Method for manufacturing a coil winding for insertion into a radially open slot of a stator or rotor of an electric machine - Patents.com

Abstract

The present invention relates to a method for manufacturing a coil winding 70 for insertion into a radially open slot 82 of a rotor or stator 80 of an electric machine. The coil winding comprises a wire pack 60 of a plurality of wires 32, the wires of which run parallel to one another and are connected in pairs at one end of the wire pack. The coil winding is formed by a flat winding former that can be rotated about a rotation axis 26. The wire pack is fixed on the winding former, and a winding head 42 is generated by displacing the wire pack. The winding shaft can be rotated, so that after carrying out the method, the coil winding is in the form in which the wires of the wire pack are pre-connected in pairs at one end. This method allows for the manufacture of a particularly space-saving coil winding, which has high mechanical stability and requires minimal installation space in the rotor or stator.

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing coil windings for insertion into radially open slots in a rotor or stator of an electric machine, the coil windings being formed by a flat winding former that can be rotated about an axis of rotation.

[0002] The method is particularly suitable for use with wires that are substantially rectangular in cross section, which is favorable with regard to optimal filling of the stator slots, as traditional round wire winding methods cannot be used with this type of wire cross section.

[0003] The method is primarily useful for producing coil windings that can be subsequently inserted into the slots of a stator (or rotor), so-called distributed wave windings, such coil windings or distributed wave windings are also called bar wave windings.

[0004] A distributed wave winding has multiple parallel wires with straight sections disposed within the slots of a stator. These straight sections alternate between an inner radial position and an adjacent outer radial position within the stator as the wire pattern moves radially around the stator. This distributed wave pattern includes X phases or grouped slots within the stator. Typically, X is a multiple of 3, although constructions where X is any other integer are possible. Similarly, it is also possible to provide a wave winding without alternating straight sections for adjacent open slots in the stator or rotor.

[0005] The exact appearance of the windings that are produced will be discussed in more detail in the context of the embodiments. [Background technology]

[0006] A method for producing such windings is known from DE 10 2015 120 661 A1, which method is based on continuous wave windings. In this case, coil windings for insertion into radially open slots of the stator or rotor of an electric machine are produced, which consist of a number of interwoven wires, which are repeatedly bent in opposite directions such that the parallel legs of the wires intended to fill the slots are connected by a roof-like winding head protruding above the rotor or stator at the end side. In this case, a flat, rotatable winding former is used. The coil winding to be inserted into the stator has open ends at both ends of the wave winding, which are formed by a part of the wire.

[0007] Especially in applications with three electrical phases, when more than three wires are wound to form a wave or coil winding, the open wire end must be connected to one end of the wave or coil winding. This connection is made by specially provided connection pieces or by permanent adhesive connection of the wire ends after inserting the wave or coil winding into the stator or rotor or after finishing the manufacturing of the coil winding. In such cases, additional installation space is required for this type of connection by connection pieces and / or the electrical contact is impaired by transition resistances and / or material differences. In addition, an additional assembly step is required when equipping the stator or rotor with respect to the electrical configuration of the coil winding. Summary of the Invention [Problem to be solved by the invention]

[0008] The object of the invention is to provide a method of the type mentioned at the beginning, which simplifies the manufacture of a stator or rotor having a wave winding or coil winding and allows reliable and space-saving operation of an electric machine having such a stator or rotor. [Means for solving the problem]

[0009] According to the invention, this object is achieved by a method of the type mentioned in the introduction, in which the coil winding comprises a wire pack consisting of a plurality of wires, the wires of the wire pack running parallel to one another and connected to one another in pairs at one end of the wire pack, the method comprising the steps of: a) feeding a wire pack to be used for winding a coil perpendicular to a winding former; b) holding the wire pack at a fixed point within a first holding area on the winding former; c) holding the wire pack at a fixed point in a second holding area at a distance in front of the winding former relative to the unwinding direction; d) displacing the first holding area relative to the second holding area in a direction parallel to the rotation axis of the winding former to form a wire portion between the first holding area and the second holding area that is inclined with respect to the unwinding direction; e) rotating the winding former 180° about the axis of rotation while feeding the wire pack from the feeding direction, whereby the fixing point is displaced from the first holding area into a third holding area opposite the first holding area of ​​the winding former and the fixing point is displaced from the second holding area into the first holding area, whereby a winding head extending around the winding former is formed on the wire pack by forming a bending area; f) subsequently fixing the unwound wire pack at a fixing point within the second holding region; g) repeating steps d) to f), where the holding effect on the fixed point in the third holding region is released before or after the repetition of step f), and the holding effect on the second fixed point is released before the repetition of step e); h) repeating steps b) to g) until the coil winding is completed; i) severing the wire pack in the area of ​​the second holding area; j) stripping the coil winding from the winding former; Includes.

[0010] The fact that the method is carried out with a wire pack, the wires of which run parallel to one another and are connected to one another in pairs at one end of the wire pack, results in the advantage that the wires do not have to be connected subsequently, i.e. after the manufacture of the coil winding or after the coil winding has been installed in the core of the rotor or stator with open slots. This considerably simplifies the manufacture of the stator or rotor with wave windings or coil windings. The wire pack, on which the coil windings are manufactured, can be preassembled to the electrical configuration by providing the corresponding connections.

