Tool for shortening winding heads of a winding mat for a stator, method for shortening winding heads of a winding mat

Abstract

The invention relates to a tool (1) for processing a winding mat (2) which is provided for current conduction in a stator of an electric machine, wherein the tool (1) has two jaws (3) which can be moved apart from one another and each have a plurality of protrusions (4) for engaging in the winding mat (2) structured from a wire (5), wherein a spacing mechanism (6) is provided between the jaws (3) in order, as the jaws (3) become further apart, to cause straight sections (7) of the wire (5) of the winding mat (2) to be lengthened, with the two winding-mat-side winding heads (8) being correspondingly shortened. The invention also relates to a method for processing a winding mat (2) made of a wire (5) for current conduction in a stator, wherein the winding mat (2) is first wound from a wire (5) and then first sections (19) of the wire (5) are specifically lengthened and / or bent and second sections (23) of the wire (5) are arranged closer to one another and / or bent in order to lengthen a central section (18) of the winding mat (2) between two winding heads (8) and to shorten the winding heads (8).

Description

[0001] Tool for shortening winding heads of a winding mat for a stator, method for shortening winding heads of a winding mat

[0002] The invention relates to a tool for machining a winding mat intended for conducting current in a stator of an electric machine.

[0003] When it comes to stators for electrical machines, it's essential to make optimal use of the already limited installation space. The primary focus is on keeping the installation space as small as possible without sacrificing performance. A winding mat produced using flat wire wave winding has straight sections with a winding head on both sides. These straight sections of the winding mat are then positioned in the stator core.

[0004] In the state of the art, the height of the winding head depends on the one hand on the slot spacing in the stator and on the other hand on the thickness of the wire from which the winding mat is wound.

[0005] The object of the present invention is to ensure an adaptation of the winding mat with regard to the height of the winding heads.

[0006] This is achieved in a present tool in that the tool has two removable jaws / strips / plates, each having a plurality of projections / pins / tenons projecting in the same direction for engaging the winding mat constructed from a wire, wherein a spacing mechanism is present between the jaws in order to cause an elongation of straight sections of the wire of the winding mat with increasing spacing of the jaws and a corresponding shortening of the two winding heads on the winding mat side. With the aid of the tool, machining of the winding mat is facilitated, since the less complex design of the tool enables efficient and less error-prone machining and adjustment of the winding mat. Advantageous embodiments are claimed in the subclaims and are explained in more detail below.

[0007] Preferably, the jaws / plates are guided by guide rails. This facilitates spacing the jaws.

[0008] Additionally, the two jaws can be part of a linear magazine. This simplifies processing the winding mat with the jaws.

[0009] The spacing mechanism is preferably formed from at least one or more mechanically extendable elements, preferably a cylinder arrangement. As an alternative to this cylinder arrangement, a screw arrangement is also conceivable. The screw arrangement particularly preferably comprises a plurality of clamping screws. The spacing mechanism ensures that the jaws are moved in opposite directions and allows for uniform movement of the jaws / plates.

[0010] Furthermore, a control and / or regulation system can be provided that is configured to cause / cause the jaws to move apart, taking into account / mutually compensating for stretch extensions and contractions of the wire in the winding mat. This allows for automation of the tool, which facilitates processing.

[0011] In an alternative embodiment, the tool additionally has a stop for each of the jaws, with the stop serving as an (additional) compression element for the winding heads. This promotes shortening / compression of the winding head, as the winding head is actively moved against a side surface of the stop. The stop can be made of various materials, preferably a plastic, particularly preferably natural PET, to protect the winding mat from damage upon contact with the stop.

[0012] The invention also relates to a method for processing a winding mat made from a wire for conducting current in a stator, wherein the winding mat is first wound from a wire and then first sections of the wire are specifically lengthened and / or bent and second sections of the wire are arranged and / or bent closer to one another in order to lengthen a central section of the winding mat between two winding heads and to compress / shorten the winding heads. With the aid of the method, an efficient solution is created for adapting the winding mat and, above all, the winding heads in a very simple manner such that the overall installation space for the winding mat is reduced, the performance of the stator is increased, weight is saved, and power loss is reduced.

