Method for producing a wire packet for use in a wave winding mat, wire packet for use in a wave winding mat and device for producing a wire packet formed from at least one first bent wire blank and at least one second bent wire blank
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-04-18
- Publication Date
- 2026-03-18
AI Technical Summary
Existing methods for producing wire packages for wave winding mats fail to achieve electromagnetic symmetry, which is crucial for building electromagnetically symmetrical electrical machines, and often require welded connections that complicate processing.
A method involving at least a first wire blank bent into a bow shape and a second wire blank bent into a bow shape, where the second wire section is offset and inserted into a loop formed in the transition section of the first wire blank, allowing for symmetrical winding patterns and avoiding changes in wire thickness, enabling continuous processing without welded connections.
This approach results in a wire package that allows for symmetrical winding patterns, reducing asymmetries and instabilities, and facilitates the production of electromagnetically symmetrical wave winding mats with reduced processing complexity.
Smart Images
Figure DE2024100336_14112024_PF_FP_ABST
Abstract
Description
[0001] Method for producing a wire package for use in a wave winding mat, wire package for use in a wave winding mat and device for producing a wire package formed from at least one first bow-shaped bent wire blank and at least one second bow-shaped bent wire blank
[0002] The present invention relates to a method for producing a wire package for use in a wave winding mat, a wire package for use in a wave winding mat and a device for producing a wire package formed from at least one first bow-shaped bent wire blank and at least one second bow-shaped bent wire blank.
[0003] Wire packages, consisting of bow-shaped bent wire blanks, can be used to manufacture wave winding mats. These are used in the rotors or stators of electric motors. Wave winding mats, as a form of coil winding, can be produced by winding individual wires in wire packages around a winding template. If the individual wires have a rectangular cross-section, they are referred to as flat wire windings. This process results in a flat, wave-shaped coil winding, also known as a wave winding, which has roof-shaped winding heads arranged between two straight wire webs along the individual wires of the wave winding.When inserted into a rotor or stator with a cylindrical rotor or stator body, the wave winding with the superimposed individual wires is drawn into slots in the area of the webs, and the winding heads protrude axially beyond the rotor or stator body and form the offset of the individual wires across various slots. Coil windings produced in this way allow coils from multiple electrical circuits to be inserted into a stator or rotor body at once, enabling, for example, three-phase operation of an electric motor. Therefore, the wire packages used preferably have a number of individual wires that is a multiple of three. However, other configurations are also conceivable. It is also conceivable that the manufactured wave winding is not drawn directly into a rotor or stator, but first into a drawing-in tool, which ultimately transfers the wave winding into a rotor or stator body.For the purpose of simplifying processing, it is advantageous if the wire blanks can be processed continuously, and in particular, connecting sections by welds can be avoided. DE 102021 104217 B4 discloses a method for producing at least one bow-shaped wire blank, which allows bow-shaped wire blanks to be manufactured in a space-saving manner. However, this method does not allow for a winding with a layer exchange of the wires, which is required to construct an electrical machine that is as electromagnetically symmetrical as possible.
[0004] It is therefore an object of the present invention to provide a method for producing a wire package for use in a wave winding mat, a wire package for use in a wave winding mat and a device for producing a wire package formed from at least one first bow-shaped bent wire blank and at least one second bow-shaped bent wire blank, which does not have the disadvantages mentioned above.
[0005] This problem is solved by the subject matter of the independent patent claims.
[0006] Advantageous embodiments and further developments are the subject of the dependent claims, the enclosed description and the figures.
[0007] According to one aspect of the invention, a method is provided for producing at least one first bow-shaped bent wire blank and at least one second bow-shaped bent wire blank. Both the first and the second wire blank comprise a first wire section and a second wire section. The second wire section runs parallel to the first wire section. The first wire blank also has a bent transition section located between the first and the second wire section. The second wire section has a bent intermediate section located between the first and the second wire section. The method sequence begins with the provision of at least one first wire from a wire supply. This wire supply can, for example, be provided in the form of a large roll.The first wire is drawn from the wire stock in a withdrawal direction at least the length of the transition section and the second wire section. The first wire is straightened in the process. This is important for the later arrangement of the individual wires in a wave winding mat in order to ensure a symmetrical winding pattern. Asymmetries could lead to undesirable effects in the magnetic field, which must be avoided. A loop is then formed in the area between the first and second wire sections. This type of material reserve can prevent the wire thickness from being changed when the first wire is later relocated and shifted. The loop also provides space for the second wire to be inserted flush. The second wire section is then offset in an offset plane parallel to the withdrawal direction.This forms the transition section between two later bending points between the first and second wire sections. In a preferred embodiment, the offset position is offset from the original position by two wire positions. The loop is now located within the transition section between the first and second wire sections. In the following step, at least a second wire is prepared from the wire supply. Like the first wire, this is also pulled out in the pull-out direction at least to the length of the second wire section, with the wire being straightened during withdrawal. The second wire is then guided through the loop of the first wire, with the second wire being arranged in a wire position between the first wire section of the first wire and the second wire section of the first wire.The free wire position created by the displacement of the second wire section of the first wire is thereby occupied by the second wire.