[0011] This pre-assembly of the wire routing in the wire pack also increases the security of the electrical connection of the conductors in the coil winding. After the coil winding is installed in the rotor or stator, the subsequent connection of the corresponding wires of the wire pack from which the coil winding is composed can be omitted. The assembly of the electrical connection can preferably be performed under ideal conditions in advance, as well as in the installed state of the coil winding in the stator or rotor. This ensures an optimal connection of the wires to be connected. In contrast, the subsequent connection of the wires from the coil winding in the installed state in the stator or rotor is often only possible with a clamped or screwed connection, which results in a reduced reliability.

[0012] Furthermore, it is advantageous that in this way the connection can be made particularly space-saving, since the wires have to be connected to one another individually before the production of the wave or coil windings, and thus smaller dimensions can be achieved for the rotor or stator, particularly in the axial direction.

[0013] Preferred embodiments of the method are set out in claims 2 to 11.

[0014] In a further embodiment of the invention, it is provided that the wire pack is first manufactured by determining twice the length of wire required for the coil winding and then manufacturing the wire pack by bending the wire to the length required for manufacturing the coil winding so that the wires are connected to each other in pairs at one end of the wire pack.

[0015] As a result, the wires connected to each other in pairs are formed in one piece, since they consist of one wire. There is therefore no need to create a separate connection. This is advantageous, since the wire packs produced according to this method are particularly space-saving and provide a particularly reliable connection between the wires in pairs.

[0016] According to a further embodiment of the invention it is provided that the wire pack, starting from the end where the wires are connected to one another in pairs, is fed perpendicularly to the winding former.

[0017] Such a feed results in the advantage that the end with the wires connected in pairs is placed on the winding former first. Connecting the wires in pairs increases the completeness of the placement of the wires on the winding former. Furthermore, there is the further advantage that the open end of the wire pack, which does not have wires connected to each other in pairs, is placed on the feed side. As a result, the placement of the wires in the wire pack can be changed during its feed, which allows a variably designed sequence of the wires on the winding former.

[0018] In a further embodiment of the method, the displacement in method step d) is performed in only one section parallel to the rotation axis of the winding former, the length of the section being approximately equal to half the distance between the outermost wires of the wire pack for all wires, whereby a wire portion inclined with respect to the rotation axis of the winding former is formed between the first and second holding areas.

[0019] By providing a displacement whose length is approximately equal to half the distance between the outermost wires for all wires, the inclined wire sections are formed with a geometry that is favorable for the installation of the coil winding in the open slots of a rotor or stator. The coil windings thus produced can be inserted in the open slots of a stator or rotor in a space-saving manner, without the geometry of the wave winding or coil winding hindering its use. In particular, this configuration is advantageous, since it also makes it possible to form winding heads that only minimally protrude in the axial direction beyond the body of the stator or rotor core.

[0020] According to a further aspect of the method, it is provided that the winding head is reshaped in the bend area formed by step e) For this purpose, it is provided that a contour shaping tool is pressed against the winding head for final shaping of the winding head after method step e).

[0021] The reshaping can compensate for irregularities in the shape of the winding heads, and also serves to further reduce the protrusion of the winding heads on the stator or rotor cores, among other things.

[0022] According to a further embodiment, it is provided that in step b) the wire pack is held on the winding former by a first holding device in a first holding area and in step c) the wire pack is held by a second holding device in a second holding area.

[0023] According to a further embodiment of the invention, it is preferably provided that for each holding device, its individual displacement is possible parallel to the rotation axis of the winding former so that steps b) to d) of the method can be carried out. Such holding devices can be designed as active clamps or guide channels through which the wire passes or is placed on the wire. It is therefore sufficient to place a holding device with a suitable geometric shape on the wire, which provides sufficient retention against slipping during lateral displacement. The clamping device used in the second holding area is in an advantageous embodiment of the invention part of the wire or wire pack delivery. In a further optional embodiment of the invention, the clamping device in the second holding area contributes to creating a mechanical tension in the wire pack or wire between this clamping device and the clamping device in the first holding area. Alternatively or additionally, the clamping device in the second holding area can create a mechanical tension in the wire pack or wire between the wire delivery and this clamp. According to a further aspect of the invention, the holding devices are not bound to the corresponding holding areas but can move between the three holding areas, whereby the holding devices can maintain their holding effect not only during their displacement but also during rotation of the winding former.

[0024] A further embodiment of the invention results in that the first holding area, the third holding area and the second holding area follow one another in this order in the rotational direction of the winding former, and each holding device is transferred in the rotational direction from one holding area to the next with a rotation according to step e).

[0025] In this way, the release of the holding effect at the third holding area can take place, for example, before step f), and the displacement of the holding device from the third holding area to the second holding area can be performed during the next rotation process of the winding former: the holding device moves from the first holding area to the third holding area during the rotation process of the winding former, then from the third holding area to the second holding area during the next rotation process and finally again from the second holding area to the first holding area, and the sequence of movements is repeated from the first holding area when the winding former rotates further.

