Method for manufacturing a winding for an electric machine

Abstract

The invention relates to a method for manufacturing an insulated winding (10) for an electric machine, in particular an electric motor or generator, the method comprising the steps of: i. providing a winding (10), in particular by providing winding sections (11) by means of laser cutting and joining the winding sections (11) to form a winding (10), in particular a single coil, by means of laser welding and / or an additive process, in particular laser sintering or laser melting; ii. insulating the winding sections (11) from one another; and iii. insulating at least one portion of an outer surface of the winding (10), wherein the process of insulation according to step iii. is carried out using a different method than the process of insulation in step ii.

Description

[0001] Method for producing a winding for an electrical machine

[0002] Description

[0003] The invention relates to an electrical machine, in particular an electric motor or generator, and a winding for such an electrical machine. Furthermore, the invention relates to a method and system for producing a winding for an electrical machine.

[0004] Processes for manufacturing windings for electrical machines are generally known. For example, the windings are produced by deforming a wire or by metal casting. Insulation of the winding can be achieved by coating it (so that the winding is insulated both from the outside and from individual, especially adjacent, winding sections).

[0005] It is also known to produce windings for electrical machines using 3D printing. However, such 3D printing is still relatively expensive, especially for large quantities.

[0006] The object of the invention is to propose a method for producing a winding for an electrical machine, wherein the method results in comparatively precise components that are as efficient as possible in operation at comparatively low cost. Furthermore, the object of the invention is to propose a corresponding system, a corresponding winding, and a corresponding electrical machine. This object is achieved in particular by the features of claim 1.

[0007] In particular, the object is achieved according to a first aspect by a method for producing an insulated winding for an electrical machine, in particular an electric motor or generator, comprising the steps: i) providing a (in particular concentrated) winding (in particular according to the method according to the fourth aspect explained in more detail below), ii) insulating winding sections from one another, and iii) insulating at least one section of an outer surface of the winding, wherein the insulation according to iii) is carried out by a different method than the insulation under ii).

[0008] In the first aspect, the provision of the winding may comprise cutting, in particular laser cutting, and / or (subsequent) welding, in particular laser welding, of winding sections and / or subsequent additive manufacturing, preferably laser sintering or laser melting.

[0009] One idea according to the first aspect is that the insulation of an area between winding sections and the insulation of an outer surface of the winding are carried out using different methods. This allows insulation to be individually adapted to the actual requirements. This is based in particular on the recognition that these requirements are and can be different. For insulation to the outside, comparatively pronounced insulation is necessary, especially for higher dielectric strengths. Between (adjacent) individual winding sections, comparatively less pronounced insulation may be acceptable, since the voltage differences are comparatively small.

[0010] If only one winding is mentioned, this is to be understood in particular as the winding without insulation, unless otherwise stated, e.g. an "insulated winding". An outer surface of the winding is to be understood in particular as a surface whose surface normal (at any point) either does not intersect the winding (a further time) or is directed towards the interior of the winding. If the winding is configured as a hollow cylinder, for example, both the outward-facing and the inward-facing surface of the hollow cylinder form an outer surface.

[0011] Insulating winding sections from one another means, in particular, that sections of the winding that are essentially adjacent to one another are separated by insulation. This particularly applies to sections that are not part of the outer surface or are not part of the outer surface.

[0012] Sections where a surface normal (to any point of the corresponding surface) intersects the winding once more (namely in particular at the adjacent winding section).

[0013] The above-mentioned object is achieved according to a second aspect (which is preferably combined with the first aspect) by a method for producing an insulated winding for an electrical machine, in particular an electric motor or generator, comprising the steps:

[0014] Providing a (particularly concentrated) winding (particularly according to the method according to the fourth aspect explained in more detail below),

[0015] Insulating at least one section of an outer surface of the winding, wherein at least one spacer, in particular comprising an infiltrable sheet material and / or individual particles, preferably spheres, is applied and encapsulated with a potting compound, in particular in a potting mold. In the second aspect, step ii) and / or step iii) can be carried out during the insulation. Providing the winding can comprise cutting, in particular laser cutting, and / or (subsequent) welding, in particular laser welding, of winding sections, and / or (subsequent) additive manufacturing, preferably laser sintering or laser melting.

[0016] One idea of ​​the second aspect is that a spacer means, in particular comprising an infiltrable (impregnable) surface material and / or individual particles, preferably beads, is considered and is cast (co-cast) with an (insulating) casting compound.

[0017] The infiltrable surface material (preferably in the form of a nonwoven) can preferably serve as a spacer, particularly in a potting mold, so that a homogeneous distribution of the potting compound with (at least essentially) a constant layer thickness can be achieved. This allows a clearly predefined connection of the winding material to form an insulated winding in a simple manner.