[0008] In a preferred embodiment, the first wire with its second wire section is offset by two wire positions, which means that there is an unoccupied wire position between the first and second wire sections, in which only the intermediate section is located. The loop is also arranged in the intermediate section. The second wire can now be inserted into the loop in the free wire position between the first and second wire sections of the first wire or guided through this loop. The second wire sections of both wires are then bent about a bending axis. The bending takes place in the transition section of the first wire and in the intermediate section of the second wire. The bending axis lies in the offset plane and perpendicular to the pull-out direction. The second wire section of each wire is rolled about an axis parallel to the bending axis during the pull-out process and remains rolled during the offset and bending process.The length of the second wire section can be determined individually for each wire package to be produced. The longer this second wire section, the more base material will be available for winding the wave winding mat.
[0009] When shifting the wire positions, in a preferred embodiment, the movement in the offset plane and along a circular path of the two wire sections towards each other ("shifting") prevents tensile or compressive forces from acting on the wire. A change in the wire thickness, which could result in instabilities occurring at the affected points, can thus be avoided. The loop provided in the transition area ensures that there is sufficient wire in the transition area to prevent pulling and thinning. The process can be repeated with as many wires as required to obtain a wire package that has the correct basic dimensions for a planned wave winding mat.
[0010] Preferably, several first and second wires are used to produce a wire package. It can be varied whether all required first wires are first arranged in the device and then the second wires are added, or whether a first and a second wire are inserted alternately.
[0011] The wire package produced using this process now has two layers of wires. The winding heads of the first wire blanks overlap the winding heads of the second wire blanks, forming two "roof rows," one consisting of winding heads from the first wire blanks and a second consisting of those from the second wire blanks.
[0012] It is also possible to perform a different rhythm instead of changing the position by two wire positions, resulting in a different pattern. As long as this pattern is symmetrical overall in the wire packages and is a recurring pattern in the wave winding mat, individual adjustments can be made for different wire position changes.
[0013] According to a further embodiment of the invention, the first wire and the second wire are each cut after the required wire length for the wire blank has been drawn off. This creates individual wires arranged side by side. This arrangement, in combination with the coiled second wire sections in the second wire storage unit, allows the process to be carried out in a space-saving manner. Furthermore, the entire process can be carried out using a single wire supply that provides all the required wire.
[0014] According to a further embodiment of the invention, after the offsetting and bending, the wire of the second wire section is unwound and straightened so that the second wire section runs parallel to the first wire section over its length. In a preferred embodiment, the second wire section is many times longer than the first wire section. This is advantageous for using the wire blank for winding a wave winding. The beginning is then formed by the first wire section and the second wire section is then continuously wound using a winding device so that it becomes part of a wave winding mat. According to a further aspect of the invention, a wire package for use in a wave winding mat is provided. This comprises at least one first and at least one second wire blank. The wave winding mat can be produced from the wire package by continuous winding.The advantage of this design is that only one side of a wave winding mat has wire ends that protrude, which then need to be welded, connected, and insulated. Only the beginning of the mat is preformed by bending the wire blanks. It can then be transferred to a winding device, where the excess wire stacks are wound into a wave winding mat.
[0015] In a preferred embodiment, the wire package of both wire blanks comprises a multiple of three, for example 9 or 12 first and second wire blanks each, since this brings electromagnetic advantages during later use in an electric motor.
