Method and device for picking up coil mats during the production of a component of an electrical machine

Description

[0001] The invention relates to a coil mat pick-up method to be carried out during the manufacture of a component of an electrical machine for picking up a coil mat from an elongated holder and inserting the coil mat into an annular arrangement of outwardly opening grooves. Furthermore, the invention relates to a manufacturing method for producing a stator component with a coil winding, in which such a coil mat pick-up method is carried out. Furthermore, the invention relates to a coil mat pick-up device for picking up a coil mat during the manufacture of a component of an electrical machine. Furthermore, the invention relates to a coil mat transfer station for a manufacturing system for producing a component of an electrical machine, wherein the coil mat transfer station serves to transfer a linear coil mat into a wound state and comprises such a coil mat pick-up device.The invention further relates to a control system and a computer program for such a coil mat take-up device or such a coil mat transfer station. Finally, the invention relates to a manufacturing system for producing a component of an electrical machine with such a coil mat take-up device and / or such a coil mat transfer station.

[0002] The invention relates to 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 one method for manufacturing a component with such a coil winding, such a 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 in particular a stator, e.g. as a linear coil, hereinafter referred to as coil mat.

[0004] For the definition of the term, the technological background and the state of the art, please refer to the following literature: [1] WO 2019 / 020148 A1 [2] WO 2019 / 166061 A1 [3] US 2017 / 0324294 A1 [4] US 2009 / 0322178 A1 [5] WO 2018 / 019970 A1 [6] WO 2020 / 187363 A1 [7] EP 3 886 303 A1 [8] EP 3 661 017 A1 [9] US 2020 / 0389076 A1

[10] US 2009 / 001841 A1

[0005] Examples of coil mats for forming a coil winding of a stator as an example of a component of an electrical machine are known from [1] to [4]. Such coil mats, as are also to be used in embodiments of the invention, consist, for example, of several individual S-shaped conductors provided with an outer insulation layer, in particular in the form of copper wires, preferably with a rectangular cross-section, each having straight wire sections connected to winding heads. The straight wire section is later located in the component slot, such as in particular the stator slot, and in the so-called winding head, the conductor or wire jumps a corresponding number of slots.

[0006] From [5] to

[10] Devices and methods for receiving a coil mat and transferring the coil mat into a component are known. In particular, a joining tool with an arrangement of radially outwardly opening grooves is provided for inserting a coil mat into a stator laminated core. The coil mat is provided, for example, on a linearly designed holder; the joining tool receives the coil mat in its grooves and transfers it into the laminated core.

[0007] Based on the state of the art according to [5] to

[10] The object of the invention is to enable a gentler, more precise and more reliable transfer of a coil mat from a linear state to a wound state with a reduced risk of damage to the wires of the coil mat.

[0008] To achieve this object, the invention provides a coil mat pick-up method according to claim 1 and a coil mat pick-up device according to the dependent claim. A manufacturing method using such a coil mat pick-up method, a controller and a computer program containing instructions for carrying out the method, as well as a coil mat transfer station and a manufacturing system provided therewith, which include the coil mat pick-up device, are the subject of the further dependent claims. Advantageous embodiments are the subject of the dependent claims.

[0009] According to a first aspect thereof, the invention provides a coil mat receiving method to be carried out during the manufacture of a component of an electrical machine for receiving a coil mat from an elongated holder and inserting the coil mat into an annular arrangement of grooves which open outwards, comprising the steps: a) Providing the coil mat on the elongated holder, which has a row of teeth with tooth gaps between them, so that straight wire sections of the coil mat are received in the tooth gaps, b) Providing a rotating unit rotatable about a rotation axis with the annular arrangement of grooves defined by groove delimiting elements which extend radially with at least one directional component, c) Relative movement of the rotating unit and holder in the longitudinal direction of the holder and rolling the rotating unit over the holder such that several grooves with several tooth gaps are aligned in an arcuate transfer area in order to transfer the wire sections of the coil mat from the tooth gaps into the grooves and to guide them during the transfer, d) Transferring the straight wire sections from the tooth gaps in the transfer area to the grooves aligned therewith,and e) adjusting e1) the heights of the teeth and / or e2) the radial lengths of the groove limiting elements,

[0010] in the transfer area such that the heights of the teeth in case e1) or the lengths of the groove limiting elements in case e2) are smaller in the center of the transition area than at the edge areas of the transition area.

[0011] Preferably, step a): a1) comprises providing the holder with teeth that can be moved in a direction transverse to the longitudinal extent such that the height of the teeth can be changed.

[0012] Preferably, step a): a2) comprises providing the holder as a rectilinear rake with a comb structure having at least one or more rows of teeth arranged side by side.

[0013] Preferably, step a) comprises a3) providing the holder with actuators for differential movement of the teeth to individually adjust the height.

[0014] Preferably, step a): a4) providing the holder with elastically mounted teeth such that their height can be individually adjusted by external contact.

[0015] Preferably, step b) comprises providing the rotary unit in the form of a joining mandrel or joining tool, by means of which the received coil mat can be transferred into a component with inwardly opening component grooves.

[0016] Preferably, step e) comprises e3) adjusting the heights and / or lengths such that they gradually increase outwards from the center of the transfer area.

[0017] Preferably, step e): e4) comprises adjusting the heights and / or lengths such that the arc length of the transfer area is increased compared to a state with equal heights and lengths or that a distance between the tooth gaps and the grooves further out in the transfer area is reduced or eliminated compared to a state with equal heights and lengths.