[0018] Alternatively or additionally, (individual) particles, especially in a potting mold, can serve as spacers, allowing a homogeneous distribution of the potting compound with (at least essentially) a constant layer thickness. This allows a clearly predefined connection of the winding material (or winding) to form an insulated winding in a simple manner.

[0019] The particles can be present individually or preferably in agglomerates.

[0020] The particles (especially when present as agglomerates) may already be coated with a mass (in particular, a resin and / or a material corresponding to the potting compound). The agglomerates may form islands on the outer surface of the coil, with areas of the outer surface remaining free between them (before they are then filled with the potting compound in the corresponding potting mold). At least 90% (in terms of number) of the agglomerates may contain at least four particles, possibly at least 10 particles and / or at most 200 particles, or at most 50 particles.

[0021] A proportion of the outer surface covered by the particles may be at least 0.05%, where appropriate at least 0.1% or at least 1% and / or at most 15%, where appropriate at most 10% or at most 2% or at most 0.5%.

[0022] The individual particles (at least 90% or at least 99% in terms of number) can be spherical. In terms of number, a particle diameter (diameter = distance between the pair of points of the respective particle with the greatest distance from each other) of at least 80% of the particles can lie within a deviation of + / - 10% around a mean value. In terms of weight and / or number, a mean particle diameter can be present that corresponds to the layer thickness of the insulation (applied in the subsequent step), possibly up to + / - 10% of this layer thickness. Alternatively or additionally, an extension of the corresponding particles (when they are arranged on the winding) in a direction perpendicular to the outer surface is at least substantially equal to the layer thickness, possibly up to + / - 10%.

[0023] Preferably, the particles are applied in only one layer.

[0024] The particles may (at least based on 90% of a number) have an ellipsoidal shape, preferably spherical shape, and / or a cylindrical shape, preferably circular cylindrical shape, and / or a polyhedral shape, preferably a cuboid shape.

[0025] For the second aspect (but optionally also for one of the other aspects) vacuum casting can be used.

[0026] According to a specific method (particularly with regard to the second aspect), the winding can be preheated. Subsequently, the particles (e.g., glass beads) can be bonded to the outer surface of the winding using a resin (particularly the material of the potting compound). A potting mold can then be opened. The winding can then be inserted, and optionally, the potting mold can be preheated. The potting compound can be mixed. Preferably, the winding is vacuum-potted in the potting mold (or tool).

[0027] A material of the particles is preferably glass and / or a plastic, for example PMMA.

[0028] The above-mentioned object is achieved according to a third aspect (which is preferably combined with the first and / or second aspect) by a method for producing an insulated winding for an electrical machine, in particular an electric motor or generator, comprising the steps: - providing a winding (in particular concentrated) winding (in particular according to the method according to the fourth aspect explained in more detail below),

[0029] - insulating at least a portion of an outer surface of the winding, wherein the insulating comprises a first step and a second step, o wherein in the first step the winding is arranged in a first casting mold and a first portion of the outer surface is cast there, and o wherein in the second step the winding is arranged in a second casting mold and a second portion of the outer surface is cast there.

[0030] One idea of ​​the third aspect is to apply the insulation to the outer surface of the winding in (at least or exactly) two steps, namely the first step and the second step. Where no encapsulation takes place in the first step (i.e., the corresponding encapsulation mold is directly in contact with the corresponding section of the outer surface), the encapsulation mold itself serves as a holding or positioning structure to achieve a (specified, particularly constant) layer thickness in the area where encapsulation takes place.

[0031] In the second step, the second mold can then simultaneously serve as a holding or positioning device, namely where it rests against the already applied insulation. This eliminates the need for spacers (although this is not mandatory; in particular, the third aspect can also be combined with the second aspect). Furthermore, overmolding can be performed in a simple manner, eliminating the need for vacuum encapsulation.

[0032] The first and second casting molds differ at least partially (in particular with respect to at least one molded part), possibly completely. One of the molded parts, in particular a second molded part, of the first and second casting molds can be identical. Optionally, the identical molded parts can be formed by the same molded part.

[0033] In the third aspect, injection molding is preferably carried out in such a way that part of the layer thickness (which is only finally set in the overlap section in the second step) is already set in an overlap region in the first step. The final layer thickness can then be sprayed on in the corresponding overlap region in the second step. In this way, a homogeneous and self-contained insulation can be realized in a simple manner using the two-stage process. The overlap area is preferably at least 0.01%, possibly at least 1% and / or at most 20%, preferably at most 10% or at most 5% of a total area of ​​the insulation. In the first and / or second step, at least 10%, preferably at most 20% and / or at most 90%, preferably at most 80% of a total area of ​​the insulation can be sprayed on (in each case).

