Method and device for producing a layered wave winding mat for drawing into a stator or rotor

Abstract

The invention relates to a method for producing a layered wave winding mat (1) for drawing into a stator or rotor, wherein the wave winding mat (1) is made of at least one double layer (4) per phase, and each double layer (4) is made of at least two individual layers (3). Each individual layer (3) has a substantially meandering base structure and is formed with at least two winding heads (5). Each double layer (4) is made of a continuous individual wire (2), and the individual layers (3) are connected together by a transition region (8). The invention is characterized in that each double layer (4) is layered by bending the individual wire (2) about a bending axis in the transition region (8).

Description

[0001] Method and device for producing a layered wave winding mat for insertion into a stator or rotor

[0002] Description

[0003] The present invention relates to a method and a device for producing a layered wave winding mat for insertion into a stator or rotor.

[0004] Various methods for producing wave winding mats are known from the prior art. The wave winding mat can be produced by continuously winding several individual wires around a winding bar, as shown, for example, in EP 3381108 B1, and comprises several winding heads. However, it is also known to bend individual wires and then assemble them into a wave winding mat. This can be done either by changing the wire layers per winding using interweaving or, as described, for example, in JP 4973544 B2, by a stacking process.

[0005] It may be advantageous to provide wave winding mats in the form of reverse windings, as known, for example, from DE 102020 103 165 A1.

[0006] When using such a wound wave winding mat, which comprises several individual layers, a series or parallel connection of all individual wires of a phase, or a serial connection between the phases, is necessary. The connecting wires must be connected in a circumferential area of ​​the stator at the outer diameter and the inner diameter. This results in considerable contacting effort, as well as requiring installation space and complex busbars. Therefore, the advantage of the aforementioned reverse winding lies in the possibility of implementing a serial connection at one end of the mat.

[0007] It is therefore the object of the present invention to provide a method and a device for producing a layered wave winding mat for insertion into a stator or rotor, by means of which the disadvantages mentioned above are overcome and which simplifies the production process of wave winding mats for insertion into a stator or rotor. This object is achieved by the subject matter of the independent patent claims.

[0008] Advantageous embodiments and further developments are the subject of the dependent claims, the enclosed description and the figures.

[0009] According to one aspect of the invention, a method for producing a layered wave winding mat for insertion into a stator or rotor is provided. The wave winding mat is formed from at least one double layer per phase of the motor in which the wave winding mat is used. Preferably, at least two double layers are provided. Each double layer is in turn formed from at least two individual layers. However, it is also conceivable to layer more than two individual layers to form a double layer. Each individual layer is formed in a substantially meander-shaped basic structure and with at least two winding overhangs. Each double layer is formed from a continuous individual wire, and the individual layers are connected to one another by a transition region. The individual wire is bent into shape so that the meander shape with the typical winding overhangs is achieved.The advantage here is that the individual layers are bent without wire torsion, thus creating a flat basic structure. The layering of the double layer is achieved by bending the individual wire in the transition area around a bending axis. By using a layered wave winding mat produced in this way, a different shape of the winding head can be achieved, which has an edgewise wire instead of the usual wrap. The winding heads are therefore more compact than winding heads wound with a wrap. By layering the double layer by bending in the transition area, the serial connection of the outgoing and return conductor path can be realized on a single wire basis at this point, without the need for further steps for secure contact. This saves time and increases the functional reliability of the wave winding mat.The transition area is formed into another winding head during the bending process, so that it is no longer visible in the finished layered double layer. By layering the double layers, the same winding structure as with state-of-the-art wave winding mats can be achieved, but considerable effort is saved. This allows for a simple overlay of the individual layers without layer changes.

[0010] According to one embodiment, the bending axis lies on a rotational axis passing through a winding head. The individual layers can be formed continuously next to one another and are connected by a transition region. Such a bend has the advantage that a winding head can be formed from the transition region, for example, at three bending points, and one individual layer can be layered over the other by rotating it, without this winding head exhibiting torsion. This allows a consistently uniformly shaped double layer to be produced.

[0011] According to one embodiment, the bending axis lies on a central axis between two individual layers arranged in a mirror image in the transition region. This bending axis divides the individual layers into windings that are 180° out of phase and lies in the same plane as the individual layers themselves and tangential to the meandering shape of the conductor in the winding head area, which greatly simplifies the process and allows for easy implementation without requiring too much space.

[0012] According to one embodiment, the bending axis lies on a central axis between two consecutively arranged individual layers. This bending axis corresponds to the normal to the winding plane. This ensures that wire torsion in the winding head only occurs in the winding head area of ​​the serial connection between two individual layers to form a double layer. This is maintained during bending around this rotational axis. The remaining winding heads have flat basic structures due to their manufacturing process.

[0013] According to one embodiment, the wave winding mat comprises at least three double layers. It is preferably formed from six, particularly preferably from nine, double layers. By layering multiple double layers, larger geometries can be easily realized without the need for numerous interconnections.

