Winding machine and method for forming coil windings on an outer grooved winding support of a rotor or stator of an electric machine, and winding system

Abstract

A winding machine (1) for forming coil windings on an outer grooved winding support (3) of a rotor or stator of an electric machine comprises a receiving device (2) for receiving the outer grooved winding support (3) and a plurality of winding devices (4) arranged around the receiving device (2). The receiving device (2) has a longitudinal axis that lies on the longitudinal axis of the outer grooved winding support (3) when the outer grooved winding support (3) is received in the receiving device (2). Each of the winding devices (4) has wire feeding means (6) designed to move the winding along an advance direction and thus guide the winding into the receiving device (2). Each of the winding devices (4) also has a drive device designed to move the wire feeding means (4) relative to the receiving device (2) during an advancement movement of the winding wire, independently of the wire feeding means of the other winding devices (4), according to a winding operation in which the windings for forming the coil windings are wound around the winding teeth (5) of the outer grooved winding supports (3) received on the receiving device (2). The receiving device (2) has a rotational drive device (10) by which the receiving device (2) can be rotated about its longitudinal axis, and the rotational drive device (10) is designed to rotate the receiving device (2) according to the winding operation in which the respective windings for forming the respective coil windings are wound around the associated winding teeth (5) of the outer grooved winding supports (3) received on the receiving device (2). Further provided is a winding system (19) having a plurality of winding machines (1) and a method for forming coil windings.

Description

[Technical Field]

[0001] The present invention relates to a winding machine and method, and a winding system, for forming coil windings on an outer grooved winding support of a rotor or stator of an electric machine. [Background technology]

[0002] Rotors for electric motors, especially those designed as separately excited synchronous machines, and especially rotors with external grooves, are usually formed with teeth around which copper wire, e.g., enameled copper wire, is wound in the form of a concentrated winding. In the field of traction drives, such rotors are generally provided with four to eight teeth. The windings on each tooth are generally designed as a series circuit and therefore have a total of two connecting wires electrically connected to the slip ring body. The internal interconnection of the individual tooth coils is performed during the winding process itself. It is known from the prior art that rotors are provided with wire guides through which the enameled copper wire is wound by simply feeding it horizontally or vertically per tooth.

[0003] So-called needle winding machines are widely used for winding wire, in which wire is wound onto teeth by needle feed to form a coil winding. Such a system is described in EP 1 191 672. WO 2015 / 189676 and EP 1 376 829 disclose devices in which multiple teeth of an inner grooved winding support are wound by needles driven in a cooperative manner. Summary of the Invention [Problem to be solved by the invention]

[0004] SUMMARY OF THE INVENTION It is an object of the present invention to provide an improved technique for forming coil windings on an outer grooved winding support, which allows for particularly effective and efficient winding.

[0005] To this end, a winding machine for forming coil windings on an outer grooved winding support of a rotor or stator of an electric machine is developed according to independent claim 1. Furthermore, a method for forming coil windings on an outer grooved winding support of a rotor or stator of an electric machine and a winding system according to the further independent claims are provided. Embodiments are the subject of the accompanying dependent claims.

[0006] According to one aspect, a winding machine for forming a coil winding on an outer grooved winding support of a rotor or stator of an electric machine is developed. The winding machine includes a receiving device for receiving the outer grooved winding support and a plurality of winding devices arranged around the receiving device. The receiving devices have longitudinal axes that align with the longitudinal axis of the outer grooved winding support when the outer grooved winding support is received in the receiving device. Each of the winding devices has wire feeding means configured to move the winding along a feeding direction, thereby guiding the winding wire into the receiving device. Each of the winding devices also has a drive device configured to move the wire feeding means relative to the receiving device, independent of the wire feeding means of the other winding devices, during an advancement of the winding wire in accordance with the feeding motion such that the winding to form the coil winding is wound around the winding teeth of the outer grooved winding support received in the receiving device. The receiving device has a rotary drive device that allows the receiving device to rotate about its longitudinal axis. The rotary drive device is configured to rotate the receiving device in accordance with a winding motion so that each winding for forming each coil winding is wound around an associated respective winding tooth of the outer grooved winding support received on the receiving device.

[0007] According to a further aspect, there is provided a method for forming coil windings on an outer grooved winding support of a rotor or stator of an electric machine, the method comprising the steps of receiving the outer grooved winding support on a receiving device of a winding machine such that a longitudinal axis of the receiving device lies on a longitudinal axis of the outer grooved winding support, and simultaneously forming a plurality of coil windings around respective winding teeth of the outer grooved winding support with a plurality of winding devices of the winding machine arranged around the receiving device. In this case, each coil winding is formed by each winding device, the winding wire is moved along a feeding direction by the wire feeding means of each of the winding devices and thus supplied to each of the winding teeth, and during the feeding movement of the winding wire, the wire feeding means of each of the winding devices is moved relative to each of the winding teeth by the drive device of each of the winding devices in accordance with the winding operation, independently of the wire feeding means of other winding devices, and thus wound around each of the winding teeth, and the outer grooved winding support is rotated by the rotation drive device of the receiving device in accordance with the winding operation so that each of the winding wires is wound around each of the winding teeth of the outer grooved winding support to form each of the coil windings.