[0034] The first mold preferably has a step, which is preferably configured to form the overlap region. The step for forming the overlap region preferably has an intermediate step. The second mold may be stepless (entirely or at least in the corresponding region in which the first mold has said step).

[0035] The (intermediate) stage can be integrated into a (main) stage, which can be provided to separate the sections provided with insulation in the first step from the sections not provided with insulation in the first step. The (main) stage can also be designed without an intermediate stage.

[0036] In summary, the method according to the third aspect can comprise: inserting the winding into the first mold. Overmolding a portion of the winding (or in particular a first side). Inserting the winding into the second mold. Overmolding the remaining portion of the outer surface of the winding (in particular a second side).

[0037] The method according to the third aspect preferably takes place as injection molding. The method according to the third aspect preferably does not take place in a vacuum (or not as vacuum casting).

[0038] The above-mentioned object is achieved according to a fourth aspect (which is preferably combined with the first and / or second and / or third aspect) in particular by a method for producing a winding for an electrical machine, in particular an electric motor or generator, comprising: providing winding sections by laser cutting, and

[0039] - connecting the winding sections to form a (particularly concentrated) winding, in particular a single coil, by laser welding and / or an additive process, in particular laser sintering or laser melting.

[0040] In the fourth aspect, step ii) and / or step iii) can be performed. Alternatively or additionally, in the fourth aspect, at least one section of an outer surface of the winding can be insulated, wherein at least one spacer, in particular comprising an infiltrable surface material and / or individual particles, preferably spheres, is applied and encapsulated with a potting compound, in particular in a potting mold.

[0041] One idea of ​​the fourth aspect is to combine laser cutting with laser welding and / or an additive manufacturing process, in particular laser sintering or laser melting. This allows the geometric freedom provided by laser cutting to be utilized, while the laser welding or additive manufacturing process allows for a relatively precise winding.

[0042] A (respective) winding section can comprise (within the winding) at least half a turn and / or at most two turns, preferably exactly one turn. This preferably applies to (in terms of number and / or length) at least 50%, preferably at least 90%, of the winding sections.

[0043] The respective process can be carried out in such a way that no free space (not occupied by insulation) remains between adjacent winding sections.

[0044] The (respective) winding (coil) is preferably a single winding or single coil. A method for insulating winding sections from one another and a method for insulating at least one section of the outer surface of the winding can differ from one another in that the insulation is applied in a different manner and / or different materials (insulating materials; for the insulation) are used and / or a different thickness (of an insulating layer) is set and / or the respective insulations are applied at different times (during the manufacturing process). For example, the respective insulation methods can differ in that fewer materials (possibly only one material) are used in the method according to ii) than in the method according to iii).

[0045] The method preferably comprises blocking the winding into a block, preferably by gluing. Alternatively or (preferably) additionally, the method comprises milling at least sections of an outer surface of the block (for the (final) definition of its shape). A combination of the laser cutting, laser welding, and / or additive manufacturing explained above, the blocking mentioned here, and the milling leads to an insulated winding with precise geometry and dimensional accuracy, in particular with high surface accuracy. Such surface accuracy is particularly advantageous when the (high-quality) insulation explained above or described further below is implemented.

[0046] Insulation (preferably of winding sections from one another, in particular the insulation according to ii) or step iii)) preferably comprises the introduction of an insulating film, in particular a preferably pre-impregnated insulating paper (prepreg). Such an insulating film (insulating paper, in particular for layer insulation) can first be inserted between two adjacent winding sections, wherein the winding sections or the entire winding are then pressed (for example using a disc spring), heated (for example to a temperature of at least 50 °C, preferably at least 80 °C, preferably at least 100 °C) and preferably subjected to a pressure of at least 2 Newton / mm 2 , preferably at least 4 Newton / mm 2The result of such layer insulation or compression can be a block-like insulated winding (coil), in which, in particular, individual winding sections cannot be moved away from one another, but rather lie firmly against one another (structurally connected via a respective insulating film or a plurality of correspondingly inserted insulating films).

[0047] Insulating at least a portion of the outer surface of the winding, in particular the insulation according to ii) or in step iii) may alternatively or additionally comprise:

[0048] - applying a plastic, preferably provided with a fabric and / or grid structure, in particular a polymer, preferably polyimide, and / or

[0049] - applying an infiltrable surface material, in particular nonwoven fabric (for example felt), in particular to the plastic and / or applying individual particles, preferably beads, and / or

[0050] - applying a casting compound, in particular casting the fleece, preferably in a casting mold in which the winding with the fleece is arranged.

[0051] The plastic, in particular a polymer, preferably polyimide, preferably provided with a woven and / or lattice structure, can be present in the form of a liner, in particular a polymer liner, preferably a polyimide liner (or comprise such a liner), which is preferably provided with a lattice structure (e.g., woven fabric). The plastic (liner, preferably a polyimide liner or PI liner) can be pre-cut, in particular laser-cut. The plastic (liner / PI liner) can be glued to / on the outer surface of the winding (coil). The plastic preferably forms a first insulation that already has a high dielectric strength.

