Winding machine and method for producing coil windings on an externally grooved winding support of a rotor or stator of an electrical machine, and winding system
Patent Information
- Application Number
- EP2023828336
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-12-22
- Filing Date
- 2023-12-01
- Publication Date
- 2025-10-29
AI Technical Summary
Existing methods for producing coil windings on externally grooved winding carriers of electrical machines are inefficient, particularly in traction drives where multiple teeth need to be wound simultaneously, leading to increased costs and risks of electrical property differences due to manufacturing tolerances.
A winding machine with multiple winding devices arranged around a receiving device, each equipped with a wire feed system and drive mechanisms that allow independent movement and rotation, enabling simultaneous winding of multiple teeth with precise control to reduce process time and avoid gapping issues in laminated carriers.
The solution enables efficient parallel production of coil windings, reducing process time and minimizing gapping issues, allowing for individually tailored windings with improved electrical connections and increased efficiency in traction drives.
Smart Images
Figure 1.1
Abstract
Description
[0001] Winding machine and method for producing coil windings on an externally slotted winding carrier of a rotor or stator of an electrical machine, and winding system
[0002] The invention relates to a winding machine and a method for producing coil windings on an externally slotted winding carrier of a rotor or stator of an electrical machine, as well as a winding system.
[0003] Rotors, particularly externally slotted rotors, for electric motors designed particularly as separately excited synchronous machines are usually formed with teeth, each of which is wound with a copper wire, for example an enamelled copper wire, in the form of a concentrated winding. In the field of traction drives, four to eight teeth are generally provided for such a rotor. The windings of the individual teeth are usually designed as a series connection and thus have a total of two connecting wires, which are often electrically connected to a slip ring body. The internal interconnection of the individual tooth-wound coils takes place during the winding process itself. It is known from the prior art that rotors are wound tooth by tooth using a wire guide and the simple feeding of the enamelled copper wire, either horizontally or vertically.
[0004] For winding, so-called needle winding machines are widely used. These machines wind wire around a tooth using a needle-shaped feeder to form coil windings. Such a system is described in document EP 1 191 672 B1. Documents WO 2015 / 189676 A1 and EP 1 376 829 B1 disclose devices in which several teeth of an internally slotted winding carrier can be wound using jointly driven needles.
[0005] Summary
[0006] The object of the invention is to provide improved technologies for the production of coil windings on an externally slotted winding carrier, which in particular enable effective and efficient winding.
[0007] To achieve this objective, a winding machine for producing coil windings on an externally slotted winding support of a rotor or stator of an electrical machine is provided according to independent claim 1. Furthermore, methods for producing coil windings on an externally slotted winding support of a rotor or stator of an electrical machine, as well as a winding system, are provided according to further independent claims. Embodiments are the subject of dependent claims in the appended set of claims.
[0008] According to one aspect, a winding machine is provided for producing coil windings on an externally slotted winding carrier of a rotor or stator of an electrical machine. The winding machine is formed with a receiving device for receiving an externally slotted winding carrier and with a plurality of winding devices arranged around the receiving device. The receiving device has a longitudinal axis which, in a state in which an externally slotted winding carrier is received on the receiving device, lies on a longitudinal axis of the externally slotted winding carrier. Each of the winding devices has a wire feed device which is configured to move a winding wire along a feed direction and thus guide it to the receiving device.Each of the winding devices has a drive system which is configured to move the wire feed device relative to the receiving device and independently of the wire feed devices of the other winding devices during an advancing movement of the winding wire according to a winding movement such that the winding wire is wound around a winding tooth of an externally grooved winding carrier received on the receiving device to form a coil winding. The receiving device has a rotary drive by means of which the receiving device can be rotated about its longitudinal axis. The rotary drive is configured to rotate the receiving device according to the winding movement such that the respective winding wire is wound around the respective winding tooth of the externally grooved winding carrier received on the receiving device to form a respective coil winding.
[0009] According to a further aspect, a method for producing coil windings on an externally slotted winding carrier of a rotor or stator of an electrical machine is provided, comprising the steps of receiving an externally slotted winding carrier on a receiving device of a winding machine such that a longitudinal axis of the receiving device lies on a longitudinal axis of the externally slotted winding carrier; and simultaneously forming a plurality of coil windings around a respective winding tooth of the externally slotted winding carrier by means of a plurality of winding devices of the winding machine arranged around the receiving device, wherein, for forming a respective coil winding by means of a respective winding device, a winding wire is moved along a feed direction by means of a wire feed device of the respective winding device and is thus fed to the respective winding tooth,During the advance movement of the winding wire, the wire feed device of the respective winding device is moved by means of a drive system of the respective winding device relative to the respective winding tooth and independently of the wire feed devices of the other winding devices according to a winding movement and is thus wound around the respective winding tooth, and the externally slotted winding carrier is rotated by means of a rotation drive of the receiving device such that the respective winding wire is wound around the respective winding tooth of the externally slotted winding carrier to form the respective coil winding.