[0008] A winding system according to a further aspect includes a plurality of winding machines according to the present disclosure configured to simultaneously form coil windings on respective outer grooved winding supports of a rotor or a stator of an electric machine in the winding system.

[0009] The technique according to the present disclosure allows for multiple wires to be fed simultaneously to the winding support, with each wire feeding means facing a different winding tooth and operating independently. As a result of the parallel operation mode, the process time for winding onto the winding support can be reduced. In particular, the present disclosure provides for operating winding devices at least temporarily in parallel in time to simultaneously form multiple coil windings. Preferably, the winding devices are configured to operate substantially completely in parallel in time, and this operation is then provided corresponding to the method. As a result of multiple teeth of the winding support being wound simultaneously, particularly in the case of laminated winding supports, sagging of the laminations of the winding support on the side opposite each wound tooth can be avoided or reduced. According to the present disclosure, the formation of the coil windings can be provided on a laminated outer grooved winding support, i.e., a winding support consisting of an arrangement of multiple laminates, particularly a stack, the shape of which predefines the outer contour of the winding support.

[0010] The configuration of the drive system and rotary drive for movement according to the winding movement may in particular include corresponding actuation by one or more actuators provided for this purpose, where a common actuator, a respective actuator for each element generating the movement, or several actuators may be provided, in each case for one or a group of elements generating the movement.

[0011] In a preferred embodiment, the receiving device can be at least partially rotated simultaneously with each winding operation of the winding devices in accordance with the winding operation of the rotary drive means. Thus, the winding operation can be performed by at least partially superimposing the various operations provided, and this winding operation is precisely adapted to the winding support to be wound. For example, the winding wire can be precisely positioned around the rounded corners of the winding teeth and / or guided into a diagonally running groove between two winding teeth of a diagonally grooved winding support by superimposing the operation of the wire feeding means in the axial direction (i.e., in a direction parallel to the longitudinal axis) and the rotation of the receiving device.

[0012] The wire is fed from a respective wire store, in particular a respective roll, to the winding machine and here to the winding device, which can form part of the winding machine or can be arranged external to the winding machine.

[0013] The winding device is preferably arranged around the longitudinal axis of the receiving device and therefore along the circumference of the winding support received in the receiving device.

[0014] The winding devices can be constructed according to needle winding techniques known per se, and in particular each winding device can have a tubular wire feeding means, which can be called a needle or a wire guide nozzle, configured to be introduced into the intermediate space between two teeth and then moved in a manner to feed the coil winding around the teeth to form the coil winding.

[0015] In the winding machine, rotation of the receiving device serves to rotate the outer grooved winding support received on the receiving device, so that the outer grooved winding support is rotated in accordance with the method according to the present disclosure, at least partially simultaneously with each winding operation of the winding device, in accordance with the winding operation by the rotary drive means, so that each winding wire is wound onto each winding tooth of the outer grooved winding support to form a respective coil winding. The outer grooved winding support is received in the receiving device of the winding machine, thereby forming a winding arrangement comprising the winding machine and the winding support.

[0016] The winding machine can have at least three winding devices. For example, the winding machine can have exactly three winding devices. Alternatively, two or more winding devices can be provided. In particular, the number of winding devices of the winding machine can be selected so that the available installation space around the receiving device is used efficiently, for example, by arranging the maximum number of winding devices possible around the receiving device without the winding devices interfering with each other in their respective operations.

[0017] The winding devices may be uniformly distributed around the receiving device relative to the circumferential direction of the winding support disposed within the receiving device. Thus, in an embodiment with three winding devices, the angle between two adjacent winding devices relative to the longitudinal axis or the circumferential direction of the winding support disposed within the receiving device may be 120 degrees. A greater or lesser number of winding devices results in a corresponding angle for uniform distribution.

[0018] The receiving device can have a workpiece support configured to receive the outer grooved winding support and releasably positioned within the winding machine, allowing the outer grooved winding support received on the workpiece support to be transferred to and from the winding machine. Here, the winding support can be moved from the workpiece support during reception on the receiving device, so that the winding support is positioned on the receiving device but not on the workpiece support during the winding process. Here, the workpiece support itself can also be positioned on the receiving device. The workpiece support can be releasable from the receiving device to position the winding support on the workpiece support at a location separate from the receiving device. In such an embodiment, the workpiece support may alternatively not be part of the receiving device, but rather may be provided independently of the receiving device. In one embodiment, the workpiece support has a recess through which a corresponding holding protrusion of the receiving device contacts the winding support and is guided to receive the winding support on the receiving device. Here, the winding support can be moved away from the workpiece support, so that the workpiece support remains on the receiving device, separate from the winding support and outside the area where the coil winding is formed. Alternatively, the winding support can remain on the workpiece support, and the workpiece support can be received on the receiving device by being fixed to the receiving device. In this case, rotation about the longitudinal axis of the receiving device can be transmitted to the workpiece support, so that the workpiece support rotates about its longitudinal axis. In this case, rotation of the workpiece support is transmitted to the winding support, particularly to achieve rotation of the winding support as part of the winding operation.