[0052] An infiltrable surface material, fleece (felt), can be applied to the plastic (liner / PI liner, optionally with a grid structure or fabric). The infiltrable surface material, in particular the fleece (felt), preferably creates a defined distance from the walls of a (potting) mold or is comparatively easy to cast (impregnate). The grid structure or fabric can preferably comprise a glass fiber fabric (or glass grid fabric) and / or a carbon fiber fabric (or carbon grid fabric). The grid structure or fabric enables or simplifies the adhesion of the potting material, in particular resin (which in turn forms a reliable bond with the fleece). In a synergistic manner, this particularly ensures that the comparatively brittle potting material (resin) has a good bond to the comparatively smooth plastic (liner / PI liner).

[0053] Polyimide is a (highly) efficient insulation material (approx. 6 kV breakdown voltage at a thickness of 0.030 mm) and preferably forms a first insulation system.

[0054] The impregnable surface material (fleece) preferably has a dual function, namely as a spacer and to absorb an infiltrate (resin in its initial liquid state).

[0055] The resin is, in particular, a (highly) efficient insulation material, which preferably forms a further insulation system. The resin also preferably has a geometric (shaping) function and / or a further function (connecting all other components). The layer thickness of the resin can be at least 0.010, preferably at least 0.100 and / or at most 2.0, preferably at most 0.300 mm. The infiltrable surface material, in particular the nonwoven (felt), can, for example, comprise or be formed from plastic, in particular polymer. The nonwoven preferably comprises PET (polyethylene terephthalate, for example, at least 50% or at least 80% or at least 99%). The basis weight of the infiltrable surface material, in particular the nonwoven, can be at least 10 g / m 2 , preferably at least 30 g / m 2 and / or a maximum of 100 g / m 2 , preferably not more than 50 g / m 2 be.

[0056] A material used for potting (especially in the potting mold) can be epoxy-based. For example, a two-component epoxy system can be used. Potting can be performed under vacuum.

[0057] The (solidified) casting compound (with the infiltrable or infiltrated

[0058] Surface material) represents a second insulation which, particularly in combination with the first insulation, provides an advantageous, precise and yet comparatively easy-to-manufacture (total) insulation for the outside of the winding.

[0059] A thickness of a (total) insulation on an outer surface of the winding is preferably at least 1.2 times, more preferably at least 2.0 times and / or at most 20 times, optionally at most 10 times or at most 5 times as large as a thickness of an insulation between (the) winding sections of the winding.

[0060] A thickness of (total) insulation on an outer surface of the winding can be, for example, at least 0.30 mm or at least 0.60 mm and / or at most 3 mm, optionally at most 1.5 mm. The thickness mentioned in the preceding sentence can be at least 0.015, preferably at least 0.050, optionally at least 0.100 and / or at most 2.5, preferably at most 0.300, optionally at most 0.200, in mm. A thickness of (the) insulation between (the) winding sections of the winding can be, for example, at least 0.01 mm or at least 0.05 mm or at least 0.01 mm and / or at most 0.5 mm. The thickness mentioned in the preceding sentence may be at least 0.005, preferably at least 0.020, optionally at least 0.030 and / or at most 0.5, preferably at most 0.100, optionally at most 0.070, in mm.

[0061] The (respective) thickness can be constant or vary. If the (respective) thickness varies, an average thickness should be used, taking into account the above information on specific (relative or absolute) values, which represents the largest proportion of the total area of ​​the respective layer in relation to the total area. Alternatively or additionally, an average thickness can be used (determined by dividing the respective layer under consideration into square cells with an edge length of 1 mm and calculating the arithmetic mean).

[0062] The (respective) winding section is preferably a section of the winding that rotates (exactly) once (and then ultimately transitions into the next winding section, wherein an interface can be connected in particular by laser welding). The (individual or respective) winding section preferably has a constant thickness (in the manner of a sheet). The (respective) winding section can have a rectangular configuration (in plan view), wherein one side of the rectangle is, for example, at least 1.5 times or at least 3 times and / or at most 10 times as large as another side of the rectangle. A thickness of the individual (respective) winding section can, for example, be at least 0.2 mm or at least 1 mm or at least 2 mm and / or at most 5 mm.

[0063] The winding may comprise at least three winding sections, possibly at least eight winding sections and / or a maximum of 100 winding sections, possibly a maximum of 50 winding sections.

[0064] A material for the (conductive) part of the winding is preferably copper or a copper alloy, and / or aluminum or an aluminum alloy.

