Method and system for winding a coil member

Abstract

The invention relates to a method and a system for winding a flat wire (3) edgewise onto a coil member (2).

Description

[0001] Method and system for winding a coil body

[0002] The invention relates to a method and a system for directly winding a coil former with a flat wire in a vertical arrangement.

[0003] It is known to wind coil bodies directly with a round wire.

[0004] When using a flat wire, it is known from the document EP 2 854 263 B1 to first wind an air coil (i.e. to produce the coil alone without directly winding a coil body) and then to place this air coil onto a coil body, in particular a core made of a ferromagnetic material.

[0005] The known manufacturing process cannot be used for coil bodies with projecting pole faces, which improve the magnetic flux, or other projecting side faces connected to the coil body, since the coil must have a larger internal opening than the cross section of the winding area onto which the flat wire winding is to be plugged, due to the side faces projecting beyond the cross section of the winding area.

[0006] Based on this, it is the object of the invention to provide a method which enables a coil body to be directly wound with a flat wire in a vertical arrangement.

[0007] The object is achieved by a method having the features of independent patent claim 1. A system for winding a coil former is the subject of independent patent claim 11. Preferred embodiments are the subject of the dependent claims.

[0008] According to a first aspect, a method for winding a coil former with a flat wire in a vertical arrangement is disclosed. The method comprises the following steps:

[0009] First, a coil former with a winding region is provided. In a first embodiment, the winding region can have a non-circular outer circumferential contour in cross-section. In an alternative embodiment, the winding region can be rotationally symmetrical with respect to a coil former longitudinal axis, i.e., have a circular outer circumferential contour in cross-section. The coil former has an upper and a lower side surface, which preferably project, i.e., the side surfaces protrude laterally at least in sections relative to the cross-sectional area of ​​the winding region. The coil former forms, for example, a magnetic core and is made of a magnetically conductive material, for example a package comprising a plurality of core sheets or a ferrite material.An electrically insulating material, such as insulating paper, a plastic overmold, or a plastic shell, can be provided on the outside of the magnetic core, at least in sections. The opposing side surfaces preferably form the pole faces of the magnetic core.

[0010] In addition, a flat wire is provided, which can be fed to the winding area of ​​the coil former via a wire guide. The wire guide has an elongated, rail-like guide area, which is brought directly to the winding area for winding the coil former and which guides the flat wire at least on one narrow side facing away from the coil former and one wide side of the flat wire. The wire is preferably fed in a horizontal or vertical direction toward the coil former. An inclined wire feed is also conceivable in principle.

[0011] The coil former is then rotated around a coil former longitudinal axis while the flat wire is fed in simultaneously, so that the flat wire is wound in an upright position onto the outside of the winding area of ​​the coil former. Depending on the wire feed direction, the coil former longitudinal axis is aligned horizontally (with vertical wire feed), vertically (with horizontal wire feed), or diagonally. During winding, a first section of the guide area of ​​the wire guide exerts a guiding force directed radially to the coil former longitudinal axis and, at least temporarily, a second section of the guide area of ​​the wire guide exerts a contact pressure directed parallel or essentially parallel to the coil former longitudinal axis on the flat wire.

[0012] The winding area is wrapped several times with the flat wire, so that a directly wound coil body with a coil comprising several turns is created.

[0013] The technical advantage of the process is that, due to the wire guide, a coil body can be wound directly with a flat wire in an upright arrangement, in such a way that the flat wire can be wound very precisely and does not tend to become skewed or fall over.

[0014] According to one embodiment, the winding area of ​​the coil former has several winding area surfaces. Each pair of winding area surfaces preferably adjoin one another by means of a curve. The winding area surfaces are flat or essentially flat. The flat wire is guided by the wire guide over a length that is equal to or greater than the greatest width of the winding area surfaces, measured perpendicular to the coil former's longitudinal axis. This ensures that the flat wire is guided across the entire width of the winding area surfaces. This guidance of the flat wire enables very precise alignment and positioning of the flat wire during the winding process.

[0015] According to one embodiment, the flat wire is at least temporarily attached to a preceding coil winding by the wire guide, so that the coil windings adjoin one another seamlessly. This applies particularly from the second coil winding onwards. The first coil winding is preferably attached to the projecting inner regions of the side surface of the coil body facing the winding area. This allows for a tight coil winding whose windings mutually stabilize each other in position and alignment.