[0018] Preferably, step e): e5) comprises actively retracting or extending teeth and / or groove limiting elements.

[0019] Preferably, step e): e6) comprises passive retraction or extension of elastically held teeth and / or groove limiting elements during the relative movement of the holder and the rotary unit immersed therein and / or of the rotary unit and the holder immersed therein.

[0020] Preferably, step e) in case e1): e1a) comprises extending teeth outside the center of the transfer area.

[0021] Preferably, step e) in case e1): e1b) comprises retracting teeth in the center of the transfer area.

[0022] Preferably, step e) in case e1) comprises e1c) adjusting the heights of the teeth in the transfer area such that the teeth are extended further the further they are from the center.

[0023] Preferably, step e) in case e1) comprises e1d) adjusting the heights of the teeth in the transfer area such that the teeth are retracted further the closer they are to the center.

[0024] Preferably, step e) in case e2): e2a) comprises extending groove limiting elements outside the center of the transfer area.

[0025] Preferably, step e) in case e2): e2b) comprises inserting groove limiting elements in the center of the transfer area.

[0026] Preferably, step e) in case e2) comprises e2c) adjusting the radial extent of the groove limiting elements in the transfer area such that the groove limiting elements are extended further the further they are away from the center.

[0027] Preferably, step e) in case e2) comprises e2d) adjusting the radial extent of the groove limiting elements in the transfer area such that the groove limiting elements are retracted further the closer they are to the center.

[0028] According to a further aspect, the invention provides a manufacturing method for producing a stator component with a coil winding, comprising: carrying out the coil mat receiving method according to one of the preceding embodiments for inserting the coil mat onto a joining tool, relatively moving the joining tool provided with the coil mat into an annular component with an arrangement of inwardly opening component grooves and transferring the coil mat from the joining tool into the component.

[0029] According to a further aspect, the invention provides a coil mat receiving device for receiving a coil mat during the production of a component of an electrical machine, comprising: an elongated holder for providing and holding a linearly arranged coil mat, which holder has a row of teeth with tooth gaps in between, in which straight wire sections of the coil mat can be received, a rotary unit rotatable about a rotation axis with an annular arrangement of grooves that extend outwards and into which the straight wire sections can be inserted and that are delimited by radially extending groove limiting elements, a movement device for the relative movement of the rotary unit and the holder in the longitudinal direction of the holder and for rolling the rotary unit over the holder, wherein the movement device is configured to align a plurality of grooves with a plurality of tooth gaps for transferring the wire sections and guiding the wire sections during transfer as the rotary unit rolls over the holder, in a transfer area,wherein aa) the height of the respective teeth of the holder in the transfer area and / or bb) the radial extension of the respective groove limiting elements in the transfer area are individually adjustable and adaptable during rolling.

[0030] It is preferred that the holder is designed as a straight rake with a comb structure having one or more rows of teeth arranged next to one another.

[0031] It is preferred that the holder is designed with teeth that can be moved individually in a direction transverse to the longitudinal extent.

[0032] It is preferred that the holder is displaceable in the longitudinal direction by the movement device.

[0033] It is preferred that the holder has actuators for individually moving the teeth to adjust their height.

[0034] It is preferred that the holder has elastically movable teeth which can be individually adjusted in height by contact with the rotating unit and / or a (mechanical) control cam.

[0035] It is preferred that the holder has movably mounted teeth, the height of which can be individually adjusted by contact with a control cam. Preferably, the coil mat receiving device has a control cam relative to which the holder is movable, with cam-following elements provided on the teeth in contact with the control cam.

[0036] It is preferred that the rotating unit is designed as a joining mandrel or joining tool for inserting the received coil mat into inwardly opening component grooves of a component.

[0037] It is preferred that the rotary unit has actuators for individually moving the groove limiting elements.

[0038] It is preferred that the rotary unit has groove limiting elements that are elastically movable in the radial direction and that can be individually adjusted in the radial extent by contact with teeth of the holder and / or with a control cam.

[0039] According to a further aspect, the invention provides a coil mat transfer station for a manufacturing plant for producing a component of an electrical machine, for transferring a linear coil mat into a wound state, comprising a coil mat take-up device according to one of the preceding embodiments and a controller which is configured to control the coil mat take-up device for carrying out the coil mat take-up method according to one of the preceding embodiments.

[0040] According to a further aspect, the invention provides a control for a coil mat receiving device according to one of the preceding embodiments, wherein the control is configured to control the coil mat receiving device to carry out the coil mat receiving method according to one of the preceding embodiments.

[0041] According to a further aspect, the invention provides a computer program comprising machine-readable control instructions which cause a coil mat take-up device according to one of the preceding embodiments to carry out the coil mat take-up method according to one of the preceding embodiments.

[0042] According to a further aspect, the invention provides a manufacturing plant for producing a stator component provided with a coil winding, comprising a coil mat transfer station according to the above embodiment, wherein the rotating unit is designed as a joining tool, and a device for the relative insertion of the joining tool into an annular laminated core and for transferring the coil winding from the joining tool into the laminated core.

[0043] The coil mat receiving method according to embodiments of the invention is particularly suitable for receiving the coil mat onto a joining tool, such as those known from [5] to [9], wherein the joining tool has an arrangement of grooves. However, it would also be conceivable to use the coil mat receiving method to transfer a coil mat directly onto outwardly opening component grooves of a rotor body or a stator of an external rotor motor.