[0010] A winding system according to a further aspect is formed with a plurality of winding machines according to the disclosure, wherein the winding machines are configured for the parallel production of coil windings on a respective externally slotted winding carrier of a rotor or stator of an electrical machine in the winding system.
[0011] With the technologies disclosed, multiple wires can be fed to a winding carrier simultaneously, with each wire feed device facing a different winding tooth and able to operate independently. The parallel operation can reduce the process time for winding a winding carrier. In particular, the disclosure provides for the winding devices to be operated in parallel at least at times in order to produce multiple coil windings simultaneously. Preferably, the winding devices are configured for essentially completely parallel operation, which is then provided accordingly for the method. Such simultaneous winding of multiple teeth of a winding carrier can prevent or reduce gaps in the laminations of the winding carrier on a side opposite a single wound tooth, particularly in the case of a laminated winding carrier.According to the disclosure, the production of coil windings can be provided on a laminated externally grooved winding carrier, i.e. on a winding carrier which consists of an arrangement, in particular a stacking, of several sheets, the shape of which predetermines the outer contour of the winding carrier.
[0012] The arrangement of the drive systems and the rotary drive for movements according to winding movements can, in particular, comprise corresponding control by means of one or more control devices provided for this purpose. In this case, a common control device, a respective control device for each movement-generating element, or multiple control devices for one or a group of movement-generating elements can be provided.
[0013] In preferred embodiments, it can be provided that the receiving device rotates by means of the rotation drive at least partially simultaneously with a respective winding movement of the winding devices in accordance with the winding movement. Thus, by at least partially superimposing the various provided movements, a winding movement can be carried out that is precisely adapted to a winding carrier to be wound. For example, by superimposing a rotation of the receiving device with a wire feed device movement in the axial direction (i.e., parallel to the longitudinal axis), a winding wire can be precisely laid around a rounded corner of a winding tooth and / or guided in an obliquely running groove between two winding teeth of a skew-grooved winding carrier.
[0014] The wires can be fed to the winding machine, and in particular to the winding devices, from a respective wire storage device, in particular a respective reel. The wire storage devices can form part of the winding machines or be arranged outside of them.
[0015] The winding devices are preferably arranged around a longitudinal axis of the receiving device and thus along a circumference of a winding carrier received in the receiving device.
[0016] The winding devices can be designed according to a known needle winding technique. In particular, the winding devices can each have a tubular wire feed device, which can be referred to as a needle or wire guide nozzle and is designed to be inserted into the space between two teeth and then moved around a tooth, feeding a coil wire, to produce coil windings.
[0017] In the winding machine, the rotation of the receiving device serves to rotate an externally slotted winding carrier received on the receiving device, so that the externally slotted winding carrier is rotated by means of the rotary drive, at least partially simultaneously with a respective winding movement of the winding devices, according to the winding movement, in such a way that the respective winding wire is wound around the respective winding tooth of the externally slotted winding carrier to form the respective coil winding. By receiving an externally slotted winding carrier on the receiving device of the winding machine, a winding arrangement comprising the winding machine and the winding carrier can be formed.
[0018] The winding machine can have at least three winding devices. For example, the winding machine can have exactly three winding devices. Alternatively, two or more than three winding devices can be provided. In particular, the number of winding devices of the winding machine can be selected such that the available installation space around the receiving device is used efficiently, for example, by arranging the maximum possible number of winding devices around the receiving device without the winding devices interfering with each other's movements.
[0019] The winding devices can be evenly distributed around the circumference of a winding carrier to be arranged in the receiving device. Thus, in a design with three winding devices, the respective angle between two adjacent winding devices around the longitudinal axis, or in the circumferential direction, of a winding carrier to be arranged in the receiving device can be 120 degrees. With more or fewer winding devices, corresponding angles result with even distribution.
[0020] The receiving device can have a workpiece carrier that is designed to receive an externally slotted winding carrier and is detachably arranged in the winding machine to enable transport of an externally slotted winding carrier received on the workpiece carrier to and from the winding machine. In this case, it can be provided that the winding carrier is moved away from the workpiece carrier during reception on the receiving device, so that the winding carrier is arranged on the receiving device but not on the workpiece carrier during the winding process. In this case, the workpiece carrier itself can be arranged on the receiving device. The workpiece carrier can be detachable from the receiving device in order to arrange a winding carrier on the workpiece carrier away from the receiving device. In such an embodiment, the workpiece carrier can alternatively not be part of the receiving device, but can be provided independently of it.In one embodiment, the workpiece carrier has a recess through which a corresponding retaining projection of the receiving device is guided in order to come into contact with the winding carrier and receive it on the receiving device. In this case, the winding carrier can be moved away from the workpiece carrier, so that the workpiece carrier remains on the receiving device separate from the winding carrier and outside the area in which the coil windings are produced. Alternatively, it can be provided that the winding carrier remains on the workpiece carrier and is received on the receiving device by fastening the workpiece carrier to the receiving device.In this case, it can be provided that the rotation of the receiving device about its longitudinal axis is transmitted to the workpiece carrier so that the latter rotates about a longitudinal axis of the workpiece carrier, wherein in turn the rotation of the workpiece carrier is transmitted to the winding carrier in order to achieve a rotation of the winding carrier, in particular as part of a winding movement.