[0016] According to one embodiment, the flat wire rests positively in the guide area of ​​the wire guide. In other words, the inner cross-section of the guide area of ​​the wire guide is adapted to the outer contour of the flat wire. For example, the flat wire cross-section can have rounded corners or completely rounded narrow sides. The guide area of ​​the wire guide is adapted to this wire shape, enabling very precise wire guidance.

[0017] According to one embodiment, the wire guide is moved radially relative to the coil former's longitudinal axis, such that the flat wire guided by the wire guide has a predetermined position relative to the winding area surfaces of the coil former's winding area when the coil former rotates radially. Controlling the movement of the wire guide in the radial direction contributes to a very precise, upright arrangement of the flat wire, as it can be guided as precisely as possible to the winding area surfaces, thus advantageously influencing the position and orientation of the wire.

[0018] According to one embodiment, the flat wire is guided radially through the wire guide to the winding area at a distance of less than 1 mm. Preferably, the distance is between 0.2 mm and 0.5 mm. By guiding the flat wire very closely to the winding area surfaces, a skewed position of the flat wire, such as would occur with radial pressure, can be effectively prevented.

[0019] According to one embodiment, the wire guide is translationally movable at least in an axial direction extending radially to the coil former's longitudinal axis. For example, the wire guide is displaceable by means of a linear rail arrangement and can thus be radially advanced translationally in the direction of the coil former's longitudinal axis, which forms the coil former's rotational axis, depending on the coil former's rotational position. This allows the wire guide to advantageously follow the circumferential contour of the winding area, which has a non-circular cross-section on the outer circumference.

[0020] According to one embodiment, the wire guide is moved by a cam mechanism or by a motor drive. The cam mechanism can have a cam contour that is identical or substantially identical to the outer peripheral contour of the winding area. By scanning the cam contour with a contact element, the wire guide can follow the outer peripheral contour of the winding area.

[0021] According to one embodiment, the wire guide is constructed in multiple parts. To apply at least the last coil turn, the position of the second section of the guide region of the wire guide is changed so that the flat wire is only guided in the region of its narrow side facing away from the coil body when at least the last coil turn is applied. This makes it possible to fully wind the coil body despite the flat wire being guided laterally during the application of the flat wire for the majority of the coil turns by temporarily changing the position of the second section of the guide region that guides the flat wire laterally, for example, shifting or rotating it, so that the last coil turn can be introduced into the space between the penultimate coil turn and the projecting region of the side surface.

[0022] According to one embodiment, the wire guide is moved in a controlled manner in the direction of the coil body's longitudinal axis, incrementally after each coil turn is applied, by the shorter cross-sectional dimension of the flat wire. This ensures that the turns of the flat wire connect directly and seamlessly to one another. Preferably, when winding a further turn, the flat wire is pressed laterally against the previous winding.

[0023] According to a further aspect, a system for winding a coil former is disclosed. The cross-section of the coil former has a winding region onto which a flat wire is wound in an upright arrangement. The system comprises a rotationally drivable holder for the coil former and a wire guide by means of which the flat wire can be positioned on the winding region of the coil former. The wire guide has an elongated, rail-like guide region, which is positioned directly on the winding region for winding the coil former and which guides the flat wire at least on one narrow side facing away from the coil former and one broad side of the flat wire.The wire guide is designed in such a way and is positioned relative to the coil body when the coil body rotates about its coil body longitudinal axis in such a way that a guiding force directed radially to the coil body longitudinal axis is exerted on the flat wire by a first section of the guide region of the wire guide and a contact pressure directed parallel or substantially parallel to the coil body longitudinal axis is exerted on the flat wire at least temporarily by a second section of the guide region of the wire guide.

[0024] According to one embodiment of the system, the first and second sections of the guide area of ​​the wire guide enclose the flat wire at an angle. This allows wire guidance in both the lateral and radial directions.

[0025] According to one embodiment of the system, the guide region of the wire guide is shaped to match the outer contour of the flat wire region, which abuts the guide region. In particular, the first section is at least partially concavely curved, ensuring excellent guidance of the flat wire through this positive fit.

[0026] According to one embodiment of the system, the wire guide can be advanced radially relative to the coil former by a cam mechanism or a motor drive such that the wire guide maintains a defined distance from the winding area of ​​the coil former as the coil former rotates. This makes it possible for the flat wire to always be guided to the winding area at a small distance, even if the winding area is rotationally asymmetrical in cross-section, thus minimizing the positioning inaccuracy of the flat wire during coil winding.