[0044] The grooves of the outwardly opening groove arrangement can extend radially, with the groove delimiting elements, which can be, for example, (preferably radially movable) lamellae of a joining mandrel, extending in particular in the radial direction. Designs are also conceivable in which the grooves are not strictly radial, but rather the (extended) longitudinal axis of the grooves does not run through the center of the arrangement, for example, through the center of a joining mandrel. Likewise, the central axis of the lamellae would then not be exactly radial.

[0045] In some embodiments, the arrangement of slots on a joining mandrel or other joining tool is provided, by means of which the received coil mat can then be transferred into inwardly opening slots of a component. The component can in particular be a component of an electrical machine, such as a laminated core of a stator with stator slots. However, the component can also be an intermediate handling device for joining into the stator of an external rotor motor. For example, the coil mat is transferred from the joining mandrel to an intermediate handling tool and thus into a stator of an external rotor motor, in which the stator slots open radially outward. Examples of the "component" are therefore the stator or its laminated core in an internal rotor motor, whereas in an external rotor motor, it is the intermediate handling tool. In the latter case, however, the "component" is different from the stator component to be manufactured.

[0046] Preferred embodiments of the invention relate to a holder for wave winding wires with a movable guide.

[0047] Embodiments of the invention are preferably used in the manufacture of a component of an electrical machine, such as in particular a stator or rotor, which component is provided with a coil winding realized by a wave winding. In a wave winding, wires are formed into mats in a holder, such as a rake, and then wound onto a rotating unit provided with grooves (or laminations) (such as a rotor, onto which the coil winding is to be wound, or a mandrel, in particular a winding mandrel, as a joining tool). In this case, an exact transfer from holder to rotating unit is crucial. In particular, the holder moves linearly relative to the rotating unit and synchronously with the peripheral speed of the rotating unit. In a transfer area, the wires are then transferred to the rotating unit, such as the mandrel.

[0048] In the state of the art, the teeth of the holder, such as rake teeth, are designed to be immobile (in the vertical direction).

[0049] To ensure precise transfer, the wires should be guided at all times during the transfer from the holder to the winding-rotary unit by teeth on the holder and / or by slats or similar groove-limiting elements on the rotating unit. Otherwise, the wires would lose their guidance during the transfer. The wires could end up in the wrong groove or be damaged. Due to the geometric design—round mandrel to linear rake—the state of the art only provides wire guidance within a very small arc segment.

[0050] When transferring the wire from the holder (e.g., a rake) to the rotating unit (e.g., a winding mandrel, particularly suitable for use as a joining tool), the current technology requires the entire stroke to occur in a short arc segment—which requires a steep incline. This creates significant forces and stresses on the wire. The wire's insulation, in particular, can be damaged.

[0051] With embodiments of the invention, however, the transfer area can be enlarged so that the forces on the wire can be reduced.

[0052] In some designs, the bracket adapts to the radius of the rotating unit through an axial movement of the teeth. For example, some teeth are raised, particularly at the beginning and end of the transfer area.

[0053] In preferred embodiments of the invention, the transfer area is enlarged compared to the corresponding devices and methods in the prior art; the stroke of the wires can thus take place in a larger arc segment, which leads to a smaller gradient.

[0054] The forces acting on the wire can be significantly reduced, allowing for more precise wire transfer. The result is less damage and fewer faulty coilings.

[0055] Examples of embodiments are explained in more detail below using the attached drawings. They show: Fig. 1 is a schematic partial view of a conventional coil mat receiving device for receiving a linearly provided coil mat on an annular arrangement of radially outward-opening grooves; Fig. 2 is a schematic partial view of a coil mat receiving device for receiving a linearly provided coil mat on an annular arrangement of radially outward-opening grooves according to an embodiment of the invention to illustrate a coil mat receiving method that can be carried out therewith; Fig. 3 is a schematic partial view of a coil mat receiving device according to a first embodiment of the invention; Fig. 4 is a schematic partial view of a coil mat receiving device according to a second embodiment of the invention; Fig. 5 is a schematic partial view of a coil mat receiving device according to a third embodiment of the invention;6 shows a schematic partial view of a coil mat receiving device according to a fourth embodiment of the invention; Fig. 7 shows a schematic partial view of a coil mat receiving device for receiving a linearly provided coil mat on an annular arrangement of radially outwardly opening grooves according to a further embodiment of the invention to illustrate a variant of the coil mat receiving method; Fig. 8 shows a schematic partial view of a coil mat receiving device according to a fifth embodiment of the invention; Fig. 9 shows a schematic partial view of a coil mat receiving device according to a sixth embodiment of the invention; Fig. 10 shows a schematic representation of a variant for a rotating unit usable in the coil mat receiving device and the coil mat receiving method, with an arrangement of outwardly opening grooves; and Fig.11 a schematic block diagram of a manufacturing plant for producing a component of an electrical machine provided with a coil winding, such as in particular for producing a stator; .

[0056] In the Figures 1 to 9 different embodiments of a coil mat receiving device 10 for receiving a coil mat 18 during the manufacture of a component of an electrical machine are shown. In Fig. 1 is a conventional coil mat receiving device 10 according to the prior art, for example as known from [5] to [9], and in the Fig. 2 to 9 a coil mat receiving device 10 in accordance with the invention is shown.

[0057] The coil mat receiving device 10 has a holder 12, a rotating unit 14 and a moving device 16.