[0026] According to a further embodiment of the invention, the cutting of the wire pack in step i) is performed in a rotational position of the winding former, in which the ends of the wire pack in which the wires are connected to each other in pairs are on the side of the second holding area.

[0027] This results in a particularly advantageous method in which the start and end of the coil winding or wire pack are located on the same side of the rotor or stator in the inserted state, as viewed in the axial direction. This facilitates any access to the electrical connection and connection of the pairs of wires, if necessary. According to a further aspect of the invention, the cutting of the wire pack in step i) is performed in a rotational position of the winding former, in which the ends of the wire pack, in which the wires are connected to each other in pairs, are on the opposite side of the second holding area. In the case of such a method sequence, after the installation of the coil winding in the rotor or stator, the arrangement of the open ends of the coil winding, as viewed in the axial direction, can be on another side of the rotor or stator, which can result in advantages, in particular with regard to the connection and utilization of the installation space.

[0028] According to a further aspect of the invention, it is provided that the wires connected in pairs are swapped in pairs one or more times during delivery prior to reaching the second holding area with other wires connected in pairs during the course of the method.

[0029] By exchanging wires connected to each other in pairs, coil windings inserted into open slots of a rotor or stator have the advantage in terms of current conduction that the wires connected in pairs can each take different positions in the open slot in the radial direction, which advantageously reduces the generation of eddy currents.

[0030] In an alternative embodiment of the method, it is provided that the wire pack is cut to length prior to carrying out method step a), and that the unwinding of the wire pack used for the coil winding in step a), with the wires not being connected to each other in pairs at one end of the wire pack, is carried out in a unwinding direction perpendicular to the winding former, and step i) is omitted.

[0031] In this way, the method is somewhat simpler since one method step is omitted. Naturally, this results in a shorter cycle time. Furthermore, on the wire delivery side, the wires connected to each other in pairs provide better integrity of the wire pack, which makes it easier to configure the wire delivery section.

[0032] Claim 12 relates according to a further aspect of the invention to a wire pack for use in the method according to the invention according to the embodiment as claimed in claim 13, which comprises a plurality of wires extending parallel to one another, the wires being respectively connected to one another in pairs at one end of the wire pack. According to this embodiment, the wires connected to one another in pairs are integrally formed from a continuous single wire bent at one end of the wire pack, the bent shape of all the continuous wires corresponding to the shape of the winding head.

[0033] This pre-assembly of the wire routing in the wire pack also increases the security of the electrical connection of the conductors in the coil winding. After the coil winding is installed in the rotor or stator, the subsequent connection of the corresponding wires of the wire pack from which the coil winding is composed can be omitted. The assembly of the electrical connection can be performed under ideal conditions in advance, and not only when the coil winding is in the installed state in the stator or rotor. This ensures an optimal connection of the wires to be connected. In contrast, the subsequent connection of the wires from the coil winding in the installed state in the stator or rotor is often only possible with a clamped or screwed connection, which results in a reduced reliability. By providing an integral connection, it is not necessary to create a separate connection. This is advantageous, since such a wire pack is particularly space-saving and provides a particularly reliable connection between the wires in pairs.

[0034] Claim 14 relates according to a further aspect of the invention to a stator or rotor of an electric machine with a coil winding manufactured by the method according to the invention and a further embodiment according to claim 15, according to which the coil winding manufactured by the method is inserted into the slots such that a first half of the wire of the coil winding arranged between two winding heads is inserted into a first slot of two consecutive slots and a second half of the wire of the coil winding arranged between two winding heads is inserted into a second slot of two consecutive slots. According to this embodiment, it is provided that the end of the coil winding with the wires connected to each other in pairs and the end of the coil winding where the wire pack is cut are located on the same side of the stator or rotor.

[0035] Inserting the coil winding produced by this method into a rotor or stator or rotor or stator core has the advantage that this rotor or stator or rotor or stator core can be designed in a particularly space-saving manner, since the wires have to be connected to one another separately before the production of the wave winding or coil winding, and therefore the dimensions of the rotor or stator, in particular the axial dimensions, can be made smaller, since no additional installation space needs to be provided for the connections.

[0036] Subsequently, embodiments of the invention will be discussed in more detail with reference to the accompanying drawings. [Brief description of the drawings]