[0019] For each winding device, a respective drive system may be configured to move the wire feeding means relative to the receiving device in a first direction extending parallel to the longitudinal axis of the receiving device and to move the wire feeding means in a second direction extending perpendicular to and passing through the longitudinal axis of the receiving device according to the winding operation, such that axial movement is provided as movement in the first direction and radial movement is provided as movement in the second direction with respect to the winding support received on the receiving device.

[0020] The movement of the winding device in the respective second direction can in particular serve to feed the respective wire feeding means to the winding support received on the receiving device (e.g., into the intermediate space between the teeth of the winding support). The movement of the winding device in the respective first direction can in particular serve to move the respective wire feeding means along and / or through the intermediate space between the teeth of the winding support received on the receiving device. By rotation of the receiving device, a relative movement of the winding device, in particular the wire feeding means of the winding device, with respect to the winding support in a tangential direction of the winding support can be provided by the rotation of the winding support received on the receiving device. A combination of the rotation of the receiving device and the movement of the winding device, in particular the wire feeding means of the winding device, can provide a relative movement of the winding device with respect to the winding support received on the receiving device in a circumferential direction of the winding support.

[0021] A winding operation on the tooth to be wound of the winding support received on the receiving device can be realized for each winding device, in which the wire feeding means of the winding device, preferably configured as a wire feeding means according to needle winding techniques known per se, are introduced into an intermediate space between the tooth to be wound and an adjacent tooth of the winding support, are guided through the intermediate space in a direction parallel to the axis of the winding support until the wire feeding means emerges from the intermediate space in a direction parallel to the axis of the winding support, and are then wound at least partially around the end of the tooth to be wound. The wire is guided in the tangential and / or circumferential direction of the winding support, then introduced in a direction parallel to the axis of the winding support into a further intermediate space between the tooth to be wound and a further adjacent tooth opposite the adjacent tooth, guided through the further intermediate space in a direction parallel to the axis of the winding support until it leaves the further intermediate space, at least partially guided in the tangential and / or circumferential direction of the winding support around the opposite end of the tooth to be wound, and then introduced again in a direction parallel to the axis of the winding support into the intermediate space between the tooth to be wound and the adjacent tooth of the winding support. Here, the wire is fed by the wire feeding means so that it is wound around the tooth to be wound. An individual coil winding is placed around the tooth to be wound with each repetition of the described winding operation.

[0022] Each, individual, or one of the plurality of winding devices may be movable in a third direction extending perpendicular to the first direction and perpendicular to the second direction. Thus, with respect to the winding support received on the receiving device, movement in the third direction provides tangential movement. In preferred embodiments, movement in the third direction is not part of the winding operation. In such or other embodiments, movement in the third direction, optionally in conjunction with movement in other directions, may serve to feed the respective wire feeding means to or into the winding support received on the receiving device. Alternatively or additionally, movement in the third direction, optionally in conjunction with movement in other directions, may serve to wind the wire around a contact point of the winding support. In such a winding, the free end of the winding wire may be guided to and secured at a predetermined contact point of the winding support, in particular a receptacle provided for this purpose. The contacts may be configured to make electrical contact with the winding wires, in particular from outside the winding support, via the contacts and / or to create an electrical connection between the winding wires, in particular between the winding wires of different windings, arranged on the winding support. Following such a winding-on operation and securing the windings to the contacts, the wire feeding means may be brought into a position where the winding operation is to begin. In an embodiment, the movement in the third direction may be part of the winding operation, in particular alternatively or additionally to the rotation of the receiving device.

[0023] Alternatively or additionally to the third direction, each of the plurality of winding devices, individually or one of the plurality of winding devices, may be movable in a fourth direction extending circumferentially on an arc about the longitudinal axis and thus relative to the winding support received in the receiving device. The movement in the fourth direction may be provided as part of the winding operation and / or independently of the winding operation, in particular as a feed operation and / or a winding-on operation.

[0024] A movement in a fourth direction can be provided as an alternative to the movement in the second direction, in which case each wire feeding means can feed in an axially parallel manner to the winding support into an intermediate space between the teeth of the winding support received in the receiving device.