[0058] The holder 12 extends elongated in a longitudinal direction shown from left to right in the figures. The holder 12 is designed to provide and hold a linearly arranged coil mat 18. For this purpose, the holder 12 has a row of teeth 20 with tooth gaps 22 between them. Straight wire sections 24 of the coil mat 18 can be received in the tooth gaps 22.

[0059] In the illustrated embodiments, the holder 12 is designed as a straight rake with a comb structure having one or more rows of teeth 20 arranged next to one another.

[0060] The rotary unit 14 is rotatable about a rotation axis 26 and is provided around its circumference with an annular arrangement 28 of outwardly opening grooves 30. In the embodiments shown, the grooves 30 are distributed over the circumference. The grooves 30 can, as shown in the Fig. 1 to 9shown, extend in the radial direction or extend only with a directional component in the radial direction - or in other words extend obliquely to the radial direction - as shown in Fig. 10 is indicated. In Fig. 10 an embodiment of the rotary unit 14 is shown in which the extended central axis of the grooves 30 does not pass through the axis of rotation 26.

[0061] For the rotating units 14 of the Fig. 1 to 10 The grooves 30 are designed such that the straight wire sections 24 can be inserted therein. The grooves 30 are delimited by groove delimiting elements 32 that extend radially with at least one directional component.

[0062] The Fig. 1 and 2The movement device 16, indicated only by arrows, is designed for the relative movement of the rotating unit 14 and the support 12 in the longitudinal direction of the support 12 and for rolling the rotating unit 14 over the support 12. The movement device 16 has corresponding bearings, guides, and actuators, as are generally known to those skilled in the art, see, for example, references [5] to [9]. The components of the movement device 16 are designed to perform the following movements.

[0063] In some embodiments of the movement device 16, the holder 12 is held stationary and the rotary unit 14 is moved linearly along the holder 12 while rotating. In preferred embodiments of the movement device 16, the rotary unit 14 rotates about the rotation axis 26, which is held stationary in the longitudinal direction when the coil mat 18 is picked up, while the holder 12 is moved linearly in the longitudinal direction. In the illustrated embodiments, the holder 12 as a whole is displaceable in the longitudinal direction by the movement device 16. In the height direction explained later, the rotation axis 26 is in some embodiments, as shown in Fig. 6 are indicated, movable towards and away from the holder 12 in order to exert a defined compressive force, as will be explained later.

[0064] 1 to 11, the movement device 16 is configured and controlled by an electronic controller 34 shown in Fig. 11, implemented in particular by hardware and / or software, such that the relative movement in the longitudinal direction occurs synchronously with the rotational movement during rolling and, in other words, at the same speed as the peripheral speed of the rotary unit 14. The movement device 16 is configured to align, as the rotary unit 14 rolls over the holder 12, in a transfer region 36, a plurality of grooves 30 having a plurality of tooth gaps 22 for transferring the wire sections 24 and guiding the wire sections 24 during transfer.

[0065] The rotating unit 14 is preferably designed as a joining tool 40 for inserting the coil mat 18 into a component 42 indicated in Fig. 11, such as in particular a laminated core of a stator 44 or into an intermediate handling tool. The component 42 is provided with inwardly opening component grooves (not shown in Fig. 11, but generally known, see [1] to [9]), into which the straight wire sections 24 are transferred by the joining tool 40, as described and shown, for example, in [5]. In some embodiments not shown, however, the rotating part 14 can also be the component itself, in particular, for example, a rotor with outwardly opening grooves or a stator component of an external rotor motor.

[0066] In the state of the art, as shown in the comparative example according to Fig. 1As shown, the teeth 20 are rigidly arranged on a base 38 of the holder 12. Furthermore, in a rotary unit 14 designed as a joining tool 40, it is generally known to design the groove limiting elements 32 of the rotary unit 14 to be radially movable in order to adjust the overall diameter of the rotary unit 14 to a large diameter for receiving and to a small diameter for inserting and compressing. However, all groove limiting elements 32 are moved together, so that the groove openings of the arrangement 28 of grooves 30 are located on the same radius during receiving.

[0067] Overall, the state of the art according to Fig. 1 due to the change in geometry from linear to round only a very small transfer area 36. In Fig. 1For example, only two grooves with two tooth gaps are brought so close together in the transfer area 36 that the wire sections 24 can be transferred under constant guidance by the teeth and the groove limiting elements 32. Outside of this small transfer area 36, which extends over only two grooves, guidance is no longer possible, as indicated by the arrow 46. The wire sections 24 must be transferred in this small transfer area 36 with a large stroke 48. The gradient of the movement curve of the wire sections 24 is very large, so that a relatively large load acts on the wire sections 24.

[0068] In contrast, a new coil mat recording method is proposed here, which is described below on the basis of the Fig. 2 and 7 is explained.

[0069] The coil mat pick-up method is performed during the manufacture of a component of an electrical machine to pick up the coil mat 18 from the elongated holder 12 and insert it into the annular array 28 of grooves 30 that open outwardly in a radial direction. Specifically, the coil mat pick-up method brings a linear coil into a wound state by winding it.