[0016] According to a further aspect of the invention, a device is provided for producing a wire package formed from at least one first, bow-shaped, bent wire blank and at least one second, bow-shaped bent wire blank. This device has a wire supply for feeding at least one first wire and at least one second wire in a pull-out direction. Furthermore, it has a first straightening device, arranged downstream of the wire supply in the pull-out direction, for straightening the fed wires, which ensures that the wires are all uniformly straightened. The device also comprises a first wire storage device, in which a first wire section of the first wire and a first wire section of the second wire are received, and a shifting and bending device in which a transition section of the first wire and an intermediate section of the second wire are located.A forming device serves to form a loop of the first wire when it is placed in the displacing and bending device. The forming device can be designed, for example, as a forming roller. The forming of the transition section of the first wire can be carried out by means of the device before the second wire is fed in, so that the forming of the loop and the displacing of the second wire section, whereby the transition section is formed, are completed before the second wire is introduced. The device also comprises a second wire storage device in which a second wire section of the first wire and a second wire section of the second wire are received. This second wire storage device is designed as a ring storage device in which the second wire sections can be wound.
[0017] According to a further embodiment of the invention, the transfer and bending device comprises a first clamp for securing the first wire section and a second clamp for securing the second wire section. The second clamp is pivotable about a pivot axis perpendicular to the extension direction and located between the clamps and is displaceable parallel to the pivot axis. The second wire storage device is pivotable about the pivot axis together with the clamp. By designing the transfer and bending device with two clamps, the transition section between two bending points can be precisely formed.
[0018] According to a further embodiment of the invention, the transferring and bending device comprises a bending blade movable perpendicular to the extension direction, around which the second clamp of the transferring and bending device pivots. This allows the wire blanks to be bent to precisely defined dimensions when bent along a bending edge of the bending shear. This is advantageous for obtaining a symmetrically constructed wire package whose bending points are all uniformly bent and formed.
[0019] According to a further embodiment of the invention, the displacing and bending device is suitable for releasably fixing the first wires by means of the clamps during the forming of the loop with the forming device and the displacing, and for temporarily opening the clamps afterwards for pulling in the second wires. This means that the displacing and bending device can be used for multiple processes. First, it is used to form the first wire and then to receive and form the second wire. It is conceivable to open and close the clamps alternately in order to pull in the second wire step by step, but it is also possible to open and close both clamps simultaneously. It can be advantageous to provide grooves on the clamps so that the position of the wires is secured even further than just by clamping.
[0020] According to a further embodiment of the invention, the second wire storage device is linearly movable counter to the withdrawal direction for removing the second wire section stored therein, wherein a second straightening device is provided for the second wire storage device for straightening the second wire section removed from the second wire storage device. This serves the final production of the wire blanks, since the second wire sections, which are still rolled, are then drawn out and straightened and arranged in their final position parallel to the first wire sections. Further features, details, and advantages of the invention emerge from the wording of the claims and from the following description of exemplary embodiments based on the drawings.
[0021] They show:
[0022] Figure 1a,b: A schematic representation of the configuration of several first wires running parallel to one another in a device after withdrawal from a wire supply in a side view and a top view;
[0023] Figure 2: A schematic representation of the transferring and bending device after the transferring step in a plan view;
[0024] Figure 3: A schematic representation of the transfer and bending device after the insertion step in a plan view;
[0025] Figure 4: A schematic representation of the transfer and bending device after the bending step in a side view;
[0026] Figure 5: A schematic representation of the transfer and bending device after the production of several parallel first and second bow-shaped wire blanks in a side view; and
[0027] Figure 6: A schematic representation of a wire package.
[0028] Figures 1a and 1b show a schematic representation of the configuration of several parallel first wires 8 in a device after being drawn from a wire supply 10, in a side view and a top view. The first wire 8 is drawn and unwound from the wire supply 10 in a drawing direction A with the aid of a feed unit 25. It is straightened by means of a first straightening device 15. This is important for later achieving a uniform shape in the wire package 1.
[0029] The first wire 8 comprises a first wire section 4 and a second wire section 5, between which a transition section 6 lies. The second wire section 5 is wound into a second wire storage device 19 to the desired final length when the first wire 8 is pulled out. The wire 8 is guided through a transfer and bending device 17, where a loop 11 is formed in the transition section 6 by means of a forming device 18.
[0030] Once this process is complete, the first wire 8 can be cut using scissors 26. The process is then repeated a desired number of times, with each subsequent first wire 8 being pulled into a first wire storage 16, offset by two wire positions, parallel to the others, so that gaps are created between the individual wires 8. The first wires 8 are held in the offsetting and bending device between a first clamp 20 and a second clamp 21. This ensures that the predetermined wire position is maintained. This is particularly important for the process of forming the loop 11, which is carried out between the clamps 20, 21.
