Device for joining long component regions of a winding member of at least one winding of an electric machine and use of such a device

Abstract

The invention relates to a device (10) for joining long component sections (L1, L2) of a winding member of at least one winding of an electric machine, the device (10) comprising a first tool part (12) having a recess (14) that is tapered and thereby tapered towards the extension direction (16), and a second tool part (18), the second tool part (18) comprising a base body (20) and two clamping fingers (22, 24) that are arranged in a direction opposite to the extension direction (16). The clamp fingers (22, 24) are spaced apart from each other along a spacing direction (26) extending perpendicular to the extension direction (16), are held on the base (20) so as to be pivotable relative to the base (20) about respective pivot axes (S1, S2) extending perpendicular to the extension direction (16) and perpendicular to the spacing direction (26), and are movable along the extension direction (16) toward the recess (14) to clamp the long component regions (L1, L2) between the clamp fingers (22, 24, thereby being pivotable in a direction toward each other.

Description

[Technical Field]

[0001] The present invention relates to a device for joining long component regions of a winding member of at least one winding of an electric machine. The invention also relates to the use of such a device. [Background technology]

[0002] From US Pat. Nos. 5,999,049, 5,999,052 and 5,999,062, electric machines are known which each have a winding element and are therefore formed by winding elements, in which the respective long component regions of the respective winding elements are welded to one another and thereby connected to one another and therefore joined to one another.

[0003] Furthermore, Patent Document 4 discloses a method for positioning a laser beam when welding electrical conductors of electrical components. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-007794 [Patent Document 2] Japanese Patent Application Laid-Open No. 2014-007795 [Patent Document 3] Japanese Patent Application Laid-Open No. 2014-183623 [Patent Document 4] International Publication No. 2020 / 210855 Summary of the Invention [Problem to be solved by the invention]

[0005] The object of the present invention is to provide a device and a use of such a device, with which long component regions of the winding members of at least one winding of an electric machine can be joined together in a particularly advantageous manner. [Means for solving the problem]

[0006] This problem is solved by a device with the features of claim 1 as well as by a use with the features of claim 5. Advantageous embodiments of the invention, including preferred refinements, are set forth in the further claims.

[0007] A first aspect of the present invention relates to a device for joining elongated component regions, in particular pin-shaped, of winding elements of at least one winding of an electric machine. The feature that the elongated component regions are, for example, pin-like and thus pin-shaped is understood to mean, in particular, that each elongated component region extends elongately along its respective longitudinal extension, and thus, for example, linearly and linearly, in this case, in particular extending straight. Each elongated component region is a component of a respective winding element. In particular, the elongated component regions themselves can be understood as respective components that are joined to each other, and thus welded to each other. In particular, the components or winding elements are formed separately from each other, in which case the components or winding elements are joined to each other. For example, the components or winding elements are welded to each other and thereby connected to each other, in particular by laser welding.

[0008] In particular, the winding elements are plug-in coils, in particular each having a U-shaped geometry, in which case the plug-in coils are also called hairpins. At least one winding is made up of several plug-in coils according to the so-called hairpin technique, thus combining several plug-in coils. In this case, for example, each long component region is a respective leg of each U-shaped geometry.