[0021] For each of the winding devices, the respective drive system can be configured to move the wire feed device relative to the receiving device in accordance with the winding movement in a first direction, which runs parallel to the longitudinal axis of the receiving device, and in a second direction, which runs perpendicular to the longitudinal axis of the receiving device and through the longitudinal axis of the receiving device. Thus, with respect to a winding carrier received on the receiving device, the movement in the first direction provides an axial movement, and the second movement provides a radial movement.
[0022] The movement of the winding devices in the respective second direction can in particular serve to advance the respective wire feed device to a winding carrier received on the receiving device, for example into a gap between teeth of the winding carrier. The movement of the winding devices in the respective first direction can in particular serve to move the respective wire feed device along and / or through a gap between teeth of a winding carrier received on the receiving device. By means of the rotation of the receiving device, a resulting rotation of a winding carrier received on the receiving device can cause a relative movement of the winding devices, in particular the wire feed device of the winding devices,to the winding carrier in the tangential direction of the winding carrier. By combining the rotation of the receiving device with a movement of a winding device, in particular the wire feed device of the winding device, a relative movement of the winding device to a winding carrier received on the receiving device in the circumferential direction of the winding carrier can be provided. For each of the winding devices, a winding movement can be realized with respect to a tooth to be wound on a winding carrier received on the receiving device, in which the wire feed device of the winding device, preferably designed according to the needle winding technology known as such, is introduced into a space between the tooth to be wound and an adjacent tooth of the winding carrier, is guided through the space in the axially parallel direction of the winding carrier,until the wire feed device emerges from the intermediate space in the axially parallel direction of the winding support, then - at least partially in the tangential direction and / or circumferential direction of the winding support - is guided around one end of the tooth to be wound, then is introduced in the axially parallel direction of the winding support into a further intermediate space between the tooth to be wound and another adjacent tooth opposite the adjacent tooth, is guided in the axially parallel direction of the winding support through the further intermediate space until it emerges from the further intermediate space,is guided at least partially in the tangential direction and / or circumferential direction of the winding carrier around an opposite end of the tooth to be wound and is then reinserted in the axially parallel direction of the winding carrier into the space between the tooth to be wound and the adjacent tooth of the winding carrier. Wire is then fed by the wire feed device so that the wire is wound around the tooth to be wound, with each repetition of the described winding movement placing a single coil turn around the tooth to be wound.
[0023] Each, individual, or one of the winding devices can be movable in a third direction, which runs perpendicular to the first direction and perpendicular to the second direction. Thus, with respect to a winding carrier received on the receiving device, a tangential movement is provided with the movement in the third direction. In a preferred embodiment, the movement in the third direction is not part of the winding movement. In such or other embodiments, the movement in the third direction can serve to advance the respective wire feed device to or into a winding carrier received on the receiving device, optionally in conjunction with movements in other directions. Alternatively or additionally, the movement in the third direction, optionally in conjunction with movements in other directions, can serve to start winding at a contact point on the winding carrier.During such a winding process, it can be provided that a free end of a winding wire is guided to a predetermined contact point, in particular a receptacle provided for this purpose, on the winding carrier and fixed there. The contact point can be designed to electrically contact the winding wire via the contact point, in particular from outside the winding carrier and / or for establishing electrical connections between winding wires arranged on the winding carrier, in particular winding wires of different windings. Following such a winding movement and the fixing of the winding wire at the contact point, the wire feed device can then be brought into a position from which the winding movement begins. In embodiments, the movement in the third direction can be part of the winding movement, in particular as an alternative or in addition to a rotation of the receiving device.
[0024] Alternatively or in addition to a third direction, each, individual, or one of the winding devices can be movable in a fourth direction, which extends along a circular arc around the longitudinal axis and thus in the circumferential direction with respect to a winding support received on the receiving device. The movement in the fourth direction can be provided as part of the winding movement and / or independently of the winding movement, in particular as a feed movement and / or start-up movement.
[0025] The movement in the fourth direction can be provided as an alternative to the movement in the second direction. In this case, the respective wire feed device can be advanced into a space between teeth of a winding carrier held on the receiving device in a direction parallel to the winding carrier's axis.