[0013] It is advantageous if the prefabricated winding mat is inserted into projections of a first jaw of a tool, preferably according to a previously described tool, and is inserted into projections of a second jaw of the tool and the two jaws are then moved away from each other in a linear manner. The winding mat is held on the tool by means of the projections and the projections also enable the winding heads to be shortened while the middle section is simultaneously lengthened. This allows two processing steps to be combined into a single step, which is implemented with the linear removal of the jaws. This provides an efficient and time-saving method. The projections are preferably arranged / formed on an upper side of the jaw. The projections particularly preferably have a circular cross-section so that the winding mat can be positioned more easily since this prevents it from jamming with the straight sections.However, other cross-sectional shapes are also conceivable. It is advantageous if the numerous projections are arranged in at least one row, preferably two rows. This facilitates positioning of the winding mat and makes lengthening straight sections and shortening the winding heads less prone to errors.

[0014] It has proven to be useful if each winding head is (additionally) pressed against a stop in order to promote the compaction / shortening of the winding heads.

[0015] It is advantageous if the prefabricated winding mat is created using a winding blade. The wire used to wind the winding mat is moved at an angle along the winding blade until the first sections of the wire almost touch each other. The winding head is created by folding the winding blade with the wire on it. The winding blade enables even winding and easy production of the winding mat.

[0016] It is advisable to move the jaws apart from each other while taking into account the stretching extensions on the one hand and the compression / shortening on the other. Performing the stretching extensions and shortenings simultaneously ensures regularity / equality of the results with regard to the stretching extensions and shortenings, thus reducing machining errors and shortening the machining time.

[0017] Preferably, the winding heads protrude evenly from the sides of a linear magazine containing the jaws. This facilitates positioning of the winding mat.

[0018] It is advantageous if the bending angle and / or bending radius of the wire is / are specifically changed when moving / relocating / removing the jaws. This facilitates shortening the winding heads, as the movement process during the spacing of the two jaws and the arrangement of the winding mat on the projections causes the wire to be positioned closer together in the second sections. Preferably, the bending angle and / or bending radius are smaller after spacing, so that the second section of the wire at the winding head has a tighter mesh.

[0019] It has proven advantageous to precisely match the prefabrication of the winding mat to the elongations during the jaw movement. This ensures that the straight sections of the wire in the first section correspond to the required length, which the length would have originally been without any processing of the winding mat.

[0020] In other words, the invention relates to a method in which a winding mat is produced with a winding blade, the winding mat is then inserted into a linear magazine, and jaws of the linear magazine are subsequently displaced so that straight sections of the winding mat are lengthened and winding heads of the winding mat are shortened accordingly, and straight sections are reduced during the production of the winding mat by the value by which they were lengthened during stretching.

[0021] In addition, the winding heads can be pushed against a stop to compress the winding head and shorten the winding heads and then fix this position using screws.

[0022] Various advantageous embodiments of the invention are explained in more detail below with reference to a drawing with figures.

[0023] They show:

[0024] Fig. 1 is a plan view of a tool for processing a winding mat in a stationary state,

[0025] Fig. 2 is a plan view of the tool for processing the winding mat in a moving state, Fig. 3 is a plan view of the tool for processing the winding mat in a stationary state with the winding mat positioned,

[0026] Fig. 4 a top view of the tool for processing the winding mat in a moving state with the winding mat positioned,

[0027] Fig. 5 a section of the positioned changing mat in the stationary state,

[0028] Fig. 6 a section of the positioned changing mat in the moving state,

[0029] Fig. 7 shows a second, alternative embodiment of the tool in a plan view.

[0030] The figures are merely schematic and serve solely to facilitate understanding of the invention. The same elements are provided with the same reference numerals. Features of the individual embodiments can be interchanged and used alternatively / cumulatively.

[0031] 1 to 4 show a tool 1 according to the invention for processing a winding mat 2 (shown in Figs. 3 and 4) which is provided for conducting current in a stator (not shown) of an electric machine (not shown), the tool 1 having two jaws 3 which can be removed from one another and which each have a plurality of projections 4 for engaging in the winding mat 2 constructed by a wire 5, a spacing mechanism 6 being present between the jaws 3 in order to cause straight sections 7 of the wire 5 of the winding mat 2 to become longer with increasing spacing of the jaws 3 and to cause corresponding shortening of the two winding heads 8 on the winding mat side.