[0025] For each winding device, the drive system can be configured to pivot the wire feeding means about a pivot axis extending perpendicular to and at a distance from the longitudinal axis of the receiving device, the pivot axis therefore extending tangentially to the winding support received in the receiving device. In particular, it can be provided in this way to pivot the wire feeding means configured according to needle winding technology about the pivot axis as part of the winding operation and / or as part of the feeding operation and / or as part of the winding-on operation.

[0026] Each of the plurality of winding devices, or one of them, may have stripping means configured to remove the insulation from the winding wire. The stripping means is preferably configured to selectively remove a portion of the winding wire insulation, particularly the end portion, to allow or facilitate electrical contact. The stripping means may be configured to remove the insulation from the winding wire during the winding wire feed operation and / or while the winding wire is stopped. The stripping means may remove the insulation abrasively using one or more mechanical devices, thermally, particularly using a heating device, and / or by other methods. Abrasive removal of the insulation can be achieved, for example, by rotating blades of the stripping means, e.g., three or four blades, arranged around the wire to be fed. For example, the stripping means may be provided with rotary blades, preferably with diamond cutting edges, at a rotational speed of 9,000 to 15,000 revolutions per minute.

[0027] Each, individual or one of the plurality of winding devices may have wire clamping means configured to clamp the winding wire and thus prevent movement of the winding wire along the feed direction, preferably provided to clamp the winding wire while no winding operation is taking place, in particular while the winding support is not received by the receiving device, thereby preventing movement of the winding wire relative to the respective wire feed means along or against the feed direction.

[0028] Each individual or single winding device may be provided with at least one preforming element that is movable relative to the wire feed means of the winding device and that can move between a rest position and an engagement position. Here, the preforming element in the engagement position can exert a lateral force on the winding wire, thus applying an elastic or plastic prestress that permanently influences the behavior of the winding wire when it strikes the winding support received in the receiving device and during the progressive formation of the coil winding in such a way that the tendency of the laid winding wire to form bulges between bending points is fully or sufficiently compensated for. Thus, each winding device may be configured to lay strand-shaped material, i.e., winding wire, to fit the contours of a non-circular support, i.e., the teeth of a winding support received in the receiving device. In this case, bulges of the wound winding material are minimized, in particular. In this context, the embodiments described for such a winding device in EP 2 309 626 A1 may be provided accordingly.

[0029] The receiving device can be configured to receive the outer grooved winding support of a traction drive, in particular a separately excited traction drive, and the winding device can be configured in each case to form a coil winding around the winding teeth of the outer grooved winding support of the traction drive, in particular a separately excited traction drive. In this way, it is provided that the winding support of the traction drive is placed on the receiving device and the coil winding is wound thereon. Correspondingly, the method according to the present disclosure can provide that the coil winding is formed on the outer grooved winding support of the rotor or stator of the traction drive. According to the present disclosure, a traction drive is understood to mean a drive device that provides powered movement of a vehicle. For example, a traction drive can drive the rotation of the wheels of a vehicle (car, truck, motorcycle), the drive (propeller) of a watercraft or boat, or the drive (e.g., propeller) of an aircraft. In a preferred embodiment, the present disclosure relates to a traction drive designed as a separately excited synchronous machine. For rotors of such traction drives, it is customary in the art to wind the coil windings with a single wire around all teeth of the rotor winding support one after the other, so that the coil windings are connected in series. In contrast, according to the present invention, multiple coil windings are wound in parallel (simultaneously) in time, so that after the winding process is completed, they are connected according to the requirements of a given application.

[0030] In particular, in connection with forming coil windings around the winding teeth of an outer grooved winding support of a traction drive, an embodiment can be provided in which the winding devices each have stripping means. By selectively stripping (stripping) the wire ends with the stripping means, contact of the wire ends for interconnecting multiple coil windings can be facilitated, i.e., improved. In particular, selective stripping with the stripping means can enable or facilitate electrical resistance welding of the wire ends for interconnecting the coil windings. As a result of improved wire end contact, the possibility of contact errors can be eliminated or reduced, thereby completely or partially compensating for or avoiding the disadvantages associated with sequentially winding the coil windings around all teeth of the rotor winding support with a single wire.

[0031] In the outer grooved winding support of a separately excited synchronous machine of a traction drive, all windings are typically wound one after the other with a single wire. Those skilled in the art face the following drawbacks: increased costs due to the need for elements for interconnecting the windings; the risk of differences in the electrical characteristics of the windings due to manufacturing tolerances between different lots of nominally identical winding wire; and the increased expense of parallel operation of multiple winding machines as opposed to parallel production of multiple windings. Surprisingly, it has been found that these drawbacks can be offset by the advantages of the winding technology disclosed herein. Thus, the winding technology disclosed herein makes it possible to individually design different windings on the winding support, for example, with different winding (wire) diameters, different winding (materials / structures), and / or different numbers of turns. By selectively contacting and interconnecting the different windings, different circuits can be realized during operation, such as so-called star-delta circuits. Furthermore, it is also possible to design windings as parallel circuits and switch them to series circuits during operation. Thus, the present disclosure makes it possible to manufacture drives individually adapted to specific applications. In particular, the driving profile of a vehicle driven by a drive unit manufactured in this way can have advantageous effects, for example in city driving and on highways, and / or the efficiency of the drive unit can be increased.