[0070] The coil mat pickup process includes the steps a) Providing the coil mat 18 on the elongated holder, which has a row of teeth 20 with tooth gaps 22 therebetween, so that straight wire sections 24 of the coil mat 18 are received in the tooth gaps 22, b) Providing the rotary unit 14, which is rotatable about the rotation axis 26, with the annular arrangement 28 of grooves 30, which are delimited by groove limiting elements 32, which extend radially with at least one directional component, c) Relative movement of the rotary unit 14 and the holder 12 in the longitudinal direction of the holder 12 and rolling the rotary unit 14 over the holder 12 such that in an arcuate transfer area 36, several grooves 30 with several tooth gaps 22 are aligned in order to transfer the wire sections 24 of the coil mat 18 from the tooth gaps 22 into the grooves 30 and to guide them during the transfer,d) transferring the straight wire sections 24 from the tooth gaps 22 in the transfer area 36 to the grooves 30 aligned therewith, and e) adjusting e1) the heights of the teeth 20 and / or e2) the radial lengths of the groove limiting elements 32,

[0071] in the transfer area 36 such that the heights of the teeth 20 in case e1) or the lengths of the groove limiting elements 32 in case e2) in the center 50 of the transition area 36 are each smaller than at the edge areas 51 of the transition area 36.

[0072] The different adjustment of the height of the teeth 20 is in Fig. 2 shown, while the different setting of the radial length of the groove limiting elements in Fig. 7 Of course, both measures can also be combined.

[0073] The height of a tooth 20 is defined as the position of the tip of the tooth 20 in the dimension extending transversely to the longitudinal direction and transversely to the rotation axis 26. This definition is referred to below as the height direction. Preferably, the holder 12 is oriented with its longitudinal direction in the horizontal direction, so that in a preferred embodiment, the height direction coincides with the vertical direction (i.e., the direction of the effect of gravity). However, this does not have to be the case; a transfer also functions in any other orientation of the holder 12 and the rotating unit 14.

[0074] How to Fig. 2 and 7 compared to Fig. 1As can be seen, a significant enlargement of the transfer area 36 is achieved by the different adjustment of the heights of the teeth 20 and / or the radial length of the groove limiting elements 32 in the curved area where the rotary unit 14 and the holder 12 approach each other the most. A transfer with guidance is possible in the Fig. 2 to 9 In the embodiments of the invention shown, this is possible due to the different adjustment of six grooves 30 and not just two grooves 30 as in the prior art. Of course, this is only an example; more or fewer grooves 30 (e.g., three to ten) in the transfer area 36 can also be aligned with corresponding tooth gaps 22 for guided transfer.

[0075] How to Fig. 2As can be seen, the stroke 48 that each wire section 24 to be transferred must travel in the vertical or radial direction in order to be transferred under constant guidance can be distributed over a larger area in the longitudinal direction. In other words, the movement curve of the wire sections 24 is less steep. The wire sections 24 are thus subjected to less stress. This also protects the insulation layer in particular, since the guidance can be achieved with fewer guide forces - less friction of the wire sections against the teeth 20 and the groove limiting elements 32.

[0076] The coil mat receiving device 10 according to the Fig. 2 to 10 The embodiments shown are accordingly suitable and / or configured for carrying out such a coil mat receiving method. In particular, aa) the height of the respective teeth 20 of the holder 12 in the transfer area 36 and / or bb) the radial extension of the respective groove limiting elements 36 in the transfer area during rolling can each be individually adjusted and adapted.

[0077] The different adjustment of the height of the teeth 20 and / or the radial extension of the groove limiting elements 32 can be done in different ways.

[0078] To implement alternative e1), the teeth 20 are designed to be movable in the vertical direction. For example, the base 38 of the holder 12 is rigid, e.g., as a base plate or base frame, and the teeth 20 are mounted therein so that they can move vertically. However, in embodiments not shown in detail, the holder 12 can also be composed entirely of segments arranged side by side in the longitudinal direction, each of which has a tooth body and a base element, wherein the segments are movable relative to one another in the vertical direction.

[0079] In the Fig. 2 to 6 In the embodiments shown, the holder 12 is designed with teeth 20 that can be individually moved in a direction transverse to the longitudinal extent. In particular, the teeth 20 are held vertically displaceably on the rigid base 38 of the holder 12.

[0080] At the Fig. 5In the embodiment shown, the holder 12 has actuators 52 for individually moving the teeth 20 to adjust their height.

[0081] In the Fig. 4 and 6 In the embodiments shown, the holder 12 has elastically movable teeth 20, which can be individually adjusted in height by contact with the rotating unit and / or a control cam.

[0082] For the implementation of alternative e2), in particular the groove limiting elements 32 designed as lamellae are individually movable in the radial direction and can be moved differently from their adjacent groove limiting elements 32.

[0083] How to use the Fig. 2 and 7 can be seen, the heights and / or lengths are adjusted in such a way that they gradually increase from the center 50 of the transfer area 36 outwards (ie from the center 50 to the left and right in the figures).

[0084] In some embodiments, the heights and / or lengths are adjusted such that the arc length of the transfer region 36 is increased compared to a state with the same heights or lengths. In other words, compared to a state with the same heights or lengths, the respective distance between the respective tooth gap 22 and the respective groove 30 aligned therewith is reduced or eliminated further outward in the transfer region 36.

[0085] The setting can be done as in Fig. 2 to 4 and 7 to 9 represented by active retraction or extension of teeth 20 and / or groove limiting elements 32.

[0086] However, the adjustment can also be carried out by passively retracting or extending elastically held teeth 20 and / or groove limiting elements 32 during the relative movement of the holder 12 and the rotary unit 14 immersed therein and / or of the rotary unit 14 and the holder 12 immersed therein, as shown in Fig. 6 for alternative e1), whereby it is clear that this principle can also be applied to the adjustment of the groove limiting elements 32 according to alternative e2).