[0031] Figure 2 shows a schematic representation of the offsetting and bending device 17 after the offsetting step in a plan view. The first clamp 21 holds the first wire section 4, while the second clamp 20 holds the second wire section 5 of the first wires 8. The clamps 20 are displaced in an offset plane such that the second wire section 5 of the first wires 8 is arranged perpendicular to the withdrawal direction A by two wire positions from its corresponding first wire section 4. The clamp 20 can also be moved simultaneously against the withdrawal direction A, so that a circular movement is performed. This prevents a change in the wire thickness during the offsetting process. It is also conceivable for both clamps 20, 21 to be displaced. The offsetting also leads to the formation of bending points 12 that delimit the transition section 6.However, it is also possible to skip more than two wire positions to create other patterns. The second wire section 5 remains coiled in the second wire storage 19. This saves space when performing the process compared to uncoiled wires.
[0032] Figure 3 shows a schematic top view of the shifting and bending device after the insertion step. After the first wires 8 have been arranged as shown in Figure 2, the second wires 9 are pulled out and inserted. For this purpose, a second wire 9 is pulled one after the other from the wire supply 10. As with the first wires 8, this is done by means of the feed unit 25. The second wire 9 is also straightened by means of the first straightening device 15. The second wire 9 is guided through the loop 11 into the free wire position between the first wire section 4 and the second wire section 5 of the first wire 8. As a result, the intermediate section 7 of the second wire lies on the transition section 6 of the first wire 8. The first wire sections 4, 4' of the first and second wires 8, 9 are held in the first wire storage 16, and the second wire sections 5, 5' are held in the second wire storage 19.The clamps 20, 21 of the transfer and bending device 17 are subsequently suitable for securing the second wire 9. Once the second wire 9 has been drawn to the desired length and arranged in the device, it can be cut from the wire supply 10 using the scissors 26.
[0033] Figure 4 shows a schematic side view of the transfer and bending device 17 after the bending step. The first clamp 20 has been pivoted 180° counter to the extension direction A and is now positioned opposite the second clamp 21. As a result, the first and second wires 8, 9 secured in the transfer and bending device 17 are bent together in the region of their transition or intermediate sections 6, 7. The first wire sections 4, 4' are now positioned opposite the second wire sections 5, 5', which are still coiled in the second wire storage 19.
[0034] Figure 5 shows a schematic side view of the shifting and bending device 17 after the production of several first and second bow-shaped wire blanks 2, 3 running parallel to one another. The second wire storage 10 has been transferred to a linearly movable carriage 27. A second straightening device 24 is arranged on this carriage. The second wire storage 19 is moved by means of the carriage 27 counter to the withdrawal direction A, whereby the rolled-up second wire sections 5, 5' are unwound and also straightened by the second straightening device 24. If the clamps 20, 21 of the shifting and bending device 17 are now released, the finished wire blanks 2, 3, now present in a wire package 1, can be removed. The wire package 1, which is shown schematically in Figure 6, can then be further processed or stored.The first and second wire blanks 2, 3 each have winding heads 28 created by the bending process. It can be seen that the second wire blanks 3 are offset from the first wire blanks 2, and the winding heads 28 of the first wire blanks 2 are arranged above those of the second wire blanks 3. This arrangement is electromagnetically symmetrical and advantageous for later use as a wave winding mat.