[0032] The embodiments described above in relation to the winding device may also be adapted to a method for forming coil windings on an outer grooved winding support of a rotor or stator of an electric machine.

[0033] In the winding system according to the present disclosure, the winders can be arranged next to each other or one above the other so that the longitudinal axes of the respective receiving devices are arranged parallel. Alternatively, an arrangement can be provided in which the longitudinal axes of the respective receiving devices overlap each other, i.e., an axial arrangement of the winders. As a further alternative, a matrix arrangement in which the winders are arranged in rows and columns is also possible. Preferably, the winders of the winding system are configured to operate simultaneously, so that coil windings are formed simultaneously on the winding supports. Preferably, multiple coil windings are formed simultaneously on each winding support, in turn. The winders of the winding system can be configured identically or according to different embodiments, in accordance with the winding device disclosure from the previous description.

[0034] Further embodiments will now be described in more detail with reference to the drawings. [Brief explanation of the drawings]

[0035] [Figure 1] FIG. 1 is a schematic diagram showing an isometric view of a winding machine. [Figure 2] FIG. 1 is a schematic diagram showing an isometric detail view of a winding machine. [Figure 3a] FIG. 2 is a schematic diagram of a subassembly of a winding device of a winding machine. [Figure 3b] FIG. 3b is a schematic detail view of the subassembly of FIG. 3a with a pivoting needle. [Figure 4] FIG. 2 is a schematic diagram showing a winding machine in plan view. [Figure 5] FIG. 2 is a schematic detail view showing a winding machine in plan view. [Figure 6] 1 is a schematic detailed plan view of a winding machine in which a wire feeding means is disposed in an inter-tooth portion of a winding support; [Figure 7] FIG. 2 is a schematic detailed side view of the winding machine. [Figure 8] FIG. 2 is a schematic cross-sectional view of a winding machine. [Figure 9] FIG. 2 is a schematic detail view showing a winding machine in cross section. [Figure 10] FIG. 1 is a schematic diagram showing an isometric view of a winding machine with a robotic handling device. [Figure 11] FIG. 1 is a schematic detail view of an isometric view of a winding machine with a robotic handling device. [Figure 12] FIG. 1 is a schematic diagram of a winding machine equipped with a wire storage section. [Figure 13] FIG. 1 is a schematic diagram of a winding system with two winding machines. DETAILED DESCRIPTION OF THE INVENTION

[0036] 1 shows a winding machine 1 for forming coil windings on an outer grooved winding support of a rotor or stator of an electric machine. The winding machine comprises a receiving device 2 on which an outer grooved winding support 3 is arranged. In the illustrated embodiment, the winding support 3 is a winding support for the rotor of an electric motor constituting a traction drive for an electric vehicle. Three winding devices 4 are arranged around the receiving device 2, each of which serves to form a coil winding on the winding support 3.

[0037] Figure 2 is a detailed view of the winding machine 1. The winding support 3 has a plurality of teeth 5 around which coil windings for producing a rotor are wound. The winding devices 4 are arranged at regular intervals along the circumference of the winding support 3. The winding devices 4 are configured to wind the coils according to the needle winding technique known per se. For this purpose, each of the winding devices 4 has tubular wire feed means 6, which are so-called needles.

[0038] FIG. 3a shows in detail a subassembly of a winding device 4 according to the present disclosure. Above and below the wire feed means 6, which in the illustrated embodiment has an oval tubular cross-section, are arranged pre-forming elements 7 that are movable from a rest position toward an engagement position. In the engagement position, the pre-forming elements 7 apply an elastic or plastic pre-stress to the winding wire guided from the wire feed means 6 through the pre-forming elements 7. As a result of this pre-stressing, the behavior of the winding when it strikes the teeth 5 of the winding support 3 and during the ongoing formation of the coil winding is influenced by the pre-forming mechanism so that the tendency of the laid winding to form bulges between bending points is fully or substantially partially compensated for. As a result of preventing or reducing bulges, the space between the teeth 5 of the winding support 3 is better utilized, resulting in an increased winding density. The function of the pre-forming elements 7 is described in detail in EP 2 309 626 A1.

[0039] Figure 3b shows the subassembly of Figure 3a in a state in which the wire feeding means 6 has been pivoted relative to the state shown in Figure 3a. In order to pivot the part having the wire feeding means 6, the subassembly has a pivot mechanism 8. This pivoting here takes place in the vertical direction of the winding device 4, so that the pivot axis of the wire feeding means 6 in the winding machine 1 extends perpendicularly to and at a distance from the longitudinal axis of the receiving device 2, which lies on the longitudinal axis or rotation axis of the winding support 3 received in the receiving device 2.