[0087] In the embodiments shown, the adjustment of the height of the individual teeth 20 to enlarge the transfer area 36 (alternative e1) can be achieved by one or more of the following measures: e1a) Extension of teeth 20 outside the center 50 of the transfer area 36 - see Fig. 2 to 4 ; e1b) Retraction of teeth 20 in the center 50 of the transfer area 36 - see Fig. 5 and 6 , e1c) Adjusting the heights of the teeth 20 in the transfer area 36 so that the teeth are extended further, the further they are away from the center 50 - see Fig. 2 to 4 , and / or e1d) Adjusting the heights of the teeth 20 in the transfer area 36 so that the teeth are retracted further, the closer they are to the center - see Fig. 5 and6 .

[0088] In the same way as for the extension and retraction of the teeth 20 for the alternative e1) in the Fig. 2 to 6 As shown, the adjustment of the radial lengths of the groove limiting elements 32 can be carried out analogously by means of one or more of the following measures: e2a) Extension of groove limiting elements 32 outside the center 50 of the transfer area 36 - shown in Fig. 7 to 9 , e2b) Insertion of groove limiting elements 32 in the center 50 of the transfer area 36 analogous to the Fig. 5 and 6 , e2c) Adjusting the radial extension of the groove limiting elements 32 in the transfer area 36 so that the groove limiting elements 32 are extended further, the further they are away from the center 50, see Fig. 7 to 9; e2d) Adjusting the radial extent of the groove limiting elements 32 in the transfer area 36 so that the groove limiting elements 32 are retracted further, the closer they are to the center - analogous to Fig. 5 and 6 .

[0089] In the Fig. 2 to 9 Different embodiments of the coil mat take-up device 10 according to the invention are shown, which are configured to carry out the above-mentioned different variants of the coil take-up method. The features shown in only one or some of the different embodiments can also be used in the other embodiments. The features of the different embodiments can be combined as desired.

[0090] The Fig. 2 to 4 show embodiments of the coil mat receiving device 10 which are designed to raise teeth 20 to adapt to the circumference of the rotary unit 14 in order to thus enlarge the transfer area 36.

[0091] The Fig. 5 and 6 show embodiments of the coil mat receiving device 10 which are designed to lower teeth 20 to adapt to the circumference of the rotating unit 14.

[0092] The Fig. 7 to 9 show embodiments of the coil receiving device 10 that are configured to radially extend slot limiting elements 32. In further embodiments not shown, slot limiting elements 32 are radially retracted in the center of the transfer area 36 to extend the transfer area.

[0093] In some embodiments, the height of the teeth 20 and / or the radial extent of the groove limiting elements 32 is adjusted by active control by actuators 52, as shown in Fig. 5 using the example of controlling the retraction of teeth 20 and in Fig. 8for extending the groove limiting elements 32. The actuators 52 are connected to the controller 34 for this purpose and are actively controlled individually. In embodiments not shown, the teeth 20 are lifted by means of such actuators 52 as shown in Fig. 2 or the retraction of the groove limiting elements 32 arranged in the center 50.

[0094] When designing Fig. 6 The retraction of teeth 20 is not active, but passive, in this case by being pressed downward by the groove limiting elements 32 (e.g., slats) of the rotating unit 14. For this purpose, the teeth 20 are elastically mounted in the vertical direction, as indicated by spring elements 54. The rotating unit 14 is pressed downward in a defined manner against the elastically mounted teeth 20 of the holder by force on the rotation axis 26.

[0095] In the Fig. 3 , 4 and 9In the embodiments shown, the heights of the teeth 20 or the radial extent of the groove limiting elements 32 are adjusted by means of at least one mechanical control cam 56. The teeth 20 or the groove limiting elements 32 are moved relative to the at least one control cam 56 during the movement initiated by the movement device 16. The teeth 20 or the groove limiting elements 32 have contact elements 58 - in particular drivers with sliding surfaces or rollers - which engage the control cam 56. Due to the course of the control cam 56, the teeth 20 or the groove limiting elements 32 are then deflected according to their current position in the transfer area 36.

[0096] The teeth 20 or the groove limiting element 32 can be elastically prestressed against the control curve 56, as shown in the Fig. 4 and 9by the indication with spring elements 54. Pairs of contact elements 58 and a pair of control cams 56 for advancing and retracting the teeth 20 or the groove limiting elements 32 can also be provided, as shown in Fig. 3 is shown.

[0097] According to a preferred embodiment according to Fig. 11, the coil mat take-up device 10 is used in a coil mat transfer station 60 for a manufacturing system 62 for producing a component 42 of an electrical machine. The coil mat transfer station 60 is designed to transfer the linear coil mat 18 into a wound state and, in addition to the coil mat take-up device 10, also has the controller 34, which is configured to control the coil mat take-up device 10 to carry out the coil mat take-up method according to one of the previously explained preferred embodiments of the method.

[0098] As already mentioned above, the controller 34 is designed as an electronic controller and, in particular, comprises a computer unit and a computer program loaded into a memory with corresponding control instructions for carrying out the individual control steps of the method. The controller 34 can, in particular, be a part of an overall controller 64 of the manufacturing system 62, embodied as software.