[0026] For each of the winding devices, the drive system can be configured to pivot the wire feed device about a pivot axis that runs perpendicular to and spaced from the longitudinal axis of the receiving device. Thus, the pivot axis runs tangentially to a winding carrier received on the receiving device. In particular, a wire feed device configured according to a needle winding technique can be pivoted about the pivot axis as part of a winding movement and / or as part of a feed movement and / or starting winding movement.
[0027] Each, individual, or one of the winding devices can have a stripping device configured to remove insulation from the winding wire. The stripping device is preferably configured to remove insulation from the winding wire in a targeted manner in sections, particularly at ends of the winding wire, in order to enable or simplify electrical contact. The stripping device can be configured to remove insulation from the winding wire during a feed movement and / or while the winding wire is at a standstill. The stripping device can remove the insulation abrasively, by means of one or more milling devices, thermally, particularly by means of a heating device, and / or in another way. Abrasive removal of the insulation can be achieved, for example, by means of rotating blades of the stripping device, for example three or four blades arranged around the wire to be fed.For example, the stripping device can be provided with rotating blades, preferably with diamond cutting edges, with a speed of 9,000 to 15,000 revolutions per minute.
[0028] Each, individual, or one of the winding devices can have a wire clamping device configured to clamp the winding wire and thus prevent movement of the winding wire along the feed direction. Preferably, the winding wire can be clamped while no winding movement is taking place, in particular while no winding carrier is accommodated on the receiving device, in order to prevent movement of the winding wire relative to the respective wire feed device along or counter to the feed direction.
[0029] In each, individual or a winding device, at least one preforming element can be provided which is movable relative to the wire feed device of the winding device and can be movable between a rest position and an engaged position, wherein the preforming element in its engaged position is able to exert a transverse force on the winding wire and thereby an elastic to plastic pre-stress which has a lasting influence on the behavior of the winding wire when it hits a winding carrier held on the holding device and during the progressive formation of a coil winding in such a way that the tendency of the laid winding wire to form bulges between bending points is fully or sufficiently partially compensated.Thus, the winding device in question can be configured for the contour-conforming laying of strand-shaped material, namely the winding wire, on non-circular support bodies, namely a tooth of a winding support received on the receiving device, wherein, in particular, the bulging of the wound winding material is minimized. In this context, the configurations described for such a winding device in document EP 2 309 626 A1 can be provided accordingly.
[0030] The receiving device can be configured to receive an externally slotted winding carrier of a traction drive, in particular a separately excited traction drive, and the winding device can be configured to form coil windings around winding teeth of an externally slotted winding carrier of a traction drive, in particular a separately excited traction drive. It is therefore provided that a winding carrier of a traction drive is arranged on the receiving device, and coil windings are wound thereon. Accordingly, the method according to the disclosure can provide for coil windings to be produced on an externally slotted winding carrier of a rotor or stator of a traction drive. According to the disclosure, a traction drive is understood to be a drive that effects the power-driven movement of a vehicle.For example, a traction drive can drive the rotation of wheels of a vehicle (passenger car, truck, motorcycle), a ship or boat drive (screw), or an aircraft drive (e.g., a propeller). In preferred embodiments, the present disclosure relates to traction drives designed as separately excited synchronous machines. For rotors of such traction drives, it is common practice in the art to wind coil windings around all teeth of a winding support of the rotor one after the other using a single wire, so that the coil windings are connected in series. According to the invention, however, several coil windings are wound in parallel, so that after the winding process has been completed, they can be connected according to the requirements of a given application.
[0031] In connection with the formation of coil windings around the winding teeth of an externally slotted winding carrier of a traction drive, embodiments can be provided in which the winding devices each have a stripping device. Targeted stripping of wire ends using the stripping devices can facilitate or improve contact between the wire ends for interconnecting the multiple coil windings. In particular, resistance welding of the wire ends for interconnecting the coil windings can be provided, which can be enabled or facilitated by targeted stripping using the stripping devices.By means of such improved contacting of the wire ends, possible sources of error in the contacting can be excluded or reduced, so that disadvantages compared to a winding of coil windings around all teeth of a winding carrier of the rotor one after the other by means of a single wire are completely or partially compensated or avoided.
[0032] For externally slotted winding supports of separately excited synchronous machines in traction drives, all windings are typically wound sequentially using a single wire. From the perspective of those skilled in the art, the simultaneous production of multiple windings is counteracted by increased costs due to the need for elements for interconnecting the windings, the risk of differences in the electrical properties of the windings due to manufacturing tolerances between different batches of nominally identical winding wire, and the increased effort required for parallel operation of multiple winding machines. Surprisingly, it was found that these disadvantages can be offset by the advantages of the winding technology according to the disclosure.Thus, using the winding technology disclosed herein, it is possible to individually implement different windings on a winding carrier, for example, with different wire diameters, different wires (material / structure), and / or different numbers of turns. Through targeted contacting and interconnection of different windings, different circuit configurations can be enabled during operation, for example, so-called star-delta connections. Furthermore, windings can be implemented as parallel circuits, with switching to a series connection during operation being provided. Thus, according to the disclosure, the production of a drive individually adapted to specific applications is possible.In particular, an advantageous effect on the driving profile of a vehicle driven by a drive produced in this way can be achieved, for example for city driving or motorway driving, and / or an efficiency of the drive can be increased.