[0040] FIG. 4 shows a plan view of the winding machine 1, from which it becomes clear that the winding devices 4 are uniformly arranged around the receiving device 2 and the winding support 3 arranged thereon.

[0041] 1 , each winding device 4 has a drive system, which in the illustrated embodiment consists of a number of drives 9 in the form of electric motors and corresponding movement transmission mechanisms. The drive system allows each winding device 4 to move relative to a winding support 3 arranged on a receiving device 2 in axial, radial, and tangential directions parallel to the winding support 3. The receiving device 2 is equipped with a rotary drive 10, which allows the receiving device 2, together with the winding support 3 received thereon, to rotate about the longitudinal axis of the receiving device 2 and thus about the rotation axis of the winding support 3. This movement allows the winding of the winding support 3 according to the respective winding movement of the winding device 4.

[0042] The winding of one of the winding devices 4 will be described below. This description also applies to the winding operation of the other winding devices 4, in particular to the simultaneous winding operation of all winding devices 4. For this purpose, firstly, the wire is fed to the winding support 3 by the wire feeding means 6. This can be seen in particular in FIGS. 5 and 6, where FIG. 5 shows the winding machine 1 before the wire feeding by the wire feeding means 6 and FIG. 5 shows the winding machine 1 after the wire feeding by the wire feeding means 6. The wire feeding is performed so that the wire feeding means 6 is located in an intermediate space 11 between two teeth 5 of the winding support 3. Here, this feeding is performed either directly on the winding support 3 between the teeth 5 or in such a way that the wire feeding means 6 is located between the teeth 5 (but above or below the winding support 3) in plan view. During feeding, fine adjustment of the intermediate space 11 in particular can be performed by moving the winding device 4 parallel to the tangential direction of the winding support 3.

[0043] After the wire is fed, the wire feeding means 6 is guided around one of the teeth 5 of the winding support 3, and the winding is discharged from the wire feeding means by a feeding movement such that the wire is disposed around each tooth 5, thereby forming a coil winding. The wire feeding means 6 is then guided axially through the intermediate space 11. While the wire feeding means 6 emerges upward or downward from the intermediate space 11, the rotation of the winding support 3 is initiated by the rotary drive 10 of the receiving device 2 until the wire feeding means 6 is disposed above or below the other intermediate space 11 adjacent to each tooth 5. The superposition of the axial movement of the wire feeding means 6 and the rotation of the winding support 3 causes the wire feeding means 6 to follow a movement path in the shape of a segment of a circle and the (rounded) corners of each tooth 5. In another embodiment, the superposition of the axial movement of the wire feeding means 6 and the rotation of the winding support 3 can also provide a movement path in a shape other than the shape of a segment of a circle, for example, an ellipse or a shape corresponding to a functional equation. The wire feeding means 6 is then guided axially through the other intermediate space 11 and is fed back into the first intermediate space by the rotation of the receiving device 2 with the winding support 3. By repeating this winding operation, the coil winding is placed around the teeth 5. In Figure 6 it is possible to see the coil winding already wound around the teeth 5 of the winding support 3.

[0044] In the embodiment of FIGS. 1 and 2, it can be seen that the winding support 3 is received on the receiving device 2 with an oblique groove. Therefore, the winding support 3 is further rotated by the rotary drive 10 during the axial movement of the wire feeding means 6 through the respective grooves 11, so that the wire feeding means 6 follows the oblique groove shape. This rotation can be omitted in a straight-grooved winding support. In an embodiment, the rotation for feeding the wire into the other intermediate space 11 is performed only after the wire feeding means 6 has completely exited the intermediate space 11, without overlapping in time, so that the movement path of the wire feeding means 6 has an angle. Such an embodiment can be provided, for example, if the tooth edge is not rounded or if movement along a rounded path is not necessary for other reasons.

[0045] In the embodiment in which the winding device 4 is configured with a respective pivot mechanism 8 for pivoting of the wire feeding means 6, the winding movement is modified and thereby optimized by the pivoting movement.

[0046] Each winding device 4 has its own drive system, so that it can perform winding (winding) operations autonomously from the other winding devices 4, except for the rotation of the receiving device 2.