[0099] Fig. 11 shows the manufacturing system 62 for producing a stator component 44 provided with a coil winding. The manufacturing system 62 comprises a coil mat manufacturing device 66, the coil receiving device 10, in which the rotating unit 14 is designed as a joining tool 40, a laminated core supply device 68, a device 70 for the relative insertion of the joining tool 40 into an annular laminated core provided by the laminated core supply device 68 (example of the component 44 with inwardly opening component grooves) and for transferring the coil winding from the joining tool 40 into the laminated core, a stator further processing device 72 and the overall control system 64. The coil mat manufacturing device 66 is designed to produce the coil mat 18 as described, for example, in one of the literature references [1] to [4].The coil mat 18 is then provided on the holder 12 on the coil mat receiving device 10, where it is picked up by the joining tool 40 through the coil mat picking process, and transferred into the laminated core by the device 70, which can be designed analogously to that described in reference [5]. The stator processing device 70 is designed to carry out the further steps known per se for completing the stator, such as impregnation or inserting slot cover strips, wiring, functional testing, etc.

[0100] In other embodiments of the manufacturing system 62 not shown, the coil mat is first inserted by means of the joining tool 40 into an annular intermediate handling tool, which can also be provided with radially movable lamellae, between which inwardly opening grooves are formed, and from there transferred onto a laminated core of an external rotor motor stator with outwardly opening stator grooves.

[0101] Methods and devices for receiving a coil mat (18) from an elongated holder (12) and inserting the coil mat (18) into an annular arrangement (28) of outwardly opening grooves (30) have been described. The arrangement (28) of grooves (30) is formed, for example, on a joining tool (40) for inserting the wound coil mat (18) into inwardly opening component grooves of a stator or similar component.In order to enable a more gentle and reliable transfer with a lower risk of damage or errors, it is proposed that the heights of teeth (20) of the holder (12) and / or the radial lengths of slot limiting elements (32) that limit the slots (30) on the rotating unit (14) be individually adjusted in a transfer area (36), in which wire sections (24) of the coil mat (18) are transferred under constant bilateral guidance, first by the teeth (20) and then by the slot limiting elements (32), such that the heights of the teeth (32) and the lengths of the slot limiting elements (32) are each smaller in the center (50) of the transition area (36) than at the edge areas (52) of the transition area (36). As a result, the arc length of the transfer area (36) is extended compared to a state without individual adjustment, which leads to improved guidance and lower stress on the coil mat (18). List of reference symbols:

[0102] 10 Coil mat receiving device 12 Holder 14 Rotating unit 16 Movement device 18 Coil mat 20 Tooth 22 Tooth gap 24 Wire section 26 Rotation axis 28 Arrangement of grooves 30 Groove 32 Groove limiting element 34 Control system 36 Transfer area 38 Base 40 Joining tool 42 Component 44 Stator 46 No longer guiding possible 48 Stroke 50 Center 51 Edge area 52 Actuator 54 Spring element 56 Control cam 58 Contact element 60 Coil mat transfer station 62 Manufacturing system 64 Overall control system 66 Coil mat manufacturing device 68 Laminated core supply device 70 Device for transferring the wound coil winding 72 Stator further processing device

Claims

1. Coil mat receiving method to be performed during the manufacture of a component of an electric machine for receiving a coil mat (18) from an elongated holder (12) and inserting the coil mat (18) into an annular arrangement (28) of grooves (30) which open outwards, the method comprising the steps of: a) providing the coil mat (18) on the elongated holder (12) that has a series of teeth (20) with tooth gaps (22) between them, so that that straight wire sections (24) of the coil mat (18) are received in the tooth gaps (22), b) providing a rotary unit (14) which is rotatable about a rotary axis (26) and which has the annular arrangement (28) of grooves (30) that are limited by groove limiting elements (32) which extend radially with at least one directional component, c) relatively moving the rotary unit (14) and the holder (18) in the longitudinal direction of the holder (12) and rolling the rotary unit (14) over the holder (12) in such a way that several grooves (30) with several tooth gaps (22) are aligned in an arc-shaped transfer area (36) in order to transfer the wire sections (24) of the coil mat (18) from the tooth gaps (22) to the grooves and to guide them during the transfer, d) transferring the straight wire sections (24) from the tooth gaps (22) in the transfer area (36) to the grooves (30) aligned with them, characterized in that the coil mat receiving method comprises the step of: e) adjusting e1) the height of the teeth (20) and / or e2) the radial length of the groove limiting elements (32) in the transfer area (36) in such a way that the heights of the teeth (32) in the case of e1) or the lengths of the groove limiting elements (32) in the case of e2) are smaller in the center (50) of the transfer area (36) than at the edge regions (52) of the transfer area (36).

2. Coil mat receiving method according to claim 1, characterized in that step a) comprises at least one or more steps: a1) providing the holder (12) with teeth (20) movable in a direction transverse to the longitudinal direction in such a way that the height of teeth (20) is variable; a2) providing the holder (12) as a linear rake with a comb structure that comprises at least one or more rows of teeth (20) arranged side by side; a3) providing the holder (12) with actuators (52) for differently moving the teeth (20) for individual height adjustment, a4) providing the holder (12) with teeth (20) elastically supported in such a way that the height thereof is individually adjustable by contact from the outside.

3. Coil mat receiving method according to any one of the preceding claims, characterized in that step b) comprises: providing the rotary unit (14) in the form of joining mandrel or joining tool (40), by means of which the coil mat (18) received can be transferred to a component (42) having inwardly opening component grooves.