[0037] [Figure 1] FIG. 2 is a sequence diagram of the method for manufacturing a coil winding, in which in the upper part a a schematic end view of a winding device with three circumferential holding devices for carrying out the method is shown, in the middle part b a top view of the winding device is shown, and in the lower part c a plan view of only the coil turns already produced in this step is shown. [Diagram 2] FIG. 2 is another sequence diagram of the method for manufacturing a coil winding, where in the upper part a a schematic end view of a winding device with three circumferential holding devices for carrying out the method is shown, in the middle part b a top view of the winding device is shown, and in the lower part c a plan view of only the coil turns already produced in this step is shown. [Diagram 3] FIG. 2 is another sequence diagram of the method for manufacturing a coil winding, where in the upper part a a schematic end view of a winding device with three circumferential holding devices for carrying out the method is shown, in the middle part b a top view of the winding device is shown, and in the lower part c a plan view of only the coil turns already produced in this step is shown. [Figure 4] FIG. 2 is another sequence diagram of the method for manufacturing a coil winding, where in the upper part a a schematic end view of a winding device with three circumferential holding devices for carrying out the method is shown, in the middle part b a top view of the winding device is shown, and in the lower part c a plan view of only the coil turns already produced in this step is shown. [Diagram 5] FIG. 2 is another sequence diagram of the method for manufacturing a coil winding, where in the upper part a a schematic end view of a winding device with three circumferential holding devices for carrying out the method is shown, in the middle part b a top view of the winding device is shown, and in the lower part c a plan view of only the coil turns already produced in this step is shown. [Figure 6] FIG. 2 is another sequence diagram of the method for manufacturing a coil winding, where in the upper part a a schematic end view of a winding device with three circumferential holding devices for carrying out the method is shown, in the middle part b a top view of the winding device is shown, and in the lower part c a plan view of only the coil turns already produced in this step is shown. [Figure 7] FIG. 2 is another sequence diagram of the method for manufacturing a coil winding, where in the upper part a a schematic end view of a winding device with three circumferential holding devices for carrying out the method is shown, in the middle part b a top view of the winding device is shown, and in the lower part c a plan view of only the coil turns already produced in this step is shown. [Figure 8] FIG. 2 is another sequence diagram of the method for manufacturing a coil winding, where in the upper part a a schematic end view of a winding device with three circumferential holding devices for carrying out the method is shown, in the middle part b a top view of the winding device is shown, and in the lower part c a plan view of only the coil turns already produced in this step is shown. [Figure 9] FIG. 2 is another sequence diagram of the method for manufacturing a coil winding, where in the upper part a a schematic end view of a winding device with three circumferential holding devices for carrying out the method is shown, in the middle part b a top view of the winding device is shown, and in the lower part c a plan view of only the coil turns already produced in this step is shown. [Figure 10] FIG. 2 is another sequence diagram of the method for manufacturing a coil winding, where in the upper part a a schematic end view of a winding device with three circumferential holding devices for carrying out the method is shown, in the middle part b a top view of the winding device is shown, and in the lower part c a plan view of only the coil turns already produced in this step is shown. [Figure 11]FIG. 2 is another sequence diagram of the method for manufacturing a coil winding, where in the upper part a a schematic end view of a winding device with three circumferential holding devices for carrying out the method is shown, in the middle part b a top view of the winding device is shown, and in the lower part c a plan view of only the coil turns already produced in this step is shown. [Figure 12] 1A-1C show a sequence of steps for manufacturing a wire pack having wires connected in pairs at one end of the wire pack. [Figure 13] FIG. 2 is another diagram showing a sequence of steps for manufacturing a wire pack having wires connected in pairs at one end of the wire pack. [Figure 14] FIG. 2 is another diagram showing a sequence of steps for manufacturing a wire pack having wires connected in pairs at one end of the wire pack. [Figure 15] FIG. 2 is a plan view of a coil winding produced by the present method. [Figure 16] FIG. 16 is a diagram of a stator with the windings from FIG. 15 received in the slots. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] Figure 1 shows the starting point of a method for producing a coil winding 70 (see Figure 16) for a stator of an electric motor (not shown) using a wire pack 60 produced according to the steps shown in Figures 12 to 15. Such a coil winding 70, or dispersive wave winding, is also called a bar wave winding.

[0039] For this purpose, in the illustrated embodiment, a winding device 10 is provided, which has a winding head with a wire handling device 14, which in turn has three holding devices 18, 20, 22 (see also FIG. 3) and a winding head forming device 24.

[0040] The winding device 10 cooperates with a winding former 26 designed as a flat former, i.e. having a strip-like shape, a cross section of which is shown in the upper part of the diagram in Fig. 1, which reveals edge regions 27 of the winding former 26 tapering towards the sides, and the radii of the sides themselves.

[0041] The length of the winding former 26 (not shown in its entirety) is determined by the length of the coil winding 70 to be produced and the exact configuration of the method, and the length of the winding former 26 does not have to correspond to the length of the coil winding 70. The winding former 26 can be significantly shorter than the coil winding 70, for example, if the coil winding 70 has already been continuously passed from the winding former 26 to a transfer device (not shown) during the method.

[0042] The winding apparatus 10 is also associated with a wire rolling apparatus 28, which performs rolling shaping of the wire 32 being processed for better contact with the winding former 26 during the turning process.

[0043] The method sequence is as follows: According to Figure 1, the first holding device (A) 18 is in a waiting position spaced apart from the winding former 26.

[0044] The second holding device (B) 20 is in the release position so that the passing wire packs 60 are not jammed. In the embodiment shown, wire packs 60 are processed, each having 12 wires 32 connected in pairs. The wires 32 are guided parallel to one another.

[0045] 1, the wire pack 60 is positioned on the winding former 26 such that its winding head 42 rests at least partially on the winding former 26. The wire pack 60 is able to pass unimpeded through the second holding device (B) 20 which is not yet jammed.

[0046] The first holding device (A) 18 is then moved from its rest position to a holding position close or adjacent to the winding former 26. Triggering defines a first holding point in a first holding area 34 on the upper side of the flat winding former 26. Temporally adjacent to the jamming of the wire pack 60 in the first holding area 34, triggering of the second holding device (B) 20 occurs such that a second holding area 36 of the wire is defined, this second holding area being at a specific distance from the first holding area 34. The second holding area 36 is next to the first holding area 34 in the unwinding direction R.