[0047] The receiving device 2 includes a workpiece support 12 on which the winding support 3 is initially received. For this purpose, the workpiece support 12 can be separated from the receiving device 2, or the winding support 3 can be placed directly on the receiving device 2 on the workpiece support 12. Before winding begins, the receiving shaft 13 of the receiving device 2 is guided through the central bore of the winding support 3, and the shoulder of the receiving shaft 13 lifts the winding support 3 from the workpiece support 12. During winding, the receiving shaft 13 is driven and rotated by the rotary drive 10, thereby rotating the winding support 3 received on the receiving shaft 13 so as to prevent relative rotation between the receiving shaft 13 and the winding support 3. The receiving shaft 13 can be provided with a clamping device for fixing the winding support 3. It is also possible to provide a winding support that is already formed on or connected to the shaft. In this case, the shaft of the winding support 3 is received in the receiving device 2 by its outer diameter, for example, by a clamping device.

[0048] Fig. 7 is a detailed side view of the winding machine 1. Fig. 8 is a side cross-sectional view. Fig. 9 is a detailed cross-sectional side view of the winding machine 1.

[0049] Figure 10 shows a further winding machine 1. Compared to the winding machine 1 shown in Figure 1, the winding machine 1 according to Figure 10 has a robot arm 14 on which a wire end handling device 15 is arranged. Figure 11 is a detailed view in which the arrangement of the handling device 15 on the winding support 3 received on the receiving device 2 can be seen.

[0050] The handling device 15 secures the starting ends of the partial windings to the contacts on the winding support 3, allowing the winding process to begin with the mechanical winding required for this purpose. These contacts are electrical contacts, into which stripped wire is preferably inserted. After the wire is inserted into the contacts with the help of the winding device 4, the handling device 15 is used to crimp the contacts and mechanically secure the wire to the contacts. The handling device 15 then grasps and cuts off the wire protruding from the contacts on the side not connected to the coil. Only then can the wire feeding (unwinding) and winding (winding) process begin. In the illustrated embodiment, the winding machine 1 has only one robot arm 14 equipped with the handling device 15. Therefore, the same securing process is performed for each winding device 4, one after the other. This applies to the mechanical securing of the ends of the partial windings, only in reverse. The winding device 4 places the ends on the corresponding contacts. The handling device 15 then clamps or crimps the contacts, thereby mechanically securing the wire. Thereafter, the connecting wire between the contact point on the side not connected to the coil and the wire feeding means 6 is cut by the handling device 15. In this way, the winding process for this partial coil is completed. This process is also carried out successively for each winding device 4.

[0051] The wire feed can be inserted at the start end into the contact and clamped to the contact without significant ejection. This allows the robot unit to first grasp the wire end and immediately begin the winding process without cutting and discarding the wire. This provides a wire loss-free operating mode without cutting and discarding wire sections.

[0052] The above-described functionality of the handling device 15, in particular according to the operating mode without wire losses, can also be provided in different embodiments of the winding machine according to the present disclosure, in particular in embodiments other than the illustrated one, where this functionality can also be provided in a different way than the described handling device 15, in particular by a corresponding alternative device, for example a handling device corresponding to each of the winding devices 4.

[0053] The winding device 4 with the subassembly shown in Figures 3a and 3b includes stripping means 16 that can remove the insulation of the windings used. In particular, the stripping means 16 removes the insulation from the start and end of the winding, allowing or facilitating contacting of the coil windings, for example via the contacts mentioned above. Furthermore, the winding device according to Figures 3a and 3b includes wire clamping means 17 that can clamp the windings to prevent them from moving along or against the feed direction. In particular, the wire supply can be configured to clamp the windings when no movement of the windings is taking place, to release the wire by the wire clamping means 17 only when the start end of the winding is clamped at the contact, and to clamp the wire by the wire clamping means 17 after fixing the end end at the contact but before the wire is cut.

[0054] FIG. 12 shows a winding machine 1 equipped with wire storage sections 18 in the form of wire rolls, and each winding wire is supplied from each wire storage section 18 to a winding device 4, which then winds the winding wire around a tooth 5 of a winding support 3.

[0055] A winding system 19 according to the present disclosure is shown in Figure 13. This winding system includes two winding machines 1 arranged such that the longitudinal axes of the receiving devices 2, and therefore the rotation axes of the winding supports 3 received thereon, are aligned parallel to one another. Thus, in the winding system 19, coil windings can be formed in parallel on the two winding supports 3, and the coil windings are formed simultaneously on the teeth 5 provided on each of the winding supports 3.

[0056] The features disclosed in the above description, the claims and the drawings may be of importance individually or in any combination to realize various embodiments.