[0065] The above-mentioned object is further achieved in particular by a system, in particular for carrying out the above method, for producing an insulated winding for an electrical machine, in particular an electric motor or generator, comprising:

[0066] - a provision device for providing a winding, in particular according to the above method,

[0067] - a first insulation device for isolating winding sections from each other, and

[0068] - a second insulation device for insulating at least a portion of an outer surface of the winding.

[0069] The above-mentioned object is further achieved in particular by a system, in particular according to the immediately preceding paragraph and / or for carrying out the above method, for producing an insulated winding for an electrical machine, in particular an electric motor or generator, comprising: a provision device for providing a winding, - an insulation device for insulating at least a section of an outer surface of the winding in such a way that at least one spacer means, in particular comprising an infiltrable surface material and / or individual particles, preferably beads, is applied and cast with a casting compound, in particular in a casting mold.

[0070] The above-mentioned object is further achieved in particular by a system, in particular according to one of the two immediately preceding paragraphs and / or for carrying out the above method, for producing an insulated winding for an electrical machine, in particular an electric motor or generator, comprising:

[0071] - a supply device for providing a winding,

[0072] - an insulation device, comprising a first and a second casting mold, for insulating at least a portion of an outer surface of the winding such that the insulation comprises a first step and a second step, o wherein the winding is arranged in a first casting mold in the first step and a first portion of the outer surface is cast there, and o wherein the winding is arranged in a second casting mold in the second step and a second portion of the outer surface is cast there.

[0073] The above-mentioned object is further achieved in particular by a system, in particular according to one of the three immediately preceding paragraphs and / or for carrying out the above method, for producing a winding for an electrical machine, in particular an electric motor or generator, comprising:

[0074] - a laser cutting device for providing winding sections by laser cutting, and - a laser welding device and / or an additive manufacturing device, in particular a laser sintering or laser melting device, for connecting the winding sections to form a winding, in particular a single coil, by laser welding or additive manufacturing.

[0075] The system (according to one or more of the three previous paragraphs) preferably further comprises:

[0076] - a blocking device for blocking the winding into a block by gluing, and / or

[0077] - a milling device for milling at least sections of an outer surface of the block (for the (final) definition of its shape).

[0078] The above-mentioned object is further achieved in particular by a winding for an electrical machine, in particular an electric motor or generator, produced according to the above method and / or the above system.

[0079] The above-mentioned object is further achieved in particular by an electrical machine, in particular an electric motor or generator, comprising the above winding.

[0080] Preferably, the isolation according to iii) is carried out after the isolation according to ii).

[0081] Further embodiments emerge from the subclaims.

[0082] The invention is described below using exemplary embodiments, which are explained in more detail with reference to the figures. Herein:

[0083] Fig. 1 is an oblique view of a winding according to the invention;

[0084] Fig. 2 shows a schematic cross section of a winding according to the invention;

[0085] Fig. 3 shows a schematic cross-section of a comparative example; Fig. 4 shows a schematic winding in a top view;

[0086] Fig. 5 shows the winding according to Fig. 4 after an insulation process step;

[0087] Fig. 6 shows the winding according to Fig. 4 after a further process step for insulation;

[0088] Fig. 7 shows a casting mold for the insulation of the winding according to Fig. 4;

[0089] Fig. 8 shows the winding according to Fig. 6 in the casting mold according to Fig. 7;

[0090] Fig. 9 shows a winding according to Fig. 4 with applied beads in a casting mold;

[0091] Fig. 10 shows a first mold for an alternative method of insulation;

[0092] Fig. 11 a winding according to Fig. 2 in the first casting mold according to

[0093] Fig. 10;

[0094] Fig. 12 a second casting mold for the alternative method;

[0095] Fig. 13 shows the winding according to Fig. 2 with partially applied insulation according to Fig. 11 in the second casting mold according to Fig. 12;

[0096] Fig. 14 is an oblique view of a molded part of a first casting mold according to the method of Figs. 10 to 13;

[0097] Fig. 15 is an oblique view of a first casting mold according to the method of Figures 10 to 13;

[0098] Fig. 16 is an oblique view of a molded part of a second casting mold according to the method of Figs. 10 to 13;

[0099] Fig. 17 is an oblique view of a second casting mold according to the method of Figures 10 to 13; Fig. 18 is an oblique view of an intermediate stage of external insulation of a winding according to the method of Figures 10 to 13;

[0100] Fig. 19 is an oblique view of a final stage of external insulation of a winding according to the method of Figures 10 to 13; and

[0101] Fig. 20 a winding (partially exploded view).

[0102] In the following description, the same reference numbers are used for identical and equivalent parts.

