Device and method for winding coils without said coils crossing

Abstract

The invention relates to a device (1) for winding coils (2) without said coils crossing in a plurality of winding steps for one coil group. The device comprises at least two winding formers (3, 4) which are movable telescopically one inside the other, extend in parallel and rotate about a common axis of rotation (24). Each winding former is equipped with a guide rail (5) on which a first telescopic rail (6) is guided, which in turn bears a second telescopic rail (7). In the first operating position (8), the two telescopic rails (6, 7) are fully retracted, as a result of which a first chamber (9) for winding an inner coil (21) is provided. In a second operating position (11), the first telescopic rail (6) is offset in relation to the guide rail (5) in order to create a second chamber (12) for winding a central coil (22). In the third operating position (41), the second telescopic rail (7) is offset in relation to the first telescopic rail (6), as a result of which a third chamber (13) for winding an outer coil (23) is provided. After the winding process, the coils (21, 22, 23) are arranged concentrically to one another in the device (1).

Description

[0001] P240427

[0002] - 1 -

[0003] Device and method for cross-free winding of coils

[0004] The present invention relates to a device and a method for cross-free winding of coils with several winding steps in a coil group, comprising at least two telescopically movable winding templates, parallel and rotatable about a common axis of rotation, each with

[0005] In connection with devices for cross-free winding of coils, it is known from the prior art that such devices are often limited to a specific number of winding steps and a fixed number of winding templates. Typically, winding templates are used that cannot be moved telescopically. These rigid winding templates mean that the device must either have a fixed size or be limited by its design, which significantly restricts the flexibility of the winding process.

[0006] A particularly relevant problem with known devices is that the length of the winding templates is limited by the feeder tool. To ensure cross-free winding, the coils must be completely wound on the winding templates before they can be transferred to the feeder tool. However, since the length of the winding templates cannot be arbitrarily increased due to the limitations of the feeder tool, multi-stage winding processes with several winding steps quickly reach physical and design limits. This results in only two winding steps being possible in most cases, which significantly restricts the productivity and flexibility of these devices.

[0007] Furthermore, it is known from the prior art that external guides, such as rods or rails, are frequently used for the winding template process. However, these external guides are complicated to handle and prone to mechanical problems, especially when several winding templates need to be guided and moved simultaneously.

[0008] CONFIDENTIAL P240427

[0009] - 2 - also do not allow two or more templates to be moved telescopically into one another, which further limits the efficiency and compactness of the system.

[0010] Another disadvantage of known devices is that they are generally designed for specific winding patterns and can only be adapted to changing production requirements with considerable effort. This leads to increased complexity in setting up the winding processes, as well as higher costs and increased susceptibility to errors, especially in motor windings. Furthermore, the numerous wiring tasks that arise when switching between winding templates require significant effort and increase potential sources of error.

[0011] The object of the invention is therefore to provide a device and a method for cross-free winding of coils with several winding steps in a coil group, which avoids or at least reduces the disadvantages of the prior art.

[0012] This problem is solved by a device for cross-free winding of coils with multiple winding steps in a coil group, comprising at least two telescopically movable winding templates, parallel and rotatable about a common axis of rotation, each with a guide rail on which a first telescopic rail, movable relative to the guide rail, is guided, and a second telescopic rail, movable relative to the first telescopic rail and guided on it, wherein in a first operating position of the winding templates, in which the first telescopic rails and the second telescopic rails are fully retracted, the guide rails provide a first chamber for winding a first, inner coil with a winding wire.and the first telescopic rails in a second operating position of the winding templates in which the first telescopic rails and the second telescopic rails are offset from the guide rails, provide a second chamber for winding a second, middle coil with a winding wire, and the second telescopic rails in a third operating position of the winding templates in which the second telescopic rails are offset from the first telescopic rails, provide a third chamber for winding a third,

[0013] CONFIDENTIAL P240427

[0014] - 3 - provide the outer coil with a winding wire so that the first coil, the second coil and the third coil are arranged concentrically to each other in the device after winding.

[0015] This device offers the advantage of a compact design thanks to its telescopically adjustable winding templates, allowing for a shorter insertion length into the drawing tool. This enables the winding templates to be integrated into existing machine designs without requiring significant modifications to the machine structure. Furthermore, the concentric arrangement of the coils after winding allows for precise and space-saving transfer of the windings, resulting in improved winding quality and reduced wiring complexity. This translates into lower costs and reduced motor failure rates, particularly through the reduction of mechanical complexity and potential wiring errors.

[0016] It is understood that the device for cross-free winding of coils with multiple winding steps in a coil group can also have more than two telescopic rails, so that the winding wire can also be wound in more than three chambers.

[0017] First, the individual elements of the claimed invention are explained in the order in which they are mentioned in the claim set, and subsequently, particularly preferred embodiments of the invention are described.

[0018] device

[0019] For the purposes of this patent application, a device for cross-crossing coils with multiple winding steps in a coil group is a device that makes it possible to wind coils onto a winding template without overlapping winding wires. The device consists of at least two telescopically movable winding templates that rotate about a common axis of rotation. These winding templates are designed to provide one or more chambers for winding wire in different operating positions, with the winding taking place sequentially in the chambers to ensure uniform wire placement without overlaps.