[0035] - IQ -
[0036] List of reference symbols
[0037] 1 wire package
[0038] 2 First wire blank
[0039] 3 Second wire blank
[0040] 4, 4' First wire section
[0041] 5.5' Second wire section
[0042] 6 Transition section
[0043] 7 Intermediate section
[0044] 8 First wire
[0045] 9 Second wire
[0046] 10 wire stock
[0047] 11 loop
[0048] 12 bending points
[0049] 15 first straightening device
[0050] 16 First wire storage
[0051] 17 Transfer and bending device
[0052] 18 Molding device
[0053] 19 Second wire storage
[0054] 20 First clamp
[0055] 21 Second terminal
[0056] 24 second straightening device
[0057] 25 Feed unit 26 Scissors
[0058] 27 sleds
[0059] 28 winding head
[0060] A Extension direction
Claims
Patent claims 1. A method for producing a wire package (1) for use in a wave winding mat, which is formed from at least one first bow-shaped bent wire blank (2) and at least one second bow-shaped bent wire blank (3), wherein both wire blanks (2, 3) comprise a first wire section (4, 4') and a second wire section (5, 5') running parallel to the first wire section (4, 4'), wherein the first wire blank (2) comprises a bent transition section (6) between the first wire section (4) and the second wire section (5), and wherein the second wire blank (3) comprises a bent intermediate section (7) between the first wire section (4') and the second wire section (5'), comprising the method steps: • Providing at least one first wire (8) from a wire supply (10); • Pulling off the first wire (8) at least in the length of the transition section (6) and the second wire section (5) in a withdrawal direction (A), wherein the first wire (8) is straightened during withdrawal; • forming a loop (11) in the area between the first wire section (4) and the second wire section (5); • offsetting the second wire section (5) parallel to the pull-out direction (A) in an offset plane by at least two wire positions, whereby the transition section (6) is formed between two bending points (12) between the first wire section (4) and second wire section (5), wherein the loop (11) extends in the region of the transition section (6); • Providing at least one second wire (9) from the wire supply (10); • Pulling off the second wire (9) at least in the length of the second wire section (5') in the pull-out direction (A), wherein the second wire (9) is straightened during pulling off; • Inserting the second wire (9) into or guiding it through the loop (11) of the first wire (8), wherein the second wire (9) is arranged in a wire position between the first wire section (4) of the first wire (8) and the second wire section (5) of the first wire (8); • Bending the second wire sections (5, 5') about a bending axis, wherein the bending takes place in the transition section (6) of the first wire (8) and in the intermediate section (7) of the second wire (9) and the bending axis lies in the offset plane and perpendicular to the pull-out direction (A); wherein the second wire section (5, 5') is rolled about an axis parallel to the bending axis during withdrawal and remains rolled during displacement and bending.
2. The method according to claim 2, comprising the step of: • Cutting the wires (8,9) after removing the wire length required for the first and second wire blanks (2,3).
3. Method according to one of the preceding claims, wherein after the wires (8, 9) have been displaced and bent, the second wire sections (5, 5') are unrolled and straightened so that the second wire sections (5, 5') run parallel to the first wire sections (4, 4') over their length.
4. Wire package (1) for use in a wave winding mat, which can be produced by the method according to one of claims 1 to 3.
5. Device for producing a wire package (1) formed from at least one first bow-shaped bent wire blank (2) and at least one second bow-shaped bent wire blank (2), comprising • a wire supply (10) for feeding at least one first wire (8) and at least one second wire (9) in a pull-out direction (A), • a first straightening device (15) arranged in the pull-out direction (A) after the wire supply (10) for straightening the supplied wires (8,9), • a first wire storage (16) in which a first wire section (4) of the first wire (8) and a first wire section (4') of the second wire (9) are accommodated, • a displacement and bending device (17) in which a transition section (6) of the first wire (8) and an intermediate section (7) of the second wire (9) are located, • a forming device (18) for forming a loop (11) of the first wire (8), • a second wire storage (19) in which a second wire section (5) of the first wire (8) and a second wire section (5') of the second wire (9) are received, wherein the second wire storage (19) is a ring storage in which the second wire sections (5, 5') can be wound up and wherein the shaping of the transition section of the first wire (8) can be carried out before the feeding of the second wire (9).
6. Device according to claim 5, characterized in that the displacement and bending device (17) comprises a first clamp (21) for fixing the first wire section (4, 4') and a second clamp (20) for fixing the second wire section (5, 5'), wherein the second clamp (20) is pivotable about a pivot axis lying perpendicular to the pull-out direction (A) and between the clamps (20, 21) and is displaceable parallel to the pivot axis (23), and wherein the second wire storage (19) is pivotable about the pivot axis together with the second clamp (20).
7. Device according to claim 6, characterized in that the displacement and bending device (17) has a bending blade which is movable perpendicular to the extension direction (A) and about which the leg of the displacement and bending device (17) can be pivoted.
8. Device according to one of claims 6 or 7, characterized in that the displacement and bending device is suitable for releasably fixing the first wires (8) by means of the clamps (20, 21) during the forming of the loop (11) with the forming device (18) and the displacement, and for temporarily opening the clamps (20, 21) thereafter for the pulling in of the second wires (9).
9. Device according to one of claims 6 to 8, characterized in that the second wire storage (19) is linearly movable counter to the withdrawal direction (A) for removing the second wire section (5, 5') stored therein, wherein a second straightening device (24) is provided for the second wire storage (19) for straightening the second wire section (5, 5') removed from the second wire storage (19).