[0027] According to one embodiment of the system, the wire guide is designed in several parts, specifically such that during winding of the coil former, the second section of the guide region of the wire guide can be temporarily moved away, so that the flat wire is guided solely by the first section of the guide region of the wire guide. This makes it possible to wind the coil former without gaps or essentially without gaps up to the edge of the coil former.

[0028] “Flat wire” in the sense of the present disclosure is understood to mean a wire, in particular an electrically conductive wire, whose cross-sectional area has two cross-sectional axes running perpendicular to each other, wherein a first cross-sectional axis is longer than a second cross-sectional axis.

[0029] For the purposes of the present disclosure, "winding in a vertical arrangement" is understood to mean an orientation of the flat wire such that the first, longer cross-sectional axis of the flat wire runs radially to the axis of rotation (i.e., the axis around which the wire is wound) and the second, shorter cross-sectional axis runs parallel to this axis of rotation.

[0030] The terms "approximately," "essentially," or "about" within the meaning of the invention mean deviations from the exact value of + / - 10%, preferably + / - 5%, and / or deviations in the form of changes that are insignificant for function. Further developments, advantages, and possible applications of the invention will also emerge from the following description of exemplary embodiments and from the figures. All described and / or illustrated features, individually or in any combination, are fundamentally the subject of the invention, regardless of their summary in the claims or their reference back to them. The content of the claims is also made an integral part of the description.

[0031] The invention is explained in more detail below with reference to several exemplary embodiments. They show:

[0032] Fig. 1 shows two exemplary representations of a coil body from different perspectives;

[0033] Fig. 2 shows, by way of example and in a first view, a system for winding a coil body with a flat wire which is positioned on the coil body by a wire guide;

[0034] Fig. 3 shows, by way of example and in a second view, the system for winding a coil body with a flat wire which is positioned on the coil body by a wire guide;

[0035] Fig. 4 shows an example of a sectional view of the system according to Figures 2 and 3, cut along the longitudinal axis of the coil body;

[0036] Fig. 5 shows an example of a wire guide for positioning the flat wire on the coil body; and Fig. 6 shows two sectional views of the wire guide along the section plane S shown in Fig. 5, namely on the left with flat wire and on the right without flat wire.

[0037] Figure 1 shows a coil former 2 in two different perspective views. The coil former 2 is, for example, a core of an electrical coil wound with a flat wire 3. This flat wire 3 is wound onto the coil former 3 such that the coil winding extends around a coil former longitudinal axis SLA. An insulating material, such as insulating paper or a plastic layer, can be provided between the coil winding and the magnetically conductive material of the core.

[0038] The coil former 2 has a winding area 2.1, which is wound with the flat wire 3. Furthermore, the coil former 2 has an upper and a lower side surface 2.2, 2.3, which are enlarged compared to the cross-section of the winding area 2.1, so that the upper and lower side surfaces 2.2, 2.3 protrude at least partially laterally from the winding area 2.1. Due to these projecting side surfaces 2.2, 2.3, it is necessary for the coil former 2 to be wound directly; i.e., winding an air-core coil and then sliding the air-core coil onto the core is not effective here.

[0039] In the illustrated embodiment, the winding region 2.1 of the coil former 2 has a non-rotationally symmetrical cross-section, i.e., a non-circular outer circumferential contour, so that the coil winding to be wound onto the coil former 2 also does not have a circular circumferential contour. For example, the winding region 2.1 does not have any contouring on the outer circumference into which a turn of the flat wire 3 can be inserted to fix it in the upright arrangement. Alternatively, however, the winding region 2.1 can have a grooved contour, wherein the wire turns can each be arranged individually in the grooves of the grooved contour.

[0040] In the exemplary embodiment shown, the coil former 2 is designed in the shape of a circular ring segment or a pie plate, i.e. by joining several coil formers 2 together, a circular ring-shaped coil former structure can be formed. In particular, the outer peripheral contour of the winding region 2.1 of the coil former 2 is formed by several winding region surfaces 2.1.1, 2.1.2, 2.1.3 that adjoin one another directly or via curves. These winding region surfaces 2.1.1, 2.1.2, 2.1.3 are preferably flat or essentially flat. The winding region 2.1 preferably has a polygonal, in particular triangular, basic shape (preferably with rounded corners) in cross section, with the coil former longitudinal axis SLA running perpendicular to this cross-sectional area. By assembling several such coil formers 2, which are wound with flat wire 3, a stator of an axial flux motor can be formed, for example.