[0033] The embodiments described above in connection with the winding device can be provided accordingly in the method for producing coil windings on an externally slotted winding carrier of a rotor or stator of an electrical machine.
[0034] In the winding system according to the disclosure, the winding machines can be arranged side by side or one above the other such that the longitudinal axes of their respective receiving devices are arranged parallel. Alternatively, an arrangement can be provided in which the longitudinal axes of the respective receiving devices lie on top of one another, i.e., an axial arrangement of the winding machines. As a further alternative, a matrix-like arrangement can be provided in which the winding machines are arranged in rows and columns. Preferably, the winding machines of the winding system are configured for simultaneous operation, so that coil windings are produced simultaneously on several winding supports, wherein preferably, in turn, several coil windings are produced simultaneously on each of the winding supports.The winding machines of the winding system can be designed identically or according to different disclosed embodiments of winding machines according to the preceding explanations.
[0035] In the following, further embodiments are described with reference to figures of a
[0036] The drawing explains this in more detail. It shows:
[0037] Fig. 1 is a schematic representation of a winding machine in isometric view;
[0038] Fig. 2 is a schematic representation of an isometric detailed view of a winding machine;
[0039] Fig. 3a is a schematic representation of a subassembly of a winding device for a winding machine;
[0040] Fig. 3b is a schematic detailed view of the subassembly from Fig. 3b with pivoted needle;
[0041] Fig. 4 is a schematic representation of a winding machine in plan view;
[0042] Fig. 5 is a schematic detailed view of a winding machine in plan view;
[0043] Fig. 6 is a schematic detailed view of a winding machine with wire feeding devices arranged in the tooth spaces of a winding carrier in plan view;
[0044] Fig. 7 is a schematic detailed representation of a winding machine in a side view;
[0045] Fig. 8 is a schematic representation of a winding machine in a sectional view;
[0046] Fig. 9 is a schematic detailed representation of a winding machine in a sectional view;
[0047] Fig. 10 is a schematic representation of a winding machine with robotic handling device in an isometric view;
[0048] Fig. 11 is a schematic detailed representation of a winding machine with robotic handling device in an isometric view;
[0049] Fig. 12 is a schematic representation of a winding machine with wire storage; and
[0050] Fig. 13 is a schematic representation of a winding system with two winding machines.
[0051] Fig. 1 shows a winding machine 1 for producing coil windings on an externally slotted winding carrier of a rotor or stator of an electrical machine. The winding machine has a receiving device 2 on which an externally slotted winding carrier 3 is arranged. In the embodiment shown, the winding carrier 3 is a winding carrier of a rotor of an electric motor that forms a traction drive for an electric vehicle. Three winding devices 4 are arranged around the receiving device, each of which serves to form coil windings on the winding carrier 3.
[0052] Fig. 2 shows a detailed view of the winding machine 1. It can be seen that the winding support 3 is formed with a plurality of teeth 5, around which coil windings are to be wound to produce a rotor. The winding devices 4 are arranged at equal spacing along a circumferential direction of the winding support 3. The winding devices 4 are configured for winding coils according to the needle winding technique known per se. For this purpose, each of the winding devices 4 has a tubular wire feed device 6 as a so-called needle.
[0053] Fig. 3a shows a detailed assembly of a winding device 4 according to the disclosure. Preforming elements 7 are arranged above and below the wire feed device 6, which in the illustrated embodiment has an oval tubular cross-section, and are movable from a rest position forward into an engaged position. In the engaged position, a preforming element 7 exerts an elastic to plastic prestress on a winding wire guided from the wire feed device 6 past the preforming element 7. This prestress influences the behavior of the winding wire upon impact with a tooth 5 of a winding support 3 and during the progressive formation of a coil winding in such a way as to preform it, such that the tendency of the laid winding wire to form bulges between bending points is fully or sufficiently partially compensated.By preventing or reducing bulges, the space between teeth 5 of a winding support 3 can be better utilized, thus increasing the winding density. The function of such preform elements 7 is described in detail in document EP 2 309 626 A1.
[0054] In Fig. 3b, the assembly from Fig. 3a is shown in a state in which the wire feed device 6 is pivoted relative to the state shown in Fig. 3a. For pivoting a section with the wire feed device 6, the assembly has a pivoting mechanism 8. The pivoting takes place in an up-down direction of the winding device, so that the pivot axis of the wire feed device 6 in the winding machine 1 runs perpendicular to and spaced from a longitudinal axis of the receiving device 2, which lies on the longitudinal or rotational axis of a winding carrier 3 received on the receiving device 2.