[0032] 1 and 2 show the basic structure of the tool 1 in a first embodiment without a winding mat 2. To clarify the structure, an axial direction 9 and a radial direction 10 are shown. In Figs. 3 and 4, the tool 1 is then supplemented by the winding mat 2. The tool 1 is shown in a plan view. The tool 1 has two jaws 3 spaced apart from one another, a first jaw 26 and a second jaw 27, which are coupled to one another in the radial direction 10 via the spacing mechanism 6. The jaws 3 extend in the form of strips in the axial direction 9 and each have a plurality of projections 4 on an upper side 11. The projections 4 are arranged in two rows in the radial direction 10, and a plurality of projections 4 are then positioned at a uniform distance from one another in the axial direction 9.The projections 4 are positioned on the upper side 11 such that they are oriented toward an edge 12, with the edges 12 facing the respective jaws 3. The projections 4 have an elevation / extension in a transverse direction 13 to the axial direction 9.

[0033] The spacing mechanism 6 is implemented using two cylinder assemblies, a first cylinder assembly 14 and a second cylinder assembly 15. The cylinder assemblies 14, 15 are each coupled to the jaws 3, positioned extending in the radial direction 10, and arranged offset from one another along the axial direction 9, performing a linear movement in the radial direction 10. In a stationary state of the tool 1, a distance 16 in the radial direction 10 is defined between the pin 4 of the first jaw 26 and the second jaw 27. This stationary state describes the state before the jaws 3 are spaced apart from one another.

[0034] In Fig. 2, the tool 2 is now shown in a moving state. The distance 16 has changed in the radial direction 10. By actuating the spacing mechanism 6, the distance 16 is greater compared to the stationary state in Fig. 1. For better clarity, a first direction of movement 17 and a second direction of movement 30 are defined, which are positioned oriented according to the radial direction 10, with the first direction of movement 17 indicating the movement of the first jaw 26 and the second direction of movement 30 indicating the movement of the second jaw 27. Figs. 3 and 4 now show the tool 1 with the winding mat 2. Fig. 3 shows the stationary state, while Fig. 4 shows the moving state and a spacing of the jaws 3 has taken place.

[0035] In Fig. 3, the winding mat 2 is now positioned on the tool 1. The winding mat 2 has a central section 18, which is defined by straight sections 7 in a first section 19 of the wire 5. The winding mat 2 has a winding head 8 in a second section 23 on each side of the central section 18. The straight sections 7 of the wire 5 extend in the radial direction 10. The winding mat 2 is wound such that a plurality of straight sections 7 are present, which are spaced apart from one another in the axial direction 9.

[0036] The winding mat 2 is positioned on the tool 1 such that the projections 4 engage the winding mat 2 in the transverse direction 13. The winding mat 2 is oriented such that the winding head 8 is spaced apart from the edge 12 in the radial direction 10, so that a first side 20 of the winding head 8 is oriented toward the side facing away from the edge 12 in the radial direction 10.

[0037] The winding mat 2 has a length 21, 22 in the radial direction 10 for the central section 18 and the winding heads 8, which is changed by the spacing. By spacing, the length 22 of the winding head 8 is reduced, while the length 21 of the central section 18 is increased. This difference is illustrated in the comparison of Fig. 3 and Fig. 4.

[0038] In Figs 5 and 6 a section of the winding mat 2 on the tool 1 with focus on the winding head 8 is shown, in Fig. 5 in the stationary state and in Fig. 6 in the moving state.

[0039] The enlarged section shows the configuration of the wire 5 at the transition from the first sections 19 to the second sections 23. The wire 5 has a bending radius 24 and a bending angle 25 at this transition. The spacing by the spacing mechanism 6 reduces the bending radius 24 and the bending angle 25. This also reduces the length 22 of the winding head 8 and increases the length 21 of the middle section 18. The winding head 8 becomes more tightly meshed in the second section 23.