Claims

1. A winding machine (1) for forming coil windings on an outer grooved winding support (3) of a rotor or stator of an electric machine, comprising: - a receiving device (2) for receiving said outer grooved winding support (3), and - a number of winding devices (4) arranged around said receiving device (2); It is equipped with the receiving device (2) has a longitudinal axis that is aligned with the longitudinal axis of the outer grooved winding support (3) when the outer grooved winding support (3) is received on the receiving device (2); each winding device (4) has wire feeding means (6) configured to move the winding wire along a feeding direction and thus to guide it towards the receiving device (2); each winding device (4) has a drive system configured to move its wire feeding means (6) independently of the wire feeding means (6) of the other winding devices (4) relative to the receiving device (2) during a winding wire feeding operation according to a winding operation in which the winding wire is wound around the winding teeth (5) of the outer grooved winding support (3) received on the receiving device (2) to form a coil winding; and the receiving device (2) has a rotary drive (10) by means of which the receiving device (2) can be rotated about its longitudinal axis, the rotary drive (10) being configured to rotate the receiving device (2) according to the winding motion so that the respective winding wires are wound around the respective winding teeth (5) of the outer grooved winding support (3) received on the receiving device (2) to form the respective coil windings; Winding machine (1).

2. The winding machine (1) has at least three winding devices (4) A winding machine (1) according to claim 1.

3. The plurality of winding devices (4) are arranged uniformly distributed around the receiving device (2) with respect to the circumference of a winding support (3) arranged in the receiving device (2). A winding machine (1) according to claim 1 or 2.

4. The receiving device (2) has a workpiece support (12) configured to receive the outer grooved winding support (3) and releasably arranged within the winding machine (1) to allow the outer grooved winding support (3) received on the workpiece support (12) to be transported to and from the winding machine (1). A winding machine (1) according to at least one of claims 1 to 3.

5. The drive system comprises, for each of the winding devices (4): in a first direction parallel to the longitudinal axis of the receiving device (2), and in a second direction perpendicular to and passing through the longitudinal axis of the receiving device (2), The wire feeding means (6) is configured to move in response to the winding movement relative to the receiving device (2). A winding machine (1) according to at least one of claims 1 to 4.

6. Each of the winding devices (4) is movable in a third direction perpendicular to the first direction and perpendicular to the second direction. A winding machine (1) according to any one of claims 1 to 5.

7. The drive system is configured to pivot the wire feeding means (6) for each of the winding devices (4) about a pivot axis extending perpendicular to and at a distance from the longitudinal axis of the receiving device (2). A winding machine (1) according to at least one of claims 1 to 6.

8. Each of the winding devices (4) has stripping means configured to remove the insulation of the winding wire. A winding machine (1) according to at least one of claims 1 to 7.

9. Each of the winding devices (4) has wire clamping means configured to clamp the winding wire and thus prevent the winding wire from moving along the feed direction. A winding machine (1) according to at least one of claims 1 to 8.

10. For each of the winding devices (4), at least one preforming element (7) is provided which is movable relative to the wire feeding means (6) of the winding device (4), said at least one preforming element (7) being movable between a rest position and an engagement position, in which the preforming element (7) is able to exert a lateral force on the winding wire and thus to provide an elastic or plastic prestress which permanently influences the behavior of the winding wire when it strikes the winding support (3) received on the receiving device (2) and during the ongoing formation of the coil winding, in such a way that the tendency of the laid winding wire to form bulges between bending points is fully or sufficiently partially compensated. A winding machine (1) according to at least one of claims 1 to 9.

11. The receiving device (2) is configured to receive an outer grooved winding support (3) of a traction drive, and the winding devices (4) are each configured to form a coil winding around the winding teeth of the outer grooved winding support (3) of the traction drive. A winding machine (1) according to at least one of claims 1 to 10.

12. A winding system (17) comprising a plurality of winding machines (1) according to at least one of claims 1 to 11, said winding machines (1) being configured to simultaneously produce coil windings on respective outer grooved winding supports (3) of a rotor or a stator of an electric machine in said winding system (17). Winding system (17).

13. 1. A method for forming a coil winding on an outer grooved winding support (3) of a rotor or stator of an electric machine, comprising: - receiving said outer grooved winding support (3) on a receiving device (2) of the winding machine (1) in such a way that the longitudinal axis of said receiving device (2) lies on the longitudinal axis of said outer grooved winding support (3); - forming a plurality of coil windings simultaneously around each of the winding teeth (5) of the outer grooved winding support (3) by a plurality of winding devices (4) of the winding machine (1) arranged around the receiving device (2), wherein each of the winding devices (4) forms a respective coil winding; Including, - the winding wire is moved along a feeding direction by wire feeding means (6) of each said winding device (4) and thus fed to each said winding tooth (5); - during the feeding movement of the winding wire, the wire feeding means (6) of each of the winding devices (4) is moved by the drive of each of the winding devices (4) relative to each of the winding teeth (5), independently of the wire feeding means (6) of the other winding devices (4), according to the winding movement, and thus wound around each of the winding teeth (5); - the outer grooved winding support (3) is rotated according to the winding movement by the rotary drive (10) of the receiving device (2) so that each of the winding wires is wound around each of the winding teeth (5) of the outer grooved winding support (3) to form each of the coil windings; method.

14. The coil windings are formed on the outer grooved winding support (3) of the rotor or stator of the traction drive. The method of claim 13.

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