[0041] It is understood that the system 1 described below or the method for winding the coil body 2 is also applicable to other coil body shapes, for example those which have a cross-sectional area deviating from the triangular shape or which are circular or annular in cross section.

[0042] 2 and 3 show, by way of example, a section of a system 1 for directly winding the coil former 2 with the flat wire 3. Not shown is the winding drive of the system 1, which can be formed, for example, by a coil winding machine known from the prior art. The system 1 comprises a holder 5, by means of which the coil former 2 can be clamped and rotated about its coil former longitudinal axis SLA. The holder 5 has, for example, a first and a second holder section 5.1, 5.2. The first and second holder sections 5.1, 5.2 can be arranged at a distance from one another such that the coil former 2 can be placed in a holder area between these two holder sections 5.1, 5.2 and can be clamped between them by moving them towards one another. In addition, the holder 5 is drive-coupled to a motor, so that the coil former 2 clamped in the holder 5 can be rotated about the coil former longitudinal axis SLA.By rotating the coil body 2, the flat wire 3 can be wound directly onto the winding area of ​​the coil body.

[0043] In the illustrated embodiment, the coil former's longitudinal axis SLA runs horizontally or substantially horizontally during winding of the coil former 2. Alternatively, a vertical or oblique orientation of the coil former's longitudinal axis SLA can also be provided during winding of the coil former 2. The wire to be wound onto the coil former 2 is fed perpendicularly or substantially perpendicularly to the coil former's longitudinal axis SLA by means of a wire guide 4.

[0044] Fig. 4 shows a sectional view of the area of ​​the system 1 shown in Figures 2 and 3 at the beginning of a winding process, in which the wire guide 4 has already been brought to the winding area of ​​the coil body 2 to be wound, but no coil windings have yet been applied to the coil body 2.

[0045] Referring to the Cartesian diagram shown in Figs. 2 to 4

[0046] Coordinate system, the coil former 2 is rotated with its coil former longitudinal axis SLA around the z-axis. The projecting side surfaces 2.2, 2.3 of the coil former 2 are in contact with the first and second receiving sections. The wire guide 4 is guided laterally to the winding area in such a way that the flat wire 3 is aligned with its narrow side 3.1 along the coil former longitudinal axis SLA and the broad side 3.2, which is longer than the narrow side 3.1, runs perpendicular to the coil former longitudinal axis SLA. In other words, the broad side 3.2 of the flat wire 3 is radially offset from the winding area.

[0047] 2.1.

[0048] The winding process is described in more detail below.

[0049] In order to be able to wind the flat wire 3 directly onto the coil body 2 during rotation of the coil body 2, the flat wire 3 is preferably fixed to the coil body 2 or a receiving section 5.1, 5.2. For this purpose, a

[0050] 5.2, a wire holder may be provided. The flat wire can be clamped into this wire holder, for example.

[0051] The flat wire 3 is then wound in an upright arrangement onto the winding area 2.1, wherein said flat wire is guided by the wire guide 4 in order to prevent the flat wire 3 from tipping over. The wire guide, which will be described in more detail below, ensures, on the one hand, constant guidance and spacing of the flat wire in the radial direction (i.e. radial to the coil body longitudinal axis SLA or in the x-direction according to the coordinate system shown in Figs. 2 - 4), and, on the other hand, pressing it onto the projecting area of ​​at least one of the side surfaces 2.2, 2.3 of the coil body 2 or - after one or more turns have already been applied - onto a previous turn (i.e. in the direction of the coil body longitudinal axis SLA or opposite to the z-direction according to the coordinate system shown in Figs. 2 to 4).

[0052] The wire guide 4 is moved in a controlled manner in the x-direction in order to guide the flat wire 3 along the non-circular outer circumferential contour of the winding area 2.1. The wire guide 4 preferably performs a controlled stroke movement so that the flat wire 3 is pressed against the winding area 2.1 with a desired contact pressure or, preferably, is guided to the winding area 2.1 at a predetermined short distance upon rotation of the non-rotationally symmetrical cross-section of the winding area 2.1 (i.e., the winding area 2.1 has an outer circumferential contour that deviates from a circular shape).