[0040] Fig. 7 shows a plan view of a second embodiment of the tool 1 according to the invention. Compared to the embodiment according to Figs. 1 to 6, this embodiment has a spacing mechanism 6 in the form of clamping screws 28, 29, wherein each of the jaws 3 is designed with two clamping screws 28, 29, a first clamping screw 28 and a second clamping screw 29. In the present embodiment, the jaws 3 are designed in the form of a tension plate. By tightening the clamping screws 28, 29, the jaws 3 are moved in the radial direction 10, so that the winding mat 2, which is positioned on the projections 4, is pulled apart in the radial direction 10, wherein the straight sections 7 are lengthened and the winding heads 8 are shortened. This movement process is illustrated with the first movement direction 17 of the first jaw 26 and the second movement direction 30 of the second jaw 27.

[0041] The first jaw 26 is moved in the radial direction 10 toward a first stop 31, and the second jaw 27 is moved in the radial direction 10 toward a second stop 32. Due to the pulling apart of the winding mat 2, the winding heads 8 are moved in the radial direction 10 toward the stops 31, 32. The winding heads 8 are pressed with a second side 33, which is defined on the outside in the radial direction 10, against a side surface 34 of the respective stop 31, 32. The tool has two guide rails 35, 36, which ensure that the jaws 3, in the form of the tension plates, are guided. List of reference symbols

[0042] Tool

[0043] Wicke I matte

[0044] Bake

[0045] projection

[0046] wire

[0047] Spacing mechanism straight line

[0048] Winding head Axial direction Radial direction Top side

[0049] edge

[0050] Transverse direction first cylinder arrangement second cylinder arrangement distance first direction of movement middle section first section first side

[0051] length

[0052] Length of second section

[0053] Bending radius Bending angle First jaw Second jaw First clamping screw Second clamping screw Second direction of movement First stop Second stop Second side Side surface First guide rail Second guide rail

Claims

Patent claims 1. Tool (1) for machining a winding mat (2) which is provided for conducting current in a stator of an electric machine, the tool (1) having two jaws (3) which can be removed from one another and which each have a plurality of projections (4) for engaging in the winding mat (2) constructed by a wire (5), a spacing mechanism (6) being present between the jaws (3) in order to cause straight sections (7) of the wire (5) of the winding mat (2) to become longer with increasing spacing of the jaws (3) and to cause corresponding shortening of the two winding heads (8) on the winding mat side.

2. Tool (1) according to claim 1, characterized in that the two jaws (3) are part of a linear magazine.

3. Tool (1) according to claim 1 or 2, characterized in that a control or regulation is provided which is prepared to cause the jaws to be moved away from one another, taking into account stretch extensions and stretch shortenings of the wire (5) of the winding mat (2).

4. Method for processing a winding mat (2) from a wire (5) for conducting current in a stator, wherein the winding mat (2) is first wound from a wire (5) and then targeted first sections (19) of the wire (5) are lengthened and / or bent and second sections (23) of the wire (5) are arranged closer to one another and / or bent in order to lengthen a central section (18) of the winding mat (2) between two winding heads (8) and to compress / shorten the winding heads (8).

5. Method according to claim 4, characterized in that the finished winding mat (2) is inserted into projections (4) of a first jaw (26) of a tool (1) and is inserted into projections (4) of a second jaw (27) of the tool (1) and the two jaws (26, 27) are then moved away from each other.

6. Method according to claim 4 or 5, characterized in that a winding head (8) is pressed against a stop (31, 32) in order to promote the compaction / shortening.

7. Method according to claim 5 or 6, characterized in that the removal of the jaws (3) from each other takes place taking into account stretch extensions on the one hand and compressions / shortenings on the other hand.

8. Method according to one of claims 4 to 7, characterized in that the winding heads protrude laterally evenly from a linear magazine containing the jaws (3).

9. Method according to one of claims 4 to 8, characterized in that a bending angle (25) and / or a bending radius (24) of the wire (5) is specifically changed during the movement / displacement / removal of the jaws (3).

10. Method according to one of claims 4 to 9, characterized in that the manufacture of the winding mat (2) is adapted to the elongation during the movement of the jaws (3).

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