stator in the holding device Removing 118 of the stator from the holding device Replacing 120 of the first holding device with a second holding device of a different type

Claims

1. A holding device (9) for a stator (2) having a main body (3) and a multiplicity of bent and / or straight bar conductors (4), wherein the holding device (9) has at least one first set of fingers (10) for engaging between the bar conductors (4) at a first end side (11) of the main body (3), wherein the holding device (9) has a first rotatable cam disk (32) for displacing the fingers (10) of the first set, characterized in that the cam disk (32) is driven via a slide gate (38) and that the slide gate (38) has a securing means (39) which prevents displacement of the slide gate (38) in an inactivated state.

2. A manufacturing system (1) for manufacturing a stator (2) for an electric machine, in particular an electric motor, wherein the stator (2) has a main body (3) and a multiplicity of bent and / or straight bar conductors (4), wherein the manufacturing system (1) has the following: - a bending machine (5) for bending free ends (6) of the bar conductors (4), - a spreading machine (7) for spreading apart the free ends (6) of the bar conductors (4) in the radial direction, - a welding machine (8) for welding the free ends (6) of in each case at least two bar conductors (4), - a holding device (9) according to claim 1 for the stator (2), wherein the holding device (9) is able to be affixed on the bending machine (5), the spreading machine (7) and the welding machine (8), wherein the manufacturing system (1) furthermore has a loading and unloading station (17) for the holding device (9), and wherein an activation element (40) for the securing means (39) is configured on the loading and unloading station (17).

3. The manufacturing system (1) as claimed in claim 2, characterized in that the holding device (9) has a uniform interface (18) for affixing the holding device (9) on the bending machine (5), the spreading machine (7) and the welding machine (8).

4. The manufacturing system (1) as claimed in one of the preceding claims 2 or 3, furthermore having a handling apparatus (20) for moving the holding device (9) to the bending machine (5), the spreading machine (7) and the welding machine (8), in particular wherein the holding device (9) has a coupling portion (21), preferably a quick-change coupling portion, for the handling apparatus (20).

5. The manufacturing system (1) as claimed in one of the preceding claims 2 to 4, characterized in that the holding device (9) has a first component of a centering clamping system, in particular of a zero-point clamping system, and in that the bending machine (5), the spreading machine (7) and the welding machine (8) have in each case a complementary component of the centering clamping system.

6. The manufacturing system (1) as claimed in one of the preceding claims 2 to 5, characterized in that the holding device (9) has a centering element (26) for radially bearing of the fingers (10) of the first set.

7. The manufacturing system (1) as claimed in one of the preceding claims 2 to 6, characterized in that the fingers (10), between an engagement portion (30) and a drive portion (31) of the respective finger (10), have in each case an elastic element (29).

8. The manufacturing system (1) as claimed in one of the preceding claims 2 to 7, characterized in that the holding device (9) has a second set of fingers (35) for engaging between the bar conductors (4) at a second end side (36) of the main body (3).

9. The manufacturing system (1) as claimed in claim 8, characterized in that the holding device (9) has a second rotatable cam disk (37) for displacing the fingers (35) of the second set.

10. The manufacturing system (1) as claimed in claim 9, characterized in that the two cam disks (32, 37) are able to be driven in common by the slide gate (38).

11. The manufacturing system (1) as claimed in one of the preceding claims 2 to 10, characterized in that the bending machine (5), the spreading machine (7) and the welding machine (8) form a first manufacturing circuit (42) for circulating the holding device (9), in that the manufacturing system (1) has a further spreading machine (43), a further welding machine (44) and a further holding device (45) for a stator (2), and in that the bending machine (5), the further spreading machine (43) and the further welding machine (44) form a second manufacturing circuit (46) for circulating the further holding device (45).

12. The manufacturing system (1) as claimed in one of the preceding claims 2 to 11, characterized in that the manufacturing system (1) has a common platform (49) on which the components of the manufacturing system (1) are arranged.

13. A holding device (9) as claimed in claim 1, characterized in that the holding device (9) has a second set of fingers (35) for engaging between the bar conductors (4) at a second end side (36) of the main body (3), that the holding device (9) has a second rotatable cam disk (37) for moving the fingers (35) of the second set, and that the two cam disks (32, 37) are able to be driven in common by the slide gate (38).

14. A method for manufacturing a stator (2) for an electric machine, in particular an electric motor, with a manufacturing system as claimed in one of the claims 2 to 12, comprising the steps: a) affixing (100), in particular clamping, the main body (3) and the bar conductors (4) in the holding device (9, 45), wherein the fingers (10, 35) of the holding device (9, 45) engage between the bar conductors (4), b1) moving (102) the holding device (9, 45) to the bending machine (5), and bending (104) the free ends (6) of the bar conductors (4), b2) moving (106) the holding device (9, 45) to a spreading machine (7, 43), and spreading apart (108) the free ends (6) in the radial direction, c) moving (110) the holding device (9, 45) to the welding machine (8, 44), and welding (112) the free ends (6) of at least two of the bar conductors (4), d) releasing (116) the stator (2) in the holding device (9, 45), wherein the fingers (10, 35) are disengaged from between the bar conductors (4), and retrieving (118) the stator (2) from the holding device (9, 45).

15. The method as claimed in claim 14, characterized in that steps a) and d) are carried out in the loading and unloading station (17, 48), and in that the holding device (9, 45) between steps c) and d) is moved (114) to the loading and unloading station (17, 48).

16. The method as claimed in one of claims 14 or 15, characterized in that initially at least one method cycle takes place using a first holding device (9, 45), and in that subsequently at least one method cycle takes place using a second holding device for a stator of another type.