[0053] In order to be able to wind the coil former 2 along the winding area with a plurality of consecutive coil turns, the wire guide 4 is also moved in a controlled manner in the z-direction, i.e. along the coil former's longitudinal axis SLA. Preferably, the wire guide 4 is initially held at a defined position along the coil former's longitudinal axis SLA or in the z-direction according to the coordinate system shown in Fig. 4 for the application of a coil turn, and the coil turn is wound up by rotating the coil former. When the flat wire 3 approaches the beginning of this coil turn again after rotation of the coil former 2 through an angular range between 150° and 330°, in particular 300° to 330°, the wire guide 4 is advanced in the z-direction, specifically by the flat wire thickness d measured in the direction of the narrow side of the flat wire 3.After the advance is complete, another turn of flat wire 3 is wound so that the broad side of the currently applied coil turn is opposite the broad side of the previously applied coil turn. This process is repeated until the winding area 2.1 is completely wound. For the second and subsequent windings, the advance in the Z direction can occur during a rotation of the coil body 2 by 330° to 360°, or essentially 360°, and thus later in the rotation process.

[0054] As previously described, the flat wire 3 is guided through the wire guide 4, on the one hand radially to the coil former's longitudinal axis SLA, and on the other hand parallel to the coil former's longitudinal axis SLA. Preferably, the wire guide 4 is designed such that the flat wire is guided along the winding area surfaces 2.1.1, 2.1.2, 2.1.3 of the coil former 2 at a short distance, for example a distance of less than 1 mm, in particular a distance between 0.2 mm and 0.5 mm. Preferably, there is no pressure against the winding area surfaces in the radial direction relative to the coil former's longitudinal axis SLA. As a result, the flat wire can advantageously be arranged upright over a large number of turns, without it tending to fall over as the number of turns increases.

[0055] Along the coil former's longitudinal axis SLA, the wire guide 4 preferably exerts a contact force on the flat wire 3, specifically such that the flat wire 3 is pressed against the side surface of the coil former 2 or the broad side of the previous coil winding. This allows for very precise winding of the coil former in an upright position.

[0056] Figure 5 shows the wire guide 4 of system 1 in isolation. The illustrations in Fig. 6 show sectional views of the wire guide 4 in the section plane S sketched in Fig. 5, once with the flat wire 3 guided and once without.

[0057] The wire guide 4 is designed like a rail and guides the flat wire 3 in a straight line in a guide area 4.1 of length I. The term “guide” is understood here to mean that the flat wire 3 is held at least predominantly, ie over the majority of the windings, at the back and sides in a defined orientation, so that the flat wire 3 is secured against falling over when the winding is applied.

[0058] The length I of the guide area 4.1 is preferably greater than the largest width b of the winding area surface 2.1 .1 , 2.1 .2, 2.1.3 of the coil body 2. As a result, the flat wire 3 is not only guided at specific points, but over the entire width b between the ends of the respective winding area surface 2.1 .1 , 2.1.2, 2.1.3 (ie between the curves or corner areas of adjacent winding area surfaces).

[0059] As can be seen in Fig. 6, the guide area 4.1 has an angular cross-section, so that the flat wire 3 is guided on two sides, namely at the rear on a narrow side 3.1 and laterally on a wide side 3.2 of the flat wire 3. For this purpose, the guide area 4.1 of the wire guide 4 has a first section 4.1.1 and a second section 4.1.2. The first section 4.1.1 forms a contact surface for the narrow side 3.1 of the flat wire 3, which does not come into contact with the winding area 2.1, but is arranged facing away from the winding area 2.1. The second section 4.1.2 forms a contact surface for the broad side 3.2 of the flat wire 3, which, during the first turn, faces away from the side surface 2.2, 2.3 to which the flat wire 3 is attached or, if turns have already been applied to the coil body 2, is opposite an already applied turn to which the flat wire 3 is now applied.

[0060] Preferably, the guide region 4.1 is adapted to the shape of the flat wire 3, in such a way that the inner shape of the first and second sections 4.1 .1, 4.1 .2 of the guide region 4.1 resembles the wire shape of the flat wire 3.