[0055] Fig. 4 shows a plan view of the winding machine 1, from which the uniform arrangement of winding devices 4 around the receiving device 2 and a winding carrier arranged thereon is clearly evident.
[0056] As can be seen, for example, in Fig. 1, each winding device 4 has a drive system, which in the illustrated embodiment is formed with several drives 9 in the form of electric motors and corresponding motion transmission mechanisms. By means of the drive system, each winding device 4 is movable relative to a winding carrier 3 arranged on the receiving device 2 in the axial direction, radial direction, and parallel to a tangential direction of the winding carrier 3. The receiving device 2 has a rotation drive 10, by means of which the receiving device 2 with a winding carrier 3 received thereon can be rotated about the longitudinal axis of the receiving device 2 and thus a rotation axis of the winding carrier 3. By means of this movement, the winding of the winding carrier 3 according to a respective winding movement of the winding devices 4 is possible.
[0057] The following describes the winding for one of the winding devices 4. The explanations apply accordingly to the winding movements of the other winding devices 4, in particular to simultaneous winding movements of all winding devices 4. For this purpose, the wire feed device 6 is first advanced towards the winding carrier 3. This can be seen in particular in Fig. 5 and 6, wherein Fig. 5 shows the winding machine 1 before the wire feed device 6 is advanced and Fig. 5 shows the winding machine 1 after the wire feed device 6 has been advanced. The advance takes place such that the wire feed device 6 is arranged in a space 11 between two teeth 5 of the winding carrier 3. The advance can take place directly into the winding carrier 3 between the teeth 5 or such that the wire feed device 6 is arranged between the teeth 5 in plan view, but above or below the winding carrier 3.During the delivery, a fine adjustment to the intermediate space 11 can be achieved in particular by means of a movement of the winding device parallel to a tangential direction of the winding carrier 3.
[0058] After the feed, the wire feed device 6 is guided around one of the teeth 5 of the winding carrier 3, with a winding wire being released from the wire feed device by means of a feed movement, so that the wire wraps around the respective tooth 5 and thus forms coil windings. The wire feed device 6 is guided in the axial direction through a gap 11. As the wire feed device 6 emerges upwards or downwards from the gap 11, the winding carrier 3 begins to rotate by means of the rotary drive 10 of the receiving device 2 until the wire feed device 6 is arranged above or below the other gap 11 adjacent to the respective tooth 5. By superimposing the axial movement of the wire feed device 6 and the rotation of the winding carrier 3, the wire feed device 6 follows a circular segment-shaped movement path and (rounded) corners of the respective tooth 5.In alternative embodiments, the superposition of the axial movement of the wire feed device 6 and the rotation of the winding carrier 3 can also provide a movement path with a shape other than a circular segment, for example, with an elliptical shape or according to a functional equation. The wire feed device 6 is then guided axially through the other gap 11 and, by rotating the receiving device 2 with the winding carrier 3, is returned to the first-mentioned gap. By repeating this winding movement, coil windings are placed around the tooth 5. In Fig. 6, coil windings already wound around the teeth 5 of the winding carrier 3 can be seen.
[0059] In the embodiments of Figures 1 and 2, it can be seen that a slanted-slotted winding carrier 3 is received on the receiving device 2. For this reason, the winding carrier 3 is additionally rotated by means of the rotary drive 10 during the axial movement of the wire feed device 6 through the relevant slot 11, so that the wire feed device 6 follows the slanted slot path. With straight-slotted winding carriers, this rotation can be omitted. In embodiments, the rotation for advancing to a different gap 11 can only take place after the wire feed device 6 has completely emerged from the gap 11 and without temporal overlap, so that the movement path of the wire feed device 6 has a corner. Such embodiments can be provided, for example, in the case of non-rounded tooth edges, or when movement along a rounded path is unnecessary for other reasons.
[0060] In embodiments in which the winding devices 4 are formed with a respective pivoting mechanism 8 for pivoting the wire feed device 6, the winding movement can be modified and thereby optimized by means of the pivoting movement.
[0061] Because each of the winding devices 4 has its own drive system, they can carry out the winding movement, with the exception of the rotation of the receiving device 2, autonomously from the other winding devices 4.
[0062] The receiving device 2 has a workpiece carrier 12 on which a winding carrier 3 is initially received. For this purpose, the workpiece carrier 12 can be separable from the receiving device 2 or the winding carrier is arranged directly on the receiving device 2 on the workpiece carrier 12. Before winding begins, a receiving shaft 13 of the receiving device 2 is guided through a central bore in the winding carrier 3 and the winding carrier 3 is lifted out of the workpiece carrier 12 by means of a shoulder of the receiving shaft 13. During winding, the receiving shaft 13 is driven and rotated by the rotary drive 10, thereby causing the winding carrier 3 to rotate. The winding carrier 3 is received on the receiving shaft 13, preventing relative rotation between the receiving shaft 13 and the winding carrier 3. The receiving shaft can have a clamping device for fixing the winding carrier 3.Winding supports that are already formed or connected to a shaft can also be provided. In this case, the shaft of the winding support can be received at its outer diameter on the receiving device 2, for example, in a clamping device.