4. Coil mat receiving method according to any one of the preceding claims, characterized in that step e) comprises at least one or more of the steps: e3) adjusting the heights and / or lengths in such a way that they gradually increase in size from the center (50) of the transfer area (36) when seen towards the outside, e4) adjusting the heights and / or the lengths in such a way that the arc length of the transfer area (36) is increased in size compared to a state with equal heights or lengths or that a distance between the tooth gaps (22) and the grooves (30) is reduced in size or eliminated further out in the transfer area (36), e5) active retracting and / or extending of teeth (20) and / or groove limiting elements (32); e6) active retracting and / or extending of elastically supported teeth (20) and / or groove limiting elements (32) during relative movement of the holder (12) and the rotary unit (14) diving into the holder and / or of the rotary unit (14) and the holder (12) diving into the rotary unit.

5. Coil mat receiving method according to any one of the preceding claims, characterized in that step e) 5.1 comprises at least one more steps in the case e1): e1a) extending teeth (20) outside the center (50) of the transfer area (36), e1b) retracting teeth (20) in the center of the transfer area (36), e1c) adjusting the heights of the teeth (20) in the transfer area (36), so that teeth (20) are extended further the further they are from the center (50), e1d) adjusting the heights of the teeth (20) in the transfer area (36), so that teeth (20) are retracted further the closer they are to the center (50); and 5.2 comprises at least or more steps in the case e2): e2a) extending groove limiting elements (32) outside the center (50) of the transfer area (36), e2b) retracting groove limiting elements (32) in the center of the transfer area (36), e2c) adjusting the radial lengths of the groove limiting elements (32) in the transfer area (36), so that groove limiting elements (32) are extended further the further they are from the center (50), e2d) adjusting radial lengths of the groove limiting elements (32) in the transfer area (36), so that groove limiting elements (32) are retracted further the closer they are to the center (50).

6. Method for producing a stator component having a coil winding, the method comprising: carrying out the coil mat receiving method according to any one of the preceding claims for inserting the coil mat (18) onto a joining tool (40), relatively moving the joining tool (40) provided with the coil mat (18) into an annular component (42) having an arrangement of inwardly opening component grooves and transferring the coil mat (18) from the joining tool (40) into the component (42).

7. Coil mat receiving device (10) for receiving a coil mat (18) during the manufacture of a component of an electric machine, the device comprising: an elongated holder (12) for providing and holding a linearly arranged coil mat (18), which holder (12) comprises a row of teeth (20) with tooth gaps (22) between them, in which tooth gaps straight wire sections (24) of the coil mat (18) can be received, a rotary unit (14) which is rotatable about a rotary axis (26) and which has an annular arrangement (28) of grooves (30) which open outwards and into which the straight wire sections (24) can be inserted and which are limited by groove limiting elements (32) which extend in the radial direction with at least one directional component, a movement device (16) for relatively moving the rotary unit (14) and the holder (12) in the longitudinal direction of the holder (12) and for rolling the rotary unit (14) over the holder (12), wherein the movement device (16) is configured, during rolling the rotary unit (14) over the holder (12) in a transfer area (36), to align several grooves (30) with several tooth gaps (22) for the transfer of the wire sections (24) and for guiding the wire sections (24) during the transfer, characterized in that aa) the height of the respective teeth (20) of the holder (12) in the transfer area (36) and / or bb) the radial length of the respective groove limiting elements (32) in the transfer area (36) are in each case adjustable and adaptable individually during rolling.

8. Coil mat receiving device (10) according to claim 7, characterized in that the holder (12) 8.1 is designed as a linear rake with a comb structure that comprises at least one or more rows of teeth (20) arranged side by side; 8.2 is designed with teeth (20) individually movable in a direction transverse to the longitudinal extension, 8.3 is displaceable in the longitudinal direction by means of the movement device (16), 8.4 comprises actuators (52) for individually moving the teeth (20) for adjusting their height, and / or 8.5 comprises elastically supported teeth (20) which are individually adjustable in height by contact with the rotary unit (14) and / or a control cam (56).

9. Coil mat receiving device (10) according to any one of claims 7 or 8, characterized in that the rotary unit (14): 9.1 is designed as a joining mandrel or joining tool (40) for inserting the received coil mat (18) into inwardly opening component grooves of a component (42), 9.2 comprises actuators (52) for individually moving the groove limiting elements (32) and / or 9.3 comprises groove limiting elements (32) elastically movable in the radial direction, which are individually adjustable in the radial length by a contact with the teeth (20) of the holder (12) and / or with a control cam (56).

10. Coil mat transfer station (60) for a production plant (62) for the production of a component of an electrical machine, the transfer station for transferring a linear coil mat (18) into a coiled state and comprising a coil mat receiving device (10) according to any one of claims 7 to 9 and a controller (34) configured to control the coil mat receiving device (10) for carrying out the coil mat receiving method according to any one of claims 1 to 5.

11. Controller (34) for a coil mat receiving device (10) according to any one of claims 7 to 9, wherein the controller (34) is configured to control the coil mat receiving device (10) for carrying out the coil mat receiving method according to any one of claims 1 to 5.

12. Computer program, comprising machine-readable instructions causing a coil mat receiving device (10) according to any one of claims 7 to 9 to carry out the coil mat receiving method according to any one of claims 1 to 5.

13. Production plant (62) for the production of a stator component provided with a coil winding, the production plant comprising a coil mat transfer station (60) according to claim 10, wherein the rotary unit (14) is designed as a joining tool (40), and comprising means (70) for relatively inserting the joining tool (40) into an annular laminated core and for transferring the wound-up coil mat (18) from the joining tool (40) into the laminated core.