[0061] As shown in Fig. 6, the flat wire 3 has a substantially rectangular cross-section with rounded narrow sides 3.1, i.e. the broad sides are flat and the narrow sides 3.1 are circular arc-shaped or at least rounded in the corner regions. In order to guide this flat wire 3 in a shape-adapted manner, the first section 4.1.1 of the guide region 4.1 has, in cross-section, an inner contour that is at least partially rounded or a concave curvature in order to form a shape-adapted contact surface for the narrow side 3.1 of the guide wire 3. The second section 4.1.2 of the guide region 4.1 has a flat sliding surface that forms a sliding surface for the broad side 3.2 of the flat wire 3.

[0062] The wire guide 4 is aligned relative to the coil former and, upon rotation of the coil former about the coil former longitudinal axis SLA, is guided in such a way that the flat wire 3 is guided directly to the respective winding area surface 2.1.1, 2.1.2, 2.1.3 interacting with the wire guide, but the flat wire 3 remains spaced apart from the winding area surface 2.1.1, 2.1.2, 2.1.3. The spacing is preferably less than 1 mm, preferably less than 0.5 mm. This can prevent contact pressure being exerted on the narrow side of the flat wire 3, which could lead to an undesirable skewed position and thus to a misalignment of the flat wire 3 that increases with the number of turns. In other words, the first section 4.1.1 of the guide area 4.1 exerts no or essentially no contact pressure on the flat wire 3 and thus, via the flat wire, on the winding area 2.1. Through the second section 4.1.2 of the guide area 4.1, however, a contact pressure acting parallel to the coil body longitudinal axis SLA is exerted on the flat wire 3, namely on the projecting areas of the side surface 2.2, 2.3 during the first winding and, after one or more windings have already been wound onto the winding area, on the respective preceding winding, so that the individual windings are arranged directly against one another.

[0063] In order to be able to apply this contact pressure opposite to the z-direction shown in Figures 2 to 4, i.e. parallel to the coil former's longitudinal axis SLA, the wire guide 4 is moved in a controlled manner along the coil former's longitudinal axis SLA. Preferably, the wire guide 4 is advanced per turn by the flat wire thickness d measured in the direction of the narrow side 3.1 and remains in this position until a new turn has been wound up (i.e., for example, for the first turn at a rotation angle range between 150° and 330° and from the second turn onwards, for example, at a rotation angle range between 330° and 330° of the coil former 2). In this case, the wire guide 4 applies contact pressure to the previous turn, so that a coil winding is created with turns that are directly adjacent to one another.

[0064] The distance control of the wire guide 4 radially to the coil body longitudinal axis SLA can be cam-controlled or by means of a motor drive.

[0065] In the exemplary embodiment shown, a cam control is used to guide the flat wire 3 immediately adjacent to the respective winding area surface 2.1.1, 2.1.2, 2.1.3, but to not exert any contact pressure on them. The cam control comprises a control surface 6 that rotates with the coil former 2. The control surface 6 is provided, for example, on the first or second receiving section 5.1, 5.2. The control surface 6 preferably has an identical or essentially identical outer circumferential contour to the winding area 2.1 of the coil former 2. In addition, the rotational position (with respect to the coil former longitudinal axis SLA as the rotational axis) of the control surface 6 and the winding area 2.1 of the coil former 2 is the same or essentially the same.

[0066] The wire guide 4 has at least one contact element 4.2 that rests against the control surface 6. The contact element 4.2 is designed, for example, in the form of a web, with the longitudinal direction of the contact element 4.2 running in the direction of the longitudinal axis of the guide region 4.1 or of the flat wire 3 guided thereby. The contact element 4.2 rests against the control surface 6, so that when the control surface 6 rotates, the wire guide 4 radially follows the outer circumferential contour of the control surface 6 and thus also the outer circumferential contour of the winding region 2.1.

[0067] The wire guide 4 is preferably subjected to a force in the radial direction towards the control surface 6, for example via a spring, hydraulically or pneumatically, so that the contact element 4.2 is pressed against the control surface 6 and follows it during rotation.

[0068] Alternatively, the wire guide 4 can be moved radially to the coil former's longitudinal axis SLA by means of a motor drive, for example, a servo motor. In this case, the control surface 6 or the winding area 2.1 itself can be detected by a sensor, and the motor drive can be controlled such that the flat wire 3 follows the outer circumferential contour of the winding area 2.1. A motor drive without sensor detection of the control surface 6 or the winding area contour is also conceivable if the outer circumferential contour of the winding area 2.1 and the rotational position of the coil former 2 are known. This allows the radial distance of the wire guide 4 to be adjusted programmatically depending on the rotational position of the coil former 2.