[0009] To enable elongated sections to be precisely aligned relative to one another and fixedly secured relative to one another, particularly in a contacting relationship, in a particularly simple and process-reliable manner, so that the elongated sections can be joined and thus connected to one another, for example by welding, especially by laser beam welding, in a particularly advantageous and process-reliable manner, the device, also referred to as a tool and configured as, for example, a clamping tool or a clamping tool, has a first tool part, also referred to as a first tool half. The first tool part has a tapered recess, especially on its inner periphery, and thus a tapered recess in the extension direction. The device also has a second tool part, also referred to as a second tool half. The second tool part has a base body and two clamping fingers, also referred to as pulling fingers or clamping pins, protruding from the base body in the extension direction. The clamping fingers are spaced apart from one another along a spacing direction extending perpendicular to the extension direction. Each clamp finger is held on the base body so as to be pivotable relative to the base body about a respective pivot axis, where the pivot axes are spaced apart from one another along the spacing direction. The respective pivot axes extend perpendicular to the extension direction and perpendicular to the spacing direction. In other words, for example, the extension direction and the spacing direction may define an extension plane, where each pivot axis extends perpendicular to the extension plane. The clamp fingers are movable toward the recesses, particularly by moving the second tool part relative to the first tool part in the extension direction, particularly translationally. In particular, the clamp fingers are pivotable relative to the base body about the pivot axis so that the clamp fingers can be pivoted toward one another by moving the clamp fingers along the extension direction toward the recesses.As a result, long component regions that are or can be arranged between the clamping fingers, especially along the spacing direction, in particular those that are or can be arranged one after the other in the spacing direction, are clamped between the clamping fingers and, in particular, are pressed against each other and are therefore fixed or secured relative to each other. Furthermore, while the long component regions are arranged between the clamping fingers, especially along the spacing direction, the clamping fingers are pivoted toward each other, for example, when the long component regions are initially offset from each other, and the long component regions are moved relative to each other, especially toward each other, and are thereby brought into a favorable joining position in which the long component regions are held by the clamping fingers, in particular by clamping the long component regions. In the joining position, the long component regions have a favorable position, positioning or orientation relative to each other, so that the long component regions can be joined to each other in a reliable manner, in particular welded to each other and thereby joined to each other. In particular, since, for example, long component regions are also conductively connected to one another by joining the long component regions to one another, the present invention provides for the mechanical and electrical connection of long component regions in a precise, reliable manner that can be implemented in a time- and cost-effective manner.

[0010] The first tool part is formed, for example, as a C-bracket, in particular as a solid C-bracket, into whose recess a pivotable and thus rotatable clamping finger can be moved. The clamping finger is rotatable relative to the base body about a pivot axis, so that the clamping pin is movable. By correspondingly moving the tool part so that the clamping pin is moved toward the recess, the clamping pins (clamping fingers) are moved together and thus pivoted toward each other, so that, for example, the clamping fingers pick up the long component regions to be joined and, in particular, align and fix them in contact with each other. For example, the clamping fingers are tapered, so that they slide or rotate together as they move forward along the C-bracket, moving the long component regions into a joining position, also referred to as an end position, and firmly fixing the long component regions in that joining position, in particular so that the gap between the long component regions is as small as possible and so that twisting of the long component regions is eliminated or minimized. In particular, it is conceivable for the tool part and the clamping fingers to be matched with respect to their angles in order to realize an advantageous clamping function, in which long component regions can be particularly advantageously clamped, i.e., clamped, and thereby precisely positioned and fixed relative to one another, in particular in abutting relation to one another, using the device. The tool part can be mechanically fixed, i.e., particularly fixed relative to one another, for example, via at least one or more shafts, via at least one or more motors, and / or by at least one or more other devices, so that the long component regions can be advantageously fixed relative to one another during joining. Furthermore, for example, the device can be used as a single-cavity or multi-cavity mold.

[0011] The present invention is based, inter alia, on the following recognition and consideration: In the current state of the art, plug-in coils, also known as hairpins, for electric machines, especially for electric motors, are connected and thus joined to one another using laser beam welding. For this purpose, it is advantageous to accurately position the plug-in coils, especially the long component regions of the plug-in coils, relative to one another, thereby avoiding defective welded joints due to possible gaps, possible twists, etc. Regarding the configuration of electric machines, a distinction is made, inter alia, between radial and axial flux machines. In particular, the configuration of axial flux machines is characterized by a narrow construction space, which limits the accessibility of clamping tools for fixing the long component regions relative to one another during joining. The device according to the present invention makes it possible, inter alia, to fix the long component regions, especially relative to one another, during joining, even when access to the long component regions is limited or even restricted.