[0103] Fig. 1 shows a winding 10 according to the invention in a schematic oblique view. This winding comprises a plurality of winding sections 11, each of which has a rectangular configuration, so that the winding also has an (at least substantially) rectangular configuration in a plan view in the axial direction. The individual winding sections 11 can be cut from a sheet metal by laser cutting and connected to one another by laser welding to form the winding shown in Fig. 1. Laser-welded connections are schematically symbolized by lines 20.

[0104] Alternatively or additionally, the winding 10 can also be produced (at least partially, in particular for connecting base bodies, see Fig. 14) by casting (investment casting) and / or 3D printing (in particular laser sintering and / or laser melting).

[0105] Fig. 2 shows a highly schematic cross-section through the winding. Here, the winding is provided with outer insulation 12 and intermediate insulation layers 13. The intermediate insulation layers 13 are (considerably) thinner than the outer insulation 12. In comparison, Fig. 3 (also highly schematic) shows a corresponding cross-section of a coil manufactured using a conventional process. Here, the (winding) conductor is completely covered with insulation, so that in the area between the winding sections 11, a comparatively thick (and unnecessarily complex) insulation is present (which can basically be twice as thick as insulation on outer sections; corresponding to the outer insulation 12 in Fig. 2). The inventive solution according to Fig. 2 takes advantage of the fact that a comparatively low voltage is present between the layers (or the winding sections 11), so that a correspondingly lower insulation requirement exists.

[0106] This allows a fill factor (copper fill factor) to be increased (e.g. by 3% for 24 turns).

[0107] In contrast to the conventionally manufactured winding shown in Fig. 3, a comparatively thin and simple insulation layer is applied between the winding sections (instead of a coating on both sides). In particular, by inserting individual intermediate insulation layers 13 (e.g., as prepreg), no curvatures (radii) are required in the respective edge areas, which further reduces shaping restrictions. Any bending radii that may be necessary during production (when bending is required to apply the insulation) are also unproblematic with the procedure shown in Fig. 2, since this procedure eliminates the need for bending.

[0108] The result is a different insulation with respect to the intermediate insulation 13 and the outer insulation 12, which allows a simple yet effective space-saving winding production.

[0109] The intermediate insulations 13 shown in Fig. 2 can be produced by first placing them between the winding sections 11, then at a temperature of at least 100 °C and a pressure of at least 2 Newton / mm 2 be pressed (for example using a disc spring).

[0110] Preferably, after the intermediate insulation 13 and before the outer insulation according to Fig. 2 are applied, the winding can be milled to adjust or define its (final) shape. This improved, simple adjustment with high precision can synergistically enable the provision of the outer insulation 12 explained below, since a comparatively flat surface is particularly advantageous for this purpose. As an alternative to milling, increased precision could also be achieved by using a particularly precise pressing device.

[0111] Fig. 4 first shows the winding 10 according to Fig. 1 in a highly schematic plan view (still without insulation).

[0112] Fig. 5 shows the winding according to Fig. 4, where the increased line width indicates a polyimide liner that will be covered with a fabric. The PI liner can be laser-cut and glued onto the winding.

[0113] In the following step, a felt can be applied to the polyimide and the fabric, which is shown in Fig. 6 by the further increased line thickness and schematically indicated fibers 18.

[0114] To complete the insulation, a casting mold 14 (for example with a first mold part 15 and a second mold part 16 and a core 19) can now be provided according to Fig. 7, wherein the casting mold can be opened and closed if necessary and defines a cavity 17 in the closed state, which here, for example, approximately corresponds (at least schematically viewed) to a Q. The winding (or coil) according to Fig. 6 (i.e. including the PI liner, with fabric and the felt or fleece) can now be introduced into the casting mold 14 (see Fig. 8), wherein the fleece easily creates a (precise) distance from the mold. Furthermore, the fleece (the felt) is comparatively easy to cast or impregnate. As a result, a method is proposed in which precise insulation can be achieved in a simple manner.

[0115] The fleece can be based on PET or made from it.

[0116] The actual casting can be carried out as vacuum casting.

[0117] A 2-component epoxy system can be used as a casting compound.

[0118] After curing the winding according to Fig. 8, it is insulated, resulting in an insulated winding. In the embodiment according to Figs. 6-8, both an outward-facing surface of the winding and an inward-facing surface of the winding are provided with fibers 18. For positioning and adjusting a distance, only the outward-facing surface or only the inward-facing surface can be provided with fibers. It is also conceivable that only sections (of the outward-facing and / or the inward-facing surface) are provided with corresponding fibers 18 (or fleece) (as long as the spacing function is guaranteed).