[0069] It is preferable to completely wind the winding area 2.1 of the coil former 2 with the flat wire 3, i.e., to avoid, if possible, any gaps at the edge of the coil in which no wire winding is located. Due to the projecting side surfaces 2.2, 2.3 of the coil former 2 and the immersion of the second section 4.1.2 of the guide area 4.1, a continuous or essentially continuous winding may be difficult.

[0070] In order to ensure that the winding area 2.1 is wound over its entire extent along the coil longitudinal axis SLA, the guide area 4.1 can be made up of several parts and the second section 4.1.2 of the guide area 4.1 can be movable relative to the first section 4.1.1.

[0071] For example, the second section 4.1.2 of the guide area 4.1 can be moved away from the winding area 2.1, at least during the application of the last turn, for example by a shift, a pivoting, or a superimposed translational and rotational movement. As a result, the flat wire 3 is guided toward the end of the coil winding only by the first section 4.1.1 of the guide area 4.1, but for winding in the end area, this rear-side guidance is sufficiently good to wind the flat wire upright.

[0072] In order to be able to wind the flat wire 3 around the winding area 2.1 by rotating the coil former 2 at the beginning of the winding process, the flat wire 3 is preferably fixed to the holder 5 or to the coil former 2 itself. Fixing can be achieved, for example, by clamping, by inserting it into an eyelet or a hole, etc. This ensures that the flat wire 3 can be wound onto the winding area from the very beginning by rotating the coil former 2.

[0073] The feeding of the flat wire 3 preferably takes place in a horizontal or vertical direction and the coil body longitudinal axis SLA, around which the coil body 2 is rotated, runs perpendicular to it. The feeding of the flat wire 3 can be actively controlled, at least temporarily, by a controlled

[0074] Feeding occurs. The wire is preferably fed by the tension created by winding the flat wire onto the coil body 2.

[0075] The invention has been described above using exemplary embodiments. It is understood that numerous changes and modifications are possible without departing from the scope of protection defined by the patent claims.