[0047] 2 further shows a method step in which inclined wire portions 40 are manufactured. These wire portions 40 form further winding heads 42 between straight legs 44 that will later be located in slots of a stator or rotor. The winding heads 42 will be discussed in more detail in the subsequent method steps and also below.

[0048] It can also be clearly seen in Figure 2, in comparison with Figure 1, that the second holding device 20 is brought closer to the wire handling device 14 by a displacement step, since the length of the inclined portion 40 should preferably correspond to the distance between the first holding area 34 and the second holding area 36 in Figure 3. This readjustment movement can be induced and performed by active tracking or passive compensation movements.

[0049] After the step shown in FIG. 2 of displacing the wire portion secured in the first holding area 34 relative to the wire portion secured in the second holding area 36 by forming the inclined wire portion 40, the rotation device 28 is actuated to rotate the winding former 26 and the first holding device (A) 18, which is also rotationally coupled, from the first holding area 34 to the third holding area 46 shown in FIG. 3, and the second holding device (B) 20, which is similarly packed with wire 32, is taken from the second holding area 36 into the first holding area 34, and the wire pack 50 is further fed in the payout direction R.

[0050] With the wire 32 adhering to the side surface 27 of the winding former 26, the inclined wire portion 40 is transferred by the rotation of the winding former 26 to the already mentioned roof-shaped winding head 42, which tapers towards a turn-around point 48 corresponding to the shape of the side surface 27. The bend radius of each wire 32 of the wire pack 60 is formed at the turn-around point 48 itself. In Fig. 3 the third holding device (C) 22 is also shown for the first time, but in this case still in the rest position, since it will only be used later in the method sequence.

[0051] 4 shows an optional step in which the previously manufactured winding head 42 is given its final shape by the wire former 24. The wire former 24 has a shaping element 50, which is designed as the negative shape of the desired end shape of the winding head 42 and is pressed against the winding head 42 under pressure.

[0052] In preparation for the next method step, the third holding device (C) 22 is moved into the second holding area 36. The first holding device (A) 18 may also already be released, but it is possible that the wires 32 of the wire pack 60 remain stuck in the third holding area 46 during the next method step.

[0053] The next method step shown in FIG. 5 again results in the formation of an inclined wire portion 40 between a holding point in the second holding area 36 previously created by triggering the third holding device (C) 22 and a holding point created by the second holding device (B) 20, which is still jammed and still located within the first holding area 34.

[0054] This in turn occurs due to the relative axial displacement of the jammed holding devices (in this case holding device (B) 20 and holding device (C) 22) in the first and second holding areas 34, 36 parallel to the rotation axis of the winding former 26.

[0055] If the third holding device (C) 22 is still jammed, which may be advantageous for reasons of stabilizing the already produced portion of the coil winding 70, the holding device (A) 18, together with the holding device (B) 20 in the first holding area, moves in the third holding area 46 axially relative to the holding device (C) 22 in the second holding area 36.

[0056] At the bottom of FIG. 5 it can be seen that after this step, the first portion of the parallel leg 44 produced in the step according to FIG. 2 is located underneath the winding former 26 laterally offset relative to the wire 32 of the wire pack 60 being fed out from the feeding direction R.

[0057] This means that the generated first wire portion does not interfere with the subsequent wire when the winding process is subsequently performed again through 180° by correspondingly rotating the winding former 26. The explanation with respect to Figure 3 also applies mutatis mutandis to the winding process according to Figure 5, but the holding devices 18, 20, 22 are arranged in different holding areas.

[0058] FIG. 6 (bottom) shows a complete first turn of the future coil winding on the winding former 26 with the winding heads 42 on either side of the straight legs 44 that will later rest in slots in the stator or rotor 80.

[0059] As shown in FIG. 7, in order to optimize the shaping of the winding head 42, the optional step of shaping the winding head 42 is then carried out again by means of the shaping element 50 of the wire forming device 24 already described in relation to FIG.

[0060] 2 to 7 are then repeated corresponding to the required turns of coil winding 70, but the arrangement of holding devices 18, 20 and 22 varies and does not always correspond to the positions of the holding devices shown here, since they change their respective relative positions after each run, as is readily apparent to the skilled person from the different arrangements of Figures 2 to 4 on the one hand, and from Figures 5 to 7 on the other hand.

[0061] This sequence is of course repeated periodically so that the holding devices 18, 20, 22 return to their corresponding positions every three winding processes through 180°.

[0062] 8 to 10 show a final sequence of the method steps according to FIGS. 5 to 7, in which the arrangement of the holding devices 18, 20 and 22 according to the above-mentioned sequence is located at the different holding points 34, 36, 46 respectively.

[0063] The final step in producing a complete coil winding 70 is shown in Figure 11. At this point, a number of the straight legs 44 desired for mounting to rotor or stator slots 82 have been produced. However, in Figure 11, only a shortened version of the coil winding 70 is shown for greater clarity.