[0012] A second aspect of the present invention relates to the use of the device according to the first aspect of the present invention, where the device is used to connect long component sections of at least one winding of an electric machine, in particular winding members configured as plug-in coils. In particular, the long component sections are fixed relative to one another using the device, in particular fixed in contact with one another, while the long component sections are joined to one another, in particular welded to one another, thereby joining them to one another. Advantages and advantageous features of the first aspect of the present invention can be considered as advantages and advantageous features of the second aspect of the present invention, and vice versa.

[0013] The clamping fingers are arranged in the recesses so that the tool parts, which are also called claws or are formed as claws, are pressed against one another and thus moved against one another. By moving the clamping fingers toward the recesses and thereby pivoting them toward one another, the clamping fingers apply a clamping force along the spacing direction, and thus perpendicular to the extension direction, to the elongated component regions that are arranged along the spacing direction between the clamping fingers and that are arranged one after the other along the spacing direction. Furthermore, by pressing the tool parts against one another, the elongated component regions can be clamped between the tool parts or supported on the tool parts along a clamping direction that coincides with the extension direction, so that the elongated component regions are clamped between the tool parts not only along the spacing direction but also along the clamping direction, and thus are precisely and firmly permanently fixed to one another or fixed in contact with one another. If the long component regions, for example formed as webs, are initially positioned relative to one another, or if the long component regions are not initially positioned offset from one another, by arranging the long component regions between the clamping fingers and by pressing the tool parts against one another, the long component regions are moved relative to one another in the recesses and thus advantageously and precisely aligned relative to one another so that they can be moved into the joining position. Using the tool parts, the long component regions are held in the joining position, and in particular the long component regions are joined to one another. In particular, the tool according to the invention realizes the movement and positioning of the long component regions along the spacing direction and along the clamping direction, where the spacing direction and the clamping direction run perpendicular to one another. As a result, the long component regions can be reliably and firmly connected to one another, for example by laser welding, and thus joined to one another. Here, due to the good positioning of the long component regions, in particular the free ends of the long component regions, simple laser welding is also realized, which allows welding to be carried out with high process reliability and operational safety.

[0014] Each elongate component region has, for example, an at least substantially rectangular cross section, in which case, for example, the elongate component regions or their cross sections are parallel to one another at the joining position, so that, for example, the elongate component region clamped between the tool parts forms a cross section that is, in particular, rectangular in shape overall.

[0015] In particular, the clamping fingers, also referred to as arms or clamping arms, are tapered, in particular on the outer or circumferential side, with a tapered or truncated taper having a first angle which, for example, corresponds to and thus to the second angle of the tapered recess, so that when the clamping fingers and thus the elongated component region are pressed together and thus when the clamping fingers interact with the elongated component region, the inner surfaces of the clamping fingers at least substantially rest flat on the outer surfaces of the elongated component region, resulting in a rectangular shape for the device, with the respective inner and respective outer surfaces lying in a plane which, for example, extends parallel to the extension direction.

[0016] In particular, in the embodiment of electric machines or long component regions, especially their ends, the device configured as or functioning as a clamping device can act directly on the side of the long component region or can interact with the long component region via angled clamping jaws, the direction of force always being directed laterally, for example, relative to the end of the long component region, thereby making it possible to clamp the long component region even when the welding point is not accessible from the side.

[0017] When the clamping fingers are pivoted toward each other, a restoring force, in particular a return spring force and provided by a return spring, acts on the clamping fingers. In this case, for example, when the tool parts are pushed apart, i.e., moved away from each other, the clamping fingers are pivoted away from each other by the restoring force, thereby opening, and the clamping fingers are rotated to their initial position, from which they are again pivoted toward each other when the clamping fingers are moved toward the recess. The device can therefore be used simply, time-wise, and cost-effectively for repeatedly and successively clamping respective long component regions.