[0014] According to one embodiment, a single layer is fixed during stacking to form the double layer. For example, if two single layers are provided, a single layer can be layered on top of the fixed single layer. This fixation ensures the precisely planned arrangement in the double layer, since slippage is impossible. It is also conceivable for both single layers to be fixed, leaving only the transition area free to move during bending.

[0015] According to one embodiment, a layer jump is embossed into each winding head. The provision of layer jumps enables a wider geometry of the finished wave winding mat with layer changes of the individual layers. Because the winding heads are formed very flat by the bending process, embossing is easy and without the risk of damage, which could be disadvantageous in areas already subject to heavy torsional stress. By providing layer jumps, two conductors are always in the same position relative to one another along a winding.

[0016] According to one embodiment, the winding geometry of the winding head formed from parts of the transition region differs from that of the other winding heads. It is conceivable that only the winding head formed from parts of the transition region has a different shape, resulting in only one winding head in a double layer having a different shape. However, it is also conceivable that multiple winding heads in a double layer have different geometries.

[0017] According to a further aspect of the invention, a device for producing a layered wave winding mat is provided. The wave winding mat is formed from a plurality of double layers, each consisting of two individual layers. The device comprises at least one bending tool, wherein individual layers can be formed on the bending tool. For this purpose, the bending tool has forming elements by means of which an individual wire can be formed into the individual layers. The individual wire can be bent around the forming elements as it is guided through the device, thus creating the shape of the individual layer. The forming elements can ensure that all double layers layered with it have the same basic geometry, which is particularly important for ensuring the faultless function of the wave winding mat in a stator or rotor. Each double layer can be layered from two or more individual layers by means of a bending movement of the device around a bending axis.For this purpose, it is advantageous if the device has, for example, two sub-areas. Then, in a first step, a single layer can be formed in each sub-area. In a subsequent step, the individual layers can be easily stacked on top of one another using the bending movement around the bending axis, and another winding head can be formed from the transition area. By integrating the bending process for layering a double layer into the device, which also determines the shape of the individual layers, a smaller footprint is required than if the two steps were performed in separate devices.

[0018] Further features, details, and advantages of the invention will become apparent from the wording of the claims and from the following description of exemplary embodiments based on the drawings. They show:

[0019] Figures 1a-e 1 An embodiment of the method for producing a layered wave winding mat;

[0020] Figures 2a-d show a further embodiment of the method for producing a layered wave winding mat;

[0021] Figures 3a-d show a further embodiment of the method for producing a layered wave winding mat;

[0022] Figures 4a, b show a further embodiment of the method for producing a layered wave winding mat;

[0023] Figure 5a shows a winding head of a layered wave winding mat without layer jump; and

[0024] Figure 5b shows a winding head of a layered wave winding mat with an embossed layer jump.

[0025] Figures 1a-e schematically illustrate a method for producing a wave winding mat for insertion into a stator or rotor. Figure 1a shows a blank 6. It comprises two individual layers 3 that have been bent into their meandering shape in a device and each have multiple winding heads 5. The advantage of this type of bending of the individual wire 2 is that there is no wire torsion in the winding heads 5, as is usually the case during winding processes in the winding head 5. The two individual layers 3 are made from a single wire 2 and are connected to each other via a transition region 8. Wire ends 7 are present once per individual layer. These are later used to connect the wave winding mat. Figure 1b shows a section of a bending process. For this purpose, one individual layer 3 can be fixed in a device (not shown here), while the other individual layer 3 is rotated by a rotational movement.The bending is carried out in the transition region 8, which is slowly formed into a further winding head 5 as the bending process progresses, as can be seen in Figures 1c and d. The rotation axis, which represents the bending axis, runs through the winding head 5, which is formed from the wire in the transition region 8. In this way, the two individual layers 3 approach each other through the rotational movement similar to a U-turn until they lie on top of each other and form a double layer 4, as shown in Figure 1d. The wire ends 7 are arranged together on one end side in the double layer 4, which simplifies later wiring. Finally, Figure 1e shows a wave winding mat 1, which is created by layering several double layers 4. For this purpose, the double layers 4 can be folded open and further layers inserted, so that the wave winding mat receives its final geometry through their layering.It is advantageous that all double layers 4 already have the same basic geometry and thus all wire ends 7 can be arranged on one end side.