[0064] The above method ensures that all connecting wires 17 (see FIG. 15) of the completed coil winding 70 are on one side.

[0065] 11 shows the final method step: a final displacement process of the first holding area 34 (in this case again using the jammed first holding device (A) 18) to a second holding area 36 (in this case holding device (B) 20) parallel to the rotation axis of the winding former 26, before the finished coil winding 70 is separated from the fed wire pack 60 by a cutting device (not shown). After the cutting process of the wire 32, the wire end inclined to the leg 44 forms the connection wire 17 serving as the electrical connection of the coil winding 70. After the cutting process of the wire end from the fed wire pack 60, the finished coil winding 70 is then transferred in a manner known per se to the stator 80 or rotor, whereby it is first stripped from the winding former and, if necessary, placed in an intermediate step on a transfer device (not shown).

[0066] The method is not specified with respect to the number of wires processed in parallel, which is shown as 12 in the illustrated and described embodiment. Due to the dispersive wave pattern of the coil windings 70, any even number of wires can be processed in parallel. The method is suitable for any practical number of wires 32, although non-dispersive wave patterns may be produced for the windings. As already mentioned, the method is particularly intended for producing coil windings 70 from flat wires having a rectangular cross section.

[0067] 12-14 show how the wire pack 60 is produced, which is delivered to the winding apparatus 10 in the first method step. The wire pack 60 is first produced by determining twice the length of wire 32 required for the coil winding 70 (FIG. 12) and providing the wire 32 or wire pack 60.

[0068] Figures 12 and 14 show how the connection of the wires 32 for the wire pack 60 is produced. This is done by bending the wires 32 to the length required for the manufacture of the coil winding 70, so that they are connected to each other in pairs at one end of the wire pack 60. For this purpose, an apparatus such as that used for the method according to Figures 1 to 11 can be used, the first winding head 42 (see Figure 14) being preferably produced with about half the wire length determined by the method described above, by displacing the holding device and rotating the winding former 26 in order to produce the inclined wire portion 40.

[0069] Figure 15 shows the coil winding 70 prefabricated in a flat state, a position which corresponds to the state in which the coil winding 70 is on the strip-shaped winding former 26, not shown. This illustrated coil winding 70 is a coil winding 70 produced from a wire package 60 originally composed of six individual wires 32a-f according to Figures 12-14, whereby after the manufacturing method according to Figures 1-11, twelve connecting wires 17 are available on one side of the coil winding 70.

[0070] The basic steps in the method do not change if, for example, six parallel wires 32 are not fed to produce the wire pack 60, but rather only three or some other integer multiple of three. The axial path is correspondingly increased or decreased when displacing and forming the angled transition region 40 between the straight legs 44.

[0071] FIG. 16 shows, by way of example, a stator 80 in which coil windings 70 are inserted into the stator slots 82. The connecting wires 17 are at the axial end faces of the stator 80, which facilitates their connection. It can also be seen that in the embodiment shown, the length of the coil windings 70 is a multiple of the circumference of the stator 80, which in the embodiment shown is twice as long. Particularly in the case of a rectangular cross section, an excellent filling of the slots 82 can be achieved by the stator thus manufactured, which allows a compact motor to have a high level of efficiency. In this embodiment of the stator in which the coil windings 70 are inserted, a coil winding 70 with six connecting wires is shown, the above-mentioned coil windings 70 having a number of wires 32 corresponding to another integer multiple of three are also used. [Explanation of symbols]