[0018] In particular, the present invention makes it possible to achieve at least the following advantages: -Excellent suitability for plug-in coil (hairpin) laser beam welding of axial flux machines - Very good and precise adjustment of the long component areas to be joined, thus favorable welding conditions -Reduction of parts waste - Allows for compensation of lateral offset and torsion in long component areas -Minimal accessibility required -New configuration possibilities - Flexible applicability in or for both axial and radial flux machines -Excellent suitability for welding fewer connections - Allows for fastening of two or more long component sections or plug-in coils

[0019] Further advantages, features and details of the present invention will become apparent from the following description of preferred embodiments and from the drawings. The features and combinations of features mentioned in the above description and in the following description of the figures and / or shown only in the figures can be used not only in the respective combinations presented, but also in other combinations or alone without departing from the scope of the present invention. [Brief explanation of the drawings]

[0020] [Figure 1] 1 shows a schematic plan view of an apparatus for joining long component regions of a winding member of at least one winding of an electric machine; [Figure 2] 1 shows another schematic plan view of the device. [Figure 3] 1 shows a schematic side view of the device. DETAILED DESCRIPTION OF THE INVENTION

[0021] In the various figures, identical or functionally identical elements are designated by the same reference numerals.

[0022] FIG. 1 shows a schematic plan view of an apparatus 10, also referred to as a tool, for joining long component regions L1 and L2 of winding members of at least one winding of an electric machine. The apparatus 10 is, for example, configured as a clamping tool or a tightening tool, or functions as a clamping tool. Each winding member is, for example, a plug-in coil, also referred to as a hairpin. The at least one winding of the electric machine is, for example, formed from plug-in coils (hairpins) according to the so-called hairpin technique. Here, for example, the long component region L1 is the long component region of a first winding member of the winding members, and the long component region L2 is the long component region of a second winding member. The first and second winding members are formed separately from each other, and the long component regions L1 and L2, and thus the first and second winding members, are joined, i.e., connected, to each other. For example, the long component regions L1 and L2 are welded together, thereby connecting them mechanically and electrically. The welding of the long component regions L1 and L2 is performed, for example, by laser welding, thus laser beam welding. As will be explained in more detail below, the apparatus 10 is used to fix the long component regions L1 and L2 relative to each other, and in particular in contact with each other, when joining the long component regions L1 and L2, in particular during joining of the long component regions L1 and L2.

[0023] 1 shows that the long component regions L1 and L2, whose free ends are designated E, are initially offset from one another. As will be explained in more detail below, the long component regions L1 and L2 are positioned relative to one another and thus aligned relative to one another by the device 10. For this purpose, the long component regions L1 and L2, in particular their free ends E, are moved relative to one another using the device 10 and thereby to the joining position F shown in FIG. 2. When the long component regions L1 and L2 reach the joining position F, they are connected to one another while being held in the joining position F by means of the tool (device 10).

[0024] The apparatus 10 includes a first tool part 12 having a recess 14. The recess 14 is tapered on its inner surface, i.e., on its inner circumferential surface, in the direction of extension indicated by arrow 16 in FIG.

[0025] The apparatus 10 includes a second tooling part 18, which includes a base body 20 and two clamp fingers 22 and 24. The clamp fingers 22 and 24 are also referred to as arms, clamp arms, or clamp pins. Each clamp finger 22 and 24 is held on the base body 20 so as to be pivotable relative to the base body 20 about a respective pivot axis S1 and S2. The clamp fingers 22 and 24 can be seen spaced apart from one another along a spacing direction indicated by a double-headed arrow 26. Here, the pivot axes S1 and S2 are spaced apart from one another along the spacing direction. In FIG. 1, a double-headed arrow 28 indicates a clamping direction, also referred to as a clamping direction, which coincides with the extension direction. Along the spacing direction, each clamp finger 22 and 24 is bounded by a respective outer stop 30 and 32, as will be explained in more detail below. Furthermore, in each figure, a set of spatial directions extending perpendicular to one another is represented by x, y and z.