[0119] Fig. 9 shows an alternative embodiment in which, instead of the method according to Figs. 4-8, particles 21 (small beads, preferably made of glass) are used to set a distance for the introduction of the insulation (as described in connection with Fig. 8). The application of a primer can be omitted according to Fig. 9 (correspondingly also according to the embodiments according to Figs. 4-8). In Fig. 9, only an outward-facing surface of the winding is provided with particles 21. Alternatively or additionally, an inward-facing surface can also be provided with particles 21. The particles 21 are preferably present as agglomerates and cover only a comparatively small part of the outward-facing surface of the winding or - if present - the inward-facing surface. Apart from the particles, the method can be carried out as described in Figs. 4-8.

[0120] Figs. 10-19 describe yet another alternative method for applying (external) insulation. Fig. 10 initially shows (schematically) a first casting mold 22 with a cavity 17 (which, analogous to the casting mold 14 above, can consist of at least or exactly two mold parts 15, 16, see Figs. 14 and 15).

[0121] In a first process step, the winding 10 is now inserted into the first casting mold 22 according to Fig. 2 (see Figs. 11 and 15). A (remaining) cavity between the winding and the first casting mold 22 is then filled with casting compound, forming at least one section 27 of an outer insulation 12 (see also Fig. 14).

[0122] In a second step, a second encapsulation mold 23 is provided (which may consist of at least or exactly two mold parts 15, 16, see Figs. 16 and 17, wherein one of the mold parts, in particular the second mold part 16, may be the same as the first and second encapsulation molds, and may optionally be formed by the same mold part), and the winding 10, which was already partially provided with insulation in the first step, is arranged in the second encapsulation mold 23, so that surface sections (outer surface sections) not yet provided with insulation are provided with a further section 28 of the outer insulation 12 (see also Fig. 19). Optionally (as shown in Figs. 10-19), the outer insulation 12 may not yet be applied in its full layer thickness in an overlap region 24 in the first step. For this purpose, the first encapsulation mold may, for example, have an (intermediate) step 29 (see Figs. 10 and 15).The (intermediate) step 29 can be integrated into a (main) step 30, which can be provided to separate the sections provided with insulation in the first step from the sections not provided with insulation in the first step. The step 30 can also be designed without the step 29.

[0123] In the overlapping area, the final insulation layer thickness is then achieved in the second step (see Fig. 13). This allows for a particularly homogeneous and reliable external insulation 12 to be provided.

[0124] In the processes according to Fig. 10-19, an injection molding process is preferably used.

[0125] Fig. 20 shows a single coil (partially in an exploded view) that can be manufactured as follows. First, a plurality of winding base bodies 25 are manufactured or provided. The winding base bodies 25 are preferably designed as (particularly U-shaped) sheets. A connection (wiring) of the winding base bodies 25 in the region of a winding head 26 is preferably carried out by an additive manufacturing process (particularly laser sintering). Specifically, (e.g., cut) sheets can be mounted and a wiring can subsequently be printed on. The final geometry can then correspond to Fig. 1.

[0126] At this point, it should be noted that all parts described above, viewed individually and in any combination, particularly the details shown in the drawings, are claimed as essential to the invention. Modifications to these provisions will be familiar to those skilled in the art. Furthermore, it is pointed out that the broadest possible scope of protection is sought. Therefore, the disclosure contained in the claims may also be further clarified by features that are described with additional features (even without these additional features necessarily being included). It is explicitly pointed out that parentheses and the term "in particular" are intended to emphasize the optionality of features in the respective context (which does not imply, conversely, that without such identification, a feature is to be considered mandatory in the corresponding context).The term "element / elements" is preferably intended to designate a coherent structure, which in turn may be connected to at least one other structure (to form a possibly integral and / or inherently immobile overall structure) or may be separated from all other structures.

[0127] Reference symbol

[0128] 10 windings

[0129] 11 Winding section

[0130] 12 External insulation

[0131] 13 Intermediate insulation

[0132] 14 Casting mold

[0133] 15 first molded part

[0134] 16 second molded part

[0135] 17 Cavity

[0136] 18 fibers

[0137] 19 core

[0138] 20 laser welding connections

[0139] 21 particles

[0140] 22 first casting mold

[0141] 23 second casting mold

[0142] 24 Overlap area

[0143] 25 winding base bodies

[0144] 26 winding head

[0145] 27 first section

[0146] 28 second section

[0147] 29 (hissing) level

[0148] 30 (main) level

Claims

Claims 1. A method for producing an insulated winding (10) for an electrical machine, in particular an electric motor or generator, comprising the steps: i. providing a winding (10), in particular according to the method according to claim 4, ii. insulating winding sections (11) from one another, and iii. insulating at least one section of an outer surface of the winding (10), wherein the insulation according to iii. is carried out by a different method than the insulation under ii.

2. A method, in particular according to claim 1, for producing an insulated winding (10) for an electrical machine, in particular an electric motor or generator, comprising the steps: - Providing a winding (10), in particular according to the method according to claim 4, - Insulating at least one section of an outer surface of the winding (10), wherein at least one spacer means, in particular comprising an infiltrable surface material and / or individual particles, preferably spheres, is applied and cast with a casting compound, in particular in a casting mold.