[0076] List of reference symbols

[0077] 1 system

[0078] 2 coil bodies

[0079] 2.1 Changing area

[0080] 2.1.1 first changing area

[0081] 2.1 .2 second changing area

[0082] 2.1 .3 third changing area

[0083] 2.2 first side surface

[0084] 2.3 second side surface

[0085] 3 flat wire

[0086] 3.1 Narrow side

[0087] 3.2 Broadside

[0088] 4 Wire guide

[0089] 4.1 Management area

[0090] 4.1.1 first section of the management area

[0091] 4.1 .2 second section of the management area

[0092] 4.2 Investment element

[0093] 5 Recording

[0094] 5.1 first recording section

[0095] 5.2 second recording section

[0096] 6 Control surface b Width d Flat wire thickness

[0097] I Length

[0098] SLA coil body longitudinal axis

Claims

Patent claims 1 ) Method for winding a coil body (2) with a flat wire (3) in a vertical arrangement, the method comprising the following steps: - Providing a coil body (2) with a winding area (2.1 ); - Providing a flat wire (3) which can be fed to the winding area (2.1) of the coil body (2) via a wire guide (4), wherein the wire guide (4) has an elongated, rail-like guide area (4.1) which is brought directly to the winding area (2.1) for winding the coil body (2) and which guides the flat wire (3) at least on a narrow side (3.1) facing away from the coil body (2) and a broad side (3.2) of the flat wire (3); - Rotating the coil body (2) while simultaneously feeding the flat wire (3) by means of the wire guide (4), so that the flat wire (3) is wound onto the winding area in an upright position (2.1 ) of the coil body (2) is wound up, wherein a guiding force directed radially to the coil body longitudinal axis (SLA) is exerted on the flat wire (3) by a first section (4.1.1 ) of the guide region (4.1 ) of the wire guide (4) and a contact pressure directed parallel or substantially parallel to the coil body longitudinal axis (SLA) is exerted on the flat wire (3) at least temporarily by a second section (4.1.2) of the guide region (4.1 ) of the wire guide (4); - Multiple winding of the winding area (2.1) with the flat wire (3) so that a directly wound coil body (2) with a coil comprising several turns is produced. 2) Method according to claim 1, characterized in that the winding region (2.1) of the coil body (2) has a cross-section with a non-circular outer circumferential contour. 3) Method according to claim 2, characterized in that the winding area (2.1) of the coil body (2) has a plurality of winding area surfaces (2.1.1, 2.1.2, 2.1.3), and wherein the flat wire (3) is guided by means of the wire guide (4) over a length (I) which is equal to or greater than the greatest width of the winding area surfaces (2.1.1, 2.1.2, 2.1.3), which is measured perpendicular to the coil body longitudinal axis (SLA). 4) Method according to one of the preceding claims, characterized in that the flat wire (3) is at least temporarily attached to a preceding coil winding by the wire guide (4), so that the coil windings adjoin one another without gaps. 5) Method according to one of the preceding claims, characterized in that the flat wire (3) rests positively in the guide region (4.1) of the wire guide (4). 6) Method according to one of the preceding claims, characterized in that the wire guide (4) is moved in the radial direction relative to the coil body longitudinal axis (SLA), in such a way that the flat wire (3) guided through the wire guide (4) has a predetermined position relative to the winding area surfaces (2.1.1, 2.1.2, 2.1.3) of the winding area (2.1) of the coil body (2) when the coil body (2) rotates in the radial direction. 7) Method according to claim 6, characterized in that the flat wire (3) is guided by the wire guide (4) at a distance of less than 1 mm in the radial direction to the winding area (2.1) and / or that the flat wire (3) is pressed radially by the wire guide (4) at least partially against the winding area (2.1) of the coil body (2). 8) Method according to one of the preceding claims, characterized in that the wire guide (4) is translationally movable at least in an axial direction extending radially to the coil body longitudinal axis (SLA). 9) Method according to one of the preceding claims, characterized in that the wire guide (4) is moved by a cam gear or by a motor drive. 10) Method according to one of the preceding claims, characterized in that the wire guide (4) is designed in several parts and that the second section (4.1 .2) of the guide area (4.1) of the wire guide (4) is changed in its position for applying at least the last coil turn, so that the flat wire (3) is guided only in the area of ​​its narrow side (3.1) which is facing away from the coil body (2) when applying at least the last coil turn. 11 ) Method according to one of the preceding claims, characterized in that the wire guide (4) is movable in a controlled manner in the direction of the coil body longitudinal axis (SLA), in each case stepwise after the application of a coil turn by the shorter cross-sectional dimension of the flat wire (3). 12) System for winding a coil former (2) with a flat wire (3) in a standing arrangement, comprising a rotationally drivable holder (5) for the coil former (2) and a wire guide (4) by means of which the flat wire (3) can be positioned on a winding area (2.1) of the coil former (2), wherein the wire guide (4) has an elongated, rail-like guide area (4.1) which is positioned directly on the winding area (2.1) for winding the coil former (2) and which guides the flat wire (3) at least on a narrow side (3.1) facing away from the coil former (2) and a broad side (3.2) of the flat wire, wherein the wire guide (4) is designed in such a way and, when the coil former (2) rotates about its coil former longitudinal axis (SLA), is positioned relative to the coil former (2) in such a way that a first section (4.1.1) of the Management area (4.1 ) of the wire guide (4) a guiding force directed radially to the coil body longitudinal axis (SLA) and at least temporarily by a second section (4.1.2) of the guide region (4.1 ) of the wire guide (4) a contact pressure directed parallel or substantially parallel to the coil body longitudinal axis (SLA) is exerted on the flat wire (3). 13) System according to claim 12, characterized in that the first and second sections (4.1.1, 4.1.2) of the guide region (4.1) of the wire guide (4) enclose the flat wire (3) in an angular manner. 14) System according to claim 12 or 13, characterized in that the guide area (4.1) of the wire guide (4) is adapted to the outer contour of the flat wire area which rests against the guide area (4.1). 15) System according to one of claims 12 to 14, characterized in that the winding area (2.1) of the coil body (2) has a cross-section with a non-circular outer circumferential contour and that the wire guide (4) can be advanced by a cam gear or by a motor drive in the radial direction relative to the coil body (2) in such a way that the wire guide (4) maintains a defined distance from the winding area (2.1) of the coil body (2) when the coil body (2) rotates. 16) System according to one of the preceding claims 12 to 15, characterized in that the wire guide (4) is designed in several parts, in such a way that when winding the coil body (2) the second section (4.1.2) of the guide area (4.1 ) of the wire guide (4) can be temporarily moved away, so that the guidance of the flat wire (3) is only carried out by the first section (4.1.1 ) of the guide area (4.1 ) of the wire guide (4).

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