[0026] In the embodiment shown in the figures, the first tool part 12, also referred to as the first tool half, is formed as a solid C-bracket. It can be seen from Figures 1 and 2 that the long component regions L1 and L2 are arranged, for example, in the recess 14. The long component regions L1 and L2 are also arranged between the clamping fingers 22 and 24, in particular the long component regions L1 and L2 are arranged along the spacing direction between the clamping fingers 22 and 24 and are arranged one behind the other along the spacing direction. In particular, subsequently, the tool parts 12 and 18 are moved toward each other along the clamping direction, in particular pressed against each other, so that the clamping fingers 22 and 24 are moved in the extension direction towards the recess 14. Here, the respective outer surfaces 34 and 36 of the clamping fingers 22 and 24, which face away from each other along the spacing direction, slide, in particular directly, on respective inner surfaces 38 and 40 of the tool part 12, which are spaced apart from each other along the spacing direction and which in particular directly define the recess 14. The respective inner surfaces 38, 40 extend in respective inner surface planes which extend parallel to the respective pivot axes S1, S2 and obliquely to the spacing direction and obliquely to the extension direction and therefore obliquely to the clamping direction. Furthermore, the inner surface planes extend toward each other when viewed in the extension direction.

[0027] 1 shows the clamp fingers 22 and 24 in their respective initial positions. In the initial position, the outer surfaces 34, 36 rest against the stops 30, 32. Each clamp finger 22, 24 is also tapered, with each clamp finger 22, 24 having a respective outer surface 34, 36 and a respective separate inner surface 42, 44. The respective outer surface 34, 36 and the respective inner surface 42, 44 of each clamp finger 22, 24 form a respective surface pair, where the respective outer surface 34, 36 and the respective inner surface 42, 44 of each surface pair are also referred to as surfaces. It can be seen that each surface of a surface pair extends in a respective surface plane, such that the respective outer surface 34, 36 extends in a respective first one of the surface planes, and the respective inner surface 42, 44 extends in a respective second one of the surface planes. The surface planes of each surface pair extend parallel to the respective pivot axes S1 and S2 and obliquely to the extension direction and obliquely to the clamping direction such that the respective surface planes of each surface pair extend towards each other in the extension direction, where, for example, the inner surface plane forms a first angle with the extension direction or the clamping direction, and in the initial position, for example, the respective second surface plane forms a second angle with the extension direction, where the first angle and the second angle are in particular the same angle, and therefore the second angle corresponds to the first angle.

[0028] 2 shows that by pressing the tool parts 12 and 18 relative to one another and the resulting movement of the clamping fingers 22, 24 in the recess 14, the outer surfaces 34 and 36 come into supporting contact with the inner surfaces 38 and 40, and the inner surfaces 42 and 44 come into direct supporting contact with corresponding further outer surfaces 46 and 48 of the elongate components L1 and L2. Thus, FIG. 2 shows the state in which the outer surfaces 34, 36 rest particularly directly on the inner surfaces 38 and 40, and the inner surfaces 42 and 44 rest particularly directly on the outer surfaces 46 and 48. In this state, the clamping fingers 22 and 24 are in a clamping position different from their initial position. In the clamping position, the second surface planes extend parallel to one another and parallel to the extension direction and thus parallel to the clamping direction. The first surface planes extend obliquely relative to each other, to the stretching direction, and to the clamping direction, and extend parallel to their respective pivot axes S1 and S2 such that, like the inner surface planes, the second surface planes extend toward each other in the stretching direction. As can be seen from FIG. 2 , in the state shown in FIG. 2 , where the outer surfaces 34 and 36 directly define the recess 14 along the spacing direction and rest directly on the inner surfaces 38 and 40 spaced apart from each other along the spacing direction, each second surface plane, and thus each outer surface 34, 36, forms a first angle α with a plane, also referred to as a stretching plane, that extends parallel to the stretching direction and thus parallel to the clamping direction, and each inner surface plane, and thus each inner surface 38, 40, forms a second angle δ with the stretching plane. Here, angle α corresponds to angle δ. For example, angle α is the first angle, and angle δ is the second angle. Furthermore, for example, in the state shown in FIG. 2, the long component regions L1 and L2 are supported along the clamping direction, in particular directly, on the tool parts 12 and 18, so that in this state the long component regions L1 and L2 are clamped between and with the tool parts 12 and 18 not only along the spacing direction (double arrow 26) but also along a clamping direction (double arrow 28) extending perpendicular to the spacing direction, and are thereby fixed relative to one another.In this state, the long component regions L1 and L2 assume a joining position F in which the long component regions L1 and L2 are joined to one another, in particular welded to one another.