[0026] Figures 2 ad show a further exemplary embodiment of the method for producing a wave winding mat. Also shown is a device 10 for producing the wave winding mat. The device 10 has two partial areas 12a, b, on each of which an individual layer 3 has been formed. Forming elements 11, around which the individual wire 2 is bent, serve to ensure consistent shaping throughout the entire production process. The forming elements 11 can also serve to fix the individual layers 3. In the production process shown here, a winding head in the bending area has a different geometry than the other winding heads. A wider winding head was created in which the transition area 8 between the individual layers 3 is partially located. The partial areas 12a, b can be moved towards one another to produce a double layer, and the device 10 can be folded together.The bending movement for layering is carried out along the bending axis on a central axis between two individual layers 3 arranged side by side. In the winding overhang 5', which is located in the transition region 8, wire torsion occurs. The other winding overhangs 5 ​​do not have this. The double layer produced in this way therefore only has wire torsion in the area of ​​the serial connection. The separate winding overhang geometry of the winding overhang 5' shown here, which is formed in the transition region 8 between the individual layers 3, allows the torsion to be deliberately shifted. However, it is also conceivable to carry out this variant without changing the winding overhang geometry or to make other changes, for example to additional winding overhangs 5. Figures 3a-d show a further exemplary embodiment of a method and a device 10 for producing a wave winding mat.Here, the bending takes place on a bending axis that passes through a rotation point in the winding head 5 to be bent from the transition area 8. After the bending process, the double layer 4 layered from the two individual layers 3 has winding heads 5 that are uniformly formed throughout. This process has the advantage that there is no wire torsion in any of the winding heads 5. The individual layers 3 are formed from a single wire 2 in the partial areas 12a, b using the forming elements 11 and are connected to one another via the transition area 8. The process shown in Figures 3a-d is particularly gentle on the individual wire 2. Since several bending points can be set in the transition area 8, less localized stress on the individual wire 2 occurs than in processes in which the bending to layer the double layer 4 is only carried out at one point.The process is also more flexible in its implementation and makes it possible to obtain a uniformly shaped double layer 4 which has the same geometry in all winding heads 5.

[0027] Figures 4 a, b show a further exemplary embodiment of the method and device 10 for producing a wave winding mat. First, two individual layers 3 are formed in the device 10 in a mirrored position opposite one another. The transition region 8 connects the two individual layers 3 and is bent during the process to form a further winding head 5. The two partial regions 12a, b can be folded onto one another, whereby the individual layers 3 are layered on top of one another by bending in the winding head 5 resulting from the transition region 8. The bending axis lies on a central axis between the two individual layers 3 arranged in a mirrored manner to one another. In this embodiment, too, wire torsion is only found in this one winding head 5. The method shown here represents a particularly simple manufacturing process. The winding takes place in the device 10 in one plane over two stages.However, the bending points in the winding head 5 are always clearly defined so that a consistent winding result can be ensured.

[0028] Figures 5a and b each show a winding head 5. In Figure 5b, the winding head 5 has a layer jump 9, which was previously embossed into a simple winding head 5 as shown in Figure 5a. By providing layer jumps 9 in the winding heads 5, a layer change of the individual layers 3 is created after stacking, thus expanding the possible winding geometries for the wave winding mat. List of reference symbols

[0029] 1 wave winding mat

[0030] 2 single wires

[0031] 3 single vineyards

[0032] 4 double layers

[0033] 5.5' winding head

[0034] 6 blank

[0035] 7 Wire end

[0036] 8 Transition area

[0037] 9 layer jump

[0038] 10 Device

[0039] 11 Form element

[0040] 12a, b sub-area

Claims

Patent claims 1. A method for producing a layered wave winding mat (1) for insertion into a stator or rotor, wherein the wave winding mat (1) is formed from at least one double layer (4) per phase, wherein each double layer (4) is formed from at least two individual layers (3), wherein each individual layer (3) is formed in a substantially meandering basic structure and with at least two winding heads (5), wherein each double layer (4) is formed from a continuous individual wire (2), wherein the individual layers (3) are connected to one another by a transition region (8); characterized in that each double layer (4) is layered by bending the individual wire (2) in the transition region (8) around a bending axis.

2. Method according to claim 1, characterized in that the bending axis lies on a rotation axis passing through a winding head (5).

3. Method according to claim 1, characterized in that the bending axis lies on a central axis between two individual layers (3) arranged mirrored to one another in the transition region (8).

4. Method according to claim 1, characterized in that the bending axis lies on a central axis between two individual layers (3) arranged continuously next to one another.

5. Method according to one of claims 1 to 4, characterized in that the wave winding mat (1) comprises at least three double layers (4).

6. Method according to one of claims 1 to 5, characterized in that one of the individual layers (3) is fixed during the stratification to form the double layer (4).

7. Method according to one of claims 1 to 6, characterized in that a layer jump (12) is embossed into each winding head (5).

8. Method according to one of claims 1 to 7, characterized in that the winding geometry of the winding head (5'), which is formed from parts of the transition region (8), has a geometry that differs from the other winding heads (5). Device (10) for producing a layered wave winding mat (11) which is formed from a plurality of double layers (4) each formed from two individual layers (3), comprising at least one bending tool, wherein individual layers (3) can be formed on the bending tool, wherein the bending tool has forming elements (11) by means of which an individual wire (2) can be formed into the individual layers (3), characterized in that each double layer (4) can be formed by means of a bending movement of the device (10) about a bending axis.

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