3. Method, in particular according to one of the preceding claims, for producing an insulated winding (10) for an electrical machine, in particular an electric motor or generator, comprising the steps: - Providing a winding (10), in particular according to the method according to claim 4, - insulating at least a portion of an outer surface of the winding (10), wherein the insulating comprises a first step and a second step, o wherein in the first step the winding is arranged in a first casting mold and a first portion of the outer surface is cast there, and o wherein in the second step the winding is arranged in a second casting mold and a second portion of the outer surface is cast there.

4. Method, in particular according to one of the preceding claims, for producing a winding (10) for an electrical machine, in particular an electric motor or generator, comprising: - providing winding sections (11) by laser cutting, and - connecting the winding sections (11) to form a winding (10), in particular a single coil, by laser welding and / or an additive process, in particular laser sintering or laser melting.

5. Method according to one of the preceding claims, wherein a / the method for insulating winding sections (11) from one another and a / the method for insulating at least one section of an outer surface of the winding (10) differ from one another in that the insulation is applied in a different way and / or different materials are used and / or a different thickness is set and / or the respective insulations are applied at different times.

6. Method according to one of the preceding claims, comprising: - blocking the winding (10) into a block by gluing, and / or - milling of at least sections of an outer surface of the block.

7. Method according to one of the preceding claims, wherein insulation, preferably of winding sections (11) from one another, in particular the insulation in step ii), comprises: introducing an insulating film, in particular a preferably pre-impregnated insulating paper.

8. Method according to one of the preceding claims, wherein insulating, preferably insulating at least a portion of an outer surface of the winding (10), in particular insulating in step iii), comprises: Applying a plastic, preferably provided with a fabric and / or grid structure, in particular a polymer, preferably polyimide, and / or Applying an infiltrable surface material, in particular a fleece, in particular to the plastic, and / or Application of individual particles, preferably beads, Applying a casting compound, in particular casting the infiltrable surface material, preferably in a casting mold (14) in which the winding (10) is arranged, in particular with the infiltrable surface material and / or the particles.

9. Method according to one of the preceding claims, wherein a thickness of an insulation on / the outer surface of the winding (10) is at least 1.2 times, preferably at least 2.0 times and / or at most 20 times as great as a thickness of an insulation between(s) winding sections (11) of the winding (10).

10. System, in particular for carrying out the method according to one of the preceding claims, for producing an insulated winding (10) for an electrical machine, in particular an electric motor or generator, comprising: - a provision device for providing a winding (10), in particular according to the method according to claim 4, - a first insulation device for insulating winding sections (11) from one another, and - a second insulation device for insulating at least a portion of an outer surface of the winding (10).

11. System, in particular according to the immediately preceding claim and / or for carrying out the method according to one of the preceding claims, for producing an insulated winding (10) for an electrical machine, in particular an electric motor or generator, comprising: - a provision device for providing a winding (10), in particular according to the method according to claim 4, - an insulation device for insulating at least a portion of an outer surface of the winding (10) such that at least one spacer means, in particular comprising an infiltrable surface material and / or individual particles, preferably spheres, is applied and cast with a casting compound, in particular in a casting mold.

12. System, in particular according to one of the two immediately preceding claims and / or for carrying out the method according to one of the claims preceding the two immediately preceding claims, for producing an insulated winding (10) for an electrical machine, in particular an electric motor or generator, comprising: - a provision device for providing a winding (10), in particular according to the method according to claim 4, - an insulation device, comprising a first and a second casting mold, for insulating at least a portion of an outer surface of the winding (10) such that the insulation comprises a first step and a second step, o wherein the winding is arranged in a first casting mold in the first step and a first portion of the outer surface is cast there, and o wherein in the second step the winding is arranged in a second casting mold and a second portion of the outer surface is cast there.

13. System, in particular according to one of the three immediately preceding claims and / or for carrying out the method according to one of the claims preceding the three immediately preceding claims, for producing a winding (10) for an electrical machine, in particular an electric motor or generator, comprising: - a laser cutting device for providing winding sections (11) by laser cutting, and - a laser welding device and / or an additive manufacturing device, in particular a laser sintering or laser melting device, for connecting the winding sections (11) to form a winding (10), in particular a single coil, and preferably further comprising: - a blocking device for blocking the winding (10) into a block by gluing, and / or - a milling device for milling at least sections of an outer surface of the block (for the (final) definition of its shape).

14. Winding (10) for an electrical machine, in particular an electric motor or generator, manufactured according to the method or the system according to one of the preceding claims, or electrical machine, in particular an electric motor or generator, comprising such a winding (10).

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