[0063] Fig. 7 shows a detailed side view of winding machine 1. Fig. 8 shows a sectional side view. Fig. 9 is a detailed sectional side view of winding machine 1.
[0064] Fig. 10 shows another winding machine 1. Compared to the winding machine 1 shown in Fig. 1, the winding machine according to Fig. 10 has a robot arm 14 on which a handling device 15 for wire ends is arranged. Fig. 11 shows a detailed view in which the arrangement of the handling device 15 on a winding carrier 3 received on the receiving device 2 can be seen.
[0065] By means of the handling device 15, a starting end of a winding wire of a partial winding is fixed to a contact point of the winding carrier 3 so that the winding process can begin with the necessary mechanical wire pulling. The contact point is an electrical contact point into which the preferably stripped wire is inserted. After the wire has been inserted into the contact point with the aid of the winding device 4, the handling device 15 is used to crimp the contact point in order to mechanically fix the wire in the contact point. Any remaining wire protrusion from the contact point on the side not leading to the coil is then gripped and severed by the handling device 15. Only then do the wire feeding and winding process begin. In the embodiment shown, the winding machine 1 has only one robot arm 14 with handling device 15.For this reason, the fixing process runs sequentially for the number of winding devices 4. This also applies to the mechanical fixing of the terminal end of a wire of a partial winding, only in reverse. The winding device 4 places the terminal end into a corresponding contact point. The contact point is then crimped or crimped using the handling device 15, so that the wire is mechanically fixed. The connecting wire between the contact point and the wire feed device 6 is then severed on the side not leading to the coil using the handling device 15. The winding process for this partial coil is thus completed. This process also runs sequentially for the number of winding devices 4.
[0066] It can be designed to insert the starting end into the contact element without any significant overhang and then crimp the contact element. This allows the winding process to begin immediately, without first having to grasp a wire end with the robot unit, cut a wire, and discard it. This can provide a wire-loss-free process in which no wire sections are cut and discarded.
[0067] The functions of the handling device 15 described above, in particular in accordance with a wire-loss-free operation, can be provided in various embodiments of a winding machine according to the disclosure, in particular also in embodiments other than those illustrated in the figures. In this case, the functions can also be provided in a manner other than by means of the described handling device 15, in particular by means of corresponding alternative devices, for example, by means of a corresponding handling device for each of the winding devices 4.
[0068] The winding device 4 with the assembly shown in Figures 3a and 3b has a stripping device 16, by means of which the insulation of the winding wire used can be removed. In particular, the insulation at the starting and ending ends of the winding wire is removed by means of the stripping device 16 in order to enable or facilitate contacting of the coil windings, for example, via the contact points described above. Furthermore, the winding device according to Figures 3a and 3b has a wire clamping device 17, by means of which the winding wire can be clamped to prevent movement of the wire along or against a feed direction.In particular, it can be provided to clamp the winding wire when no winding movement takes place and to release the wire by the wire clamping device 17 only when the starting end of the wire is clamped in the contact point, as well as to clamp the wire by means of the wire clamping device 17 before the wire is severed after the terminal end has been fixed in the contact point.
[0069] Fig. 12 shows a winding machine 1 with wire stores 18 in the form of wire reels, from which a respective winding wire is fed to a winding device 4, which is wound around a tooth 5 of a winding carrier 3 by means of the respective winding device 4. A winding system 19 according to the disclosure is shown in Fig. 13. The winding system is formed with two winding machines 1, which are arranged relative to one another such that the longitudinal axes of the receiving devices 2 and thus the axes of rotation of the winding carriers 3 received thereon are aligned parallel. Thus, in the winding system 19, coil windings can be produced on two winding carriers 3 in parallel, with coil windings being produced simultaneously on several teeth 5 on each of the winding carriers 3.
[0070] The features disclosed in the above description, the claims and the drawings may be important for the realization of the various embodiments both individually and in any combination.
Claims
Claims 1. Winding machine (1) for producing coil windings on an externally slotted winding carrier (3) of a rotor or stator of an electrical machine, with - a receiving device (2) for receiving an externally slotted winding carrier (3), wherein the receiving device (2) has a longitudinal axis which, in a state in which an externally slotted winding carrier (3) is received on the receiving device (2), lies on a longitudinal axis of the externally slotted winding carrier (3); and - a plurality of winding devices (4) arranged around the receiving device (2), wherein - each of the winding devices (4) has a wire feed device (6) which is designed to move a winding wire along a feed direction and thus to guide it towards the receiving device (2); - each of the winding devices (4) has a drive system which is designed to move the wire feed device (4) relative to the receiving device (2) and independently of the wire feed devices of the other winding devices (4) during a feed movement of the winding wire according to a winding movement such that the winding wire is wound around a winding tooth (5) of an externally grooved winding carrier (3) received on the receiving device (2) to form a coil winding; and - the receiving device (2) has a rotary drive (10) by means of which the receiving device (2) is rotatable about its longitudinal axis and which is designed to rotate the receiving device (2) according to the winding movement in such a way that the respective winding wire is wound around the respective winding tooth (5) of the externally grooved winding carrier (3) received on the receiving device (2) to form a respective coil winding.