[0072] 10 Winding device 14 Wire handling equipment 17 Connecting Wires 18 First holding device 20 Second holding device 22 Third holding device 24 Wire forming equipment 26 Winding former 26 Winding former 27 Side 32 Wire 32a~32f single wire 34 First Holding Point 36 Second Holding Point 40 Inclined wire section 42 Winding head 44 Straight leg 46 Third Holding Point 50 Molding Elements 60 Wire Pack 70 Coil Winding 80 Stator 82 Stat Slot R Feeding direction [Item of invention] [Item 1] 1. A method for manufacturing a coil winding (70) for insertion into a radially open slot (82) in a rotor or stator (80) of an electric machine, comprising the steps of: the coil winding (70) comprises a wire pack (60) of a plurality of wires (32), the wires (32) of the wire pack (60) extending parallel to one another and connected to one another in pairs at one end of the wire pack (60); the coil winding (70) is formed by a flat winding former (26) that can rotate about a rotation axis; The method further comprising: a) feeding the wire pack (60) used for the coil winding (70) perpendicularly to the winding former (26); b) holding the wire pack (60) at a fixed point within a first holding area (34) on the winding former (26); c) holding the wire pack (60) at a fixed point in a second holding area (36) at a distance in front of the winding former (26) relative to the unwinding direction (R); d) displacing the first holding area (34) relative to the second holding area (36) in a direction parallel to the rotation axis of the winding former (26) to form a wire portion (40) inclined with respect to the unwinding direction (R) between the first holding area (34) and the second holding area (36); e) rotating the winding former (26) 180° about the rotation axis while feeding the wire pack (60) from the feeding direction (R), such that the fixing point is displaced from the first holding area (34) into a third holding area (46) on the opposite side of the winding former (26) from the first holding area (34), and the fixing point is displaced from the second holding area (36) into the first holding area (34), whereby a winding head (42) extending around the winding former (26) is formed on the wire pack (60) by forming a bending area; f) subsequently fixing the unwound wire pack (60) to the fixing point within the second holding area (36); g) repeating steps d) to f), wherein the holding effect on the fixed point in the third holding region (46) is released before or after the repetition of step f), and the holding effect on the second fixed point is released before the repetition of step e); h) repeating steps b) to g) until the coil winding (70) is completed; and i) severing the wire pack (60) within the area of ​​the second holding area (36); j) stripping the coil winding (70) from the winding former (26); A method comprising: [Item 2] 2. The method of claim 1, wherein the wire pack (60) is first manufactured in that twice the length of the wire (32) required for the coil winding (70) is determined, and the wire pack (60) is manufactured by bending the wires (32) to the length required for manufacturing the coil winding (70) such that the wires (32) are connected to each other in pairs at one end of the wire pack (60). [Item 3] 3. The method according to claim 1 or 2, characterized in that the wire pack (60) is fed perpendicularly to the winding former (26), starting from the ends where the wires (32) are connected to each other in pairs. [Item 4] 4. The method according to any one of claims 1 to 3, characterized in that the displacement in step d) is performed in only one section parallel to the rotation axis of the winding former (26), the length of the section being approximately equal to half the distance between the outermost wires of the wire pack (60) for all wires, whereby a wire portion (40) inclined with respect to the rotation axis of the winding former (26) is formed between the first and second holding areas (34, 36). [Item 5] 5. The method according to any one of claims 1 to 4, characterized in that the winding head (42) is reshaped in the bending area formed by step e). [Item 6] 6. The method according to claim 5, characterized in that for the final shaping of the winding head (42) after step e), a contour shaping tool (50) is pressed against the winding head (42). [Item 7] 7. The method according to any one of claims 1 to 6, characterized in that in step b) the wire pack is held on the winding former (26) in the first holding area (34) by a first holding device (18) and in step c) the wire pack is held by a second holding device (29) in the second holding area (36). [Item 8] 5. The method according to claim 4, characterized in that the first holding area (34), the third holding area (46) and the second holding area (36) follow one another in this order in a rotational direction of the winding former (26) and each holding device (28, 29, 33) is transferred in said rotational direction from a holding area (34, 36, 46) to a subsequent holding area (34, 36, 46) with a rotation according to step e). [Item 9] 9. The method according to any one of claims 1 to 8, characterized in that the cutting of the wire pack (60) in step i) is performed in a rotational position of the winding former (26), in which the ends of the wire pack (60) in which the wires are connected to each other in pairs are on the side of the second holding area (36). [Item 10] 10. The method according to any one of claims 1 to 9, characterized in that the wires (32) connected in pairs are exchanged in pairs with other wires (32) connected in pairs during the delivery before reaching the second holding area (36) one or more times during the method. [Item 11] 10. The method according to any one of claims 1 to 9, characterized in that the unwinding of the wire pack (60) used for the coil winding (70) in step a) is performed in a unwinding direction (R) perpendicular to the winding former (26), with the wire pack being cut to length before carrying out step a) and the wires (32) not being connected to each other in pairs at one end of the wire pack (60), and step i) is omitted. [Item 12] A wire pack (60) for carrying out the method according to any one of items 1 to 11, A wire pack (60) comprising a plurality of wires extending parallel to one another, each of the plurality of wires being connected to one another in pairs at one end of the wire pack (60). [Item 13] Item 13. The wire pack (60) according to item 12, characterized in that the wires connected to each other in pairs are integrally formed from a continuous single wire (32a, 32b, 32c, 32d, 32e, 32f) bent at one end of the wire pack (60), and the shape of the bend of all the continuous individual wires (32a, 32b, 32c, 32d, 32e, 32f) corresponds to the shape of the winding head (42). [Item 14] A stator (80) or rotor for an electric machine having radially open slots (82), A stator (80) or rotor, characterized in that the coil winding (70) according to any one of items 1 to 11 is inserted into the slots (82) such that a first half of a wire (32) of the coil winding (70) arranged between two winding heads (42) is inserted into a first slot (82a) of two consecutive slots (82a, 82b) and a second half of the wire (32) of the coil winding (70) arranged between two winding heads (42) is inserted into a second slot (82b) of the two consecutive slots (82a, 82b). [Item 15] 15. A stator (80) or rotor according to item 14, characterized in that the end of the coil winding (70) having the wires (32) connected to each other in pairs and the end of the coil winding (70) where the wire pack (60) is cut are located on the same side of the stator (80) or rotor.