[0029] Each clamp finger 22, 24 can be assigned a return spring which is energized when the clamp fingers 22, 24 are pivoted toward each other from their initial position, thereby providing a restoring force which acts as an elastic force, by means of which, for example, the tool parts 12 and 18 are moved away from each other and the respective clamp finger 22, 24 is pivoted back relative to the base body 20, in particular until the respective clamp finger 22, 24 comes into supporting contact with the associated stop 30, 32.

[0030] Figure 3 shows the device 10 and the long component regions L1 and L2 in the state shown in Figure 2. While the long component regions L1 and L2 are in the joining position F, welding, particularly laser welding, is performed, by which the long component regions L1 and L2 are connected to one another, particularly mechanically and electrically. In particular, the free ends E of the long component regions L1 and L2 melt and fuse to one another at the joining position F, which is shown in Figure 3 as a fusion zone S. [Explanation of symbols]

[0031] 10 equipment 12 First Tool Section 14 Recess 16 Arrow 18 Second Tool Section 20 Base 22 Clamp Finger 24 Clamp Finger 26 Double Arrow 28 double arrow 30 Stopper 32 Stopper 34 Exterior 36 Exterior 38 Inner 40 Inner 42 Another Inner Self 44 Another Inner Self 46 Another Face 48 Another Face E end F Joint position L1 Long component area L2 Long component area S fusion zone S1 rotation axis S2 pivot axis x spatial direction y spatial direction z spatial direction α angle δ angle

Claims

1. A device (10) for joining long component regions (L1, L2) of a winding member of at least one winding of an electric machine, comprising: The tool comprises a first tool part (12) having a recess (14) that is tapered and thereby tapered toward the extension direction (16), and a second tool part (18), the second tool part (18) having a base (20) and two clamp fingers (22, 24) that are spaced apart from each other along a spacing direction (26) that extends perpendicular to the extension direction (16), and and the clamping fingers (22, 24) are held on the base (20) so as to be pivotable relative to the base (20) about respective pivot axes (S1, S2) extending perpendicular to the spacing direction (26), and are movable along the extension direction (16) towards the recess (14) and thereby pivotable towards each other in order to clamp the elongated component regions (L1, L2) between the clamping fingers (22, 24).

2. 2. The method according to claim 1, characterized in that, when the outer surfaces (34, 36) of the clamping fingers (22, 24) rest directly on the inner surfaces (38, 40) of the first tool part (12) that define the recesses (14) and are spaced apart from one another along the spacing direction (26), the respective outer surfaces (34, 36) form a respective first angle (α) with a plane that extends parallel to the extension direction (16) and parallel to the respective pivot axes (S1, S2), and the respective inner surfaces (38, 40) form a respective second angle (δ) with said plane, the second angle (δ) corresponding to the first angle (α).

3. 3. The device (10) according to claim 1 or 2, characterized by a drive part capable of moving the clamping fingers (22, 24) towards the recess (14).

4. 4. The device (10) according to any one of claims 1 to 3, characterized by a fixing device by which the tool parts (12, 18) can be fixed relative to one another.

5. 5. Use of the device (10) according to any one of claims 1 to 4, wherein the device (10) is used to join together long component regions (L1, L2) of winding members of at least one winding of an electric machine.

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