2. Winding machine (1) according to claim 1, wherein the winding machine (1) has at least three winding devices (4).
3. Winding machine according to claim 1 or 2, wherein the winding devices (4) are arranged distributed uniformly around the receiving device (2) with respect to the circumference of a winding carrier (3) to be arranged in the receiving device (2).
4. Winding machine (1) according to at least one of the preceding claims, wherein the receiving device (2) has a workpiece carrier (12) which is designed to receive an externally grooved winding carrier (3) and is detachably arranged in the winding machine (1) in order to enable transport of an externally grooved winding carrier (3) received on the workpiece carrier (12) to and from the winding machine (1).
5. Winding machine (1) according to at least one of the preceding claims, wherein for each of the winding devices (4) the drive system is arranged to move the wire feed device (6) according to the winding movement relative to the receiving device (2) - to move in a first direction which is parallel to the longitudinal axis of the receiving device (2); and - to move in a second direction which is perpendicular to the longitudinal axis of the receiving device (2) and through the longitudinal axis of the receiving device (2).
6. Winding machine (1) according to at least one of the preceding claims, wherein each of the winding devices (4) is movable in a third direction which is perpendicular to the first direction and perpendicular to the second direction.
7. Winding machine (1) according to at least one of the preceding claims, wherein for each of the winding devices (4) the drive system is arranged to pivot the wire feed device (6) about a pivot axis which runs perpendicular to and spaced from the longitudinal axis of the receiving device (2).
8. Winding machine (1) according to at least one of the preceding claims, wherein each of the winding devices (4) has a stripping device which is configured to remove insulation from the winding wire.
9. Winding machine (1) according to at least one of the preceding claims, wherein each of the winding devices (4) has a wire clamping device which is designed to clamp the winding wire and thus prevent movement of the winding wire along the feed direction.
10. Winding machine (1) according to at least one of the preceding claims, wherein in each winding device (4) at least one relative to the wire feed device (6) of the A preforming element (7) movable in the winding device (4) is provided and is movable between a rest position and an engaged position, wherein the preforming element (7) in its engaged position is capable of exerting a transverse force on the winding wire and thereby an elastic to plastic pre-stress, which has a lasting influence on the behavior of the winding wire when it strikes a winding carrier (3) received on the receiving device (2) and during the progressive formation of a coil winding, such that the tendency of the laid winding wire to form bulges between bending points is fully or sufficiently partially compensated.
11. Winding machine (1) according to at least one of the preceding claims, wherein the receiving device (2) is designed to receive an externally slotted winding carrier (3) of a traction drive and the winding devices (4) are each designed to form coil windings around winding teeth of an externally slotted winding carrier (3) of a traction drive.
12. Winding system (17) with a plurality of winding machines (1) according to at least one of the preceding claims, wherein the winding machines (1) are configured for the parallel production of coil windings on a respective externally slotted winding carrier (3) of a rotor or stator of an electrical machine in the winding system (17).
13. Method for producing coil windings on an externally slotted winding carrier (3) of a rotor or stator of an electrical machine, comprising the steps - receiving an externally slotted winding carrier (3) on a receiving device (2) of a winding machine (1) such that a longitudinal axis of the receiving device (2) lies on a longitudinal axis of the externally slotted winding carrier (3); and - simultaneous formation of a plurality of coil windings around a respective winding tooth (5) of the externally grooved winding carrier (3) by means of a plurality of winding devices (4) of the winding machine (1) arranged around the receiving device (2), wherein for the formation of a respective coil winding by means of a respective winding device (4) - by means of a wire feed device (6) of the respective winding device (4), a winding wire is moved along a feed direction and thus fed to the respective winding tooth (5), - during the advance movement of the winding wire, the wire feed device (6) of the respective winding device (4) is moved by means of a drive system of the respective winding device (4) relative to the respective winding tooth (5) and independently of the wire feed devices (6) of the other winding devices (4) according to a winding movement and is thus wound around the respective winding tooth (5), and - the externally slotted winding carrier (3) is rotated by means of a rotation drive (10) of the receiving device (2) according to the winding movement such that the respective winding wire is wound around the respective winding tooth (5) of the externally slotted winding carrier to form the respective coil winding.
14. The method according to claim 13, wherein coil windings are produced on an externally slotted winding carrier (3) of a rotor or stator of a traction drive.