Claims

1. 1. A method for manufacturing a coil winding (70) for insertion into a radially open slot (82) in a rotor or stator (80) of an electric machine, comprising the steps of: The coil winding (70) has a wire pack (60) of a plurality of wires (32), the wires (32) of the wire pack (60) extending parallel to one another and connected to one another in pairs at one end of the wire pack (60); the wires connected together in pairs are integrally formed from a single continuous wire (32a, 32b, 32c, 32d, 32e, 32f) bent at one end of the wire pack (60), and the shape of the bend of all the continuous individual wires (32a, 32b, 32c, 32d, 32e, 32f) corresponds to the shape of the winding head (42); Furthermore, the coil winding (70) is formed by a flat winding former (26) that can rotate about a rotation axis; The method further comprising: a) feeding the wire pack (60) used for the coil winding (70) perpendicularly to the winding former (26); b) holding the wire pack (60) at a fixed point within a first holding area (34) on the winding former (26); c) holding the wire pack (60) at a fixed point in a second holding area (36) at a distance in front of the winding former (26) relative to the unwinding direction (R); d) displacing the first holding area (34) relative to the second holding area (36) in a direction parallel to the rotation axis of the winding former (26) to form a wire portion (40) inclined with respect to the unwinding direction (R) between the first holding area (34) and the second holding area (36); e) rotating the winding former (26) 180° about the rotation axis while feeding the wire pack (60) from the feeding direction (R), such that the fixing point is displaced from the first holding area (34) into a third holding area (46) on the opposite side of the winding former (26) from the first holding area (34) and the fixing point is displaced from the second holding area (36) into the first holding area (34), whereby the winding head (42) extending around the winding former (26) is formed with respect to the wire pack (60) by forming a bending area; f) subsequently fixing the unwound wire pack (60) to said fixing point in said second holding area (36); g) repeating steps d) to f), wherein the holding effect on the fixed point in the third holding area (46) is released before or after the repetition of step f), and the holding effect on the fixed point in the second holding area (36) is released before the repetition of step e); h) repeating steps b) to g) until the coil winding (70) is completed; i) severing the wire pack (60) in the area of ​​the second holding area (36); j) stripping the coil winding (70) from the winding former (26); A method comprising:

2. 2. The method of claim 1, wherein the wire pack (60) is first manufactured in that twice the length of the wire (32) required for the coil winding (70) is determined, and the wire pack (60) is manufactured by bending the wires (32) to the length required for manufacturing the coil winding (70) such that the wires (32) are connected to each other in pairs at one end of the wire pack (60).

3. 3. The method according to claim 1 or 2, characterized in that the wire pack (60) is fed perpendicularly to the winding former (26), starting from the ends where the wires (32) are connected to each other in pairs.

4. 4. The method according to claim 1, wherein the displacement of step d) is performed in one section parallel to the rotation axis of the winding former (26), the length of the section being approximately equal to half the distance between the outermost wires of the wire pack (60) for all wires, whereby a wire portion (40) inclined with respect to the rotation axis of the winding former (26) is formed between the first and second holding areas (34, 36).

5. Method according to any one of the preceding claims, characterized in that the winding head (42) is reshaped in the bent area formed by step e).

6. 6. The method according to claim 5, characterized in that for the final shaping of the winding head (42) after step e), a contour shaping tool (50) is pressed against the winding head (42).

7. 7. The method according to claim 1, characterized in that in step b) the wire pack is held on the winding former (26) in the first holding area (34) by a first holding device (18) and in step c) the wire pack is held by a second holding device (29) in the second holding area (36).

8. 5. The method according to claim 4, characterized in that the first holding area (34), the third holding area (46) and the second holding area (36) follow one another in this order in a rotational direction of the winding former (26) and each holding device (28, 29, 33) is transferred in said rotational direction from a holding area (34, 36, 46) to a subsequent holding area (34, 36, 46) with a rotation according to step e).

9. 9. The method according to claim 1, characterized in that the cutting of the wire pack (60) in step i) is performed in a rotational position of the winding former (26) in which the ends of the wire pack (60) in which the wires are connected to each other in pairs are on the side of the second holding area (36).

10. 10. The method according to claim 1, wherein the wires (32) connected in pairs are exchanged in pairs with other wires (32) connected in pairs during the delivery before reaching the second holding area (36) one or more times during the method.

11. 10. The method according to claim 1, wherein the wire pack is cut to length before step a) is performed, the unwinding of the wire pack (60) used for the coil winding (70) in step a) is performed in a unwinding direction (R) perpendicular to the winding former (26), and step i) is omitted.

12. A stator (80) or rotor for an electric machine having radially open slots (82), The coil winding (70) inserted into the slot (82) has a wire pack (60) consisting of a plurality of wires (32), the wires (32) of the wire pack (60) extending parallel to one another and connected to one another in pairs at one end of the wire pack (60); the wires connected together in pairs are integrally formed from a single continuous wire (32a, 32b, 32c, 32d, 32e, 32f) bent at one end of the wire pack (60), and the shape of the bend of all the continuous individual wires (32a, 32b, 32c, 32d, 32e, 32f) corresponds to the shape of the winding head (42); the coil winding (70) is inserted into the slots (82) such that a first half of the wire (32) of the coil winding (70) arranged between two winding heads (42) is inserted into a first slot (82a) of two consecutive slots (82a, 82b) and a second half of the wire (32) of the coil winding (70) arranged between two winding heads (42) is inserted into a second slot (82b) of two consecutive slots (82a, 82b); A stator (80) or rotor, characterized in that the end of the coil winding (70) having the wires (32) connected to each other in pairs and the end of the coil winding (70) where the wire pack (60) is cut are located on the same side of the stator (80) or rotor.

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