[0020] CONFIDENTIAL P240427

[0021] - 4 -

[0022] The device is characterized by a guide unit located inside the winding templates. This guide unit controls the extension and retraction of the individual telescopic rails that connect the winding templates. In a first operating position, the telescopic rails are fully retracted, creating a first chamber in which the wire winding begins. After completion of this first winding step, the guide unit moves the telescopic rails, releasing a second chamber in which the next winding step takes place. In a further operating position, a third chamber is released, allowing multiple coils to be wound in an orderly sequence without the wires crossing over each other.

[0023] The device functions by securing the wire start with a wire start clamp while the winding template rotates to wind the customer-specified number of turns. After each winding step, the next chamber is activated by releasing the clamping or locking unit and sliding the telescopic rails downwards before the clamping unit is re-locked. The winding templates thus allow for multiple winding steps to be performed consecutively without manual intervention, ensuring a high degree of process automation and efficiency.

[0024] Preferably, the clamping unit and / or the locking unit are pneumatically actuated to ensure quick and reliable fixation of the telescopic rails. This results in stable and precise movement of the templates, which significantly improves the winding process and minimizes the risk of wire crossings.

[0025] Advantageously, the winding templates can be designed to include several chambers of different sizes to allow flexible adaptation to various coil types. Furthermore, the winding templates can be identical to ensure simple manufacturing and maintenance. One conceivable embodiment is one in which the guide unit

[0026] CONFIDENTIAL P240427

[0027] - 5 - consists of one or more U-shaped bridges which guide the telescopic rails stably and precisely. These bridges ensure that the templates are moved evenly and guarantee high mechanical stability.

[0028] Furthermore, the device can be equipped with various clamping devices to securely fix the wire start and hold the wire in position throughout the entire winding process. These wire start clamping devices can be mounted on the guide rails or telescopic rails, allowing for a high degree of flexibility in the device design.

[0029] For the purposes of this patent application, coils with multiple winding steps in a coil group are to be understood as coils that are successively provided with windings of one or more winding wires in a successive process. This is a winding process in which the wire turns are applied in several separate winding steps, each step producing a defined number of turns on different chambers of a winding template. A coil group comprises several coils that are wound sequentially or simultaneously in a common device or arrangement, thus forming a group of coils that are functionally and structurally connected.

[0030] The multi-stage winding coils within a coil group serve to create different wire layers in various chambers of a winding jig in a coordinated winding process. This allows the windings to be layered or separate wire paths to be implemented as required. This multi-stage winding process enables the efficient and precise creation of numerous layers or separate windings within a single coil group, which is particularly advantageous in complex electrical or electromagnetic applications. Each winding jig provides multiple chambers that can be moved telescopically, allowing the winding process to be carried out in different spatial planes.

[0031] CONFIDENTIAL P240427

[0032] - 6 - to be carried out without the need to reset or adjust the template during the process.

[0033] wrapping template

[0034] For the purposes of this patent application, a winding template is a component used to hold and guide wire or other winding materials within a predetermined geometry, enabling the precise winding of a coil. Winding templates are a central component of the winding process, ensuring that the wire is guided without crossings and in precisely defined winding steps.

[0035] The winding templates preferably comprise telescopically extendable elements that allow multiple winding steps to be performed sequentially without the template length exceeding the capacity of the feed tool. The various parts of the winding templates, such as the telescopic rails, are movably mounted on guide rails and can be positioned in different operating positions to expose different chambers of the templates for winding. These operating positions allow several coils to be wound sequentially and subsequently arranged concentrically on top of each other.

[0036] The templates rotate around a common axis of rotation while the wire is continuously fed and wound onto the template surfaces around the two winding templates. Once the winding process is complete, the winding templates are inserted into the feeder tool, ensuring the windings are transferred securely.

[0037] Advantageously, a winding template can consist of several sliding segments, allowing the template length to be varied without affecting the operation of the winding machine. These segments can be held securely in position by clamping or locking units to ensure precise guidance of the template throughout the entire winding process. These clamping units are preferably...

[0038] CONFIDENTIAL P240427

[0039] - 7 - pneumatically actuated to enable quick and reliable fixing of the individual template parts.

[0040] Possible embodiments of the winding template include a version with a varying number of winding chambers, which can be individually adapted depending on the application. For example, the template can be designed for winding processes with two, three, or more chambers, where each chamber can be controlled separately for winding.

[0041] Guide rail

[0042] For the purposes of this patent application, a guide rail is a mechanical component used for the precise guidance of moving components, in particular telescopic slides. The guide rail is a stable, elongated element designed to direct the movement of the telescopic slides in a defined direction while simultaneously ensuring smooth and low-friction movement of the slides. The guide rail thus forms the structural backbone along which the telescopic slides are moved, preventing unwanted lateral movement or tilting of the slides.

[0043] Preferably, the guide rail is made of a strong, durable material such as steel or aluminum, which provides the necessary mechanical stability while remaining light enough not to unnecessarily increase the overall mass of the device. Advantageously, the guide rail is equipped with precision sliding guides or bearings that ensure smooth and quiet operation of the telescopic slides.

[0044] A preferred embodiment of the invention can be a guide rail with a U-shaped cross-section, in which the outer surface acts as a contact surface for the winding.

[0045] For the purposes of this patent application, a first and second telescopic rail are to be understood as rails that are movable and can be slid into one another, guided along a guide rail. The first telescopic rail is positioned opposite the

[0046] CONFIDENTIAL P240427

[0047] - 8 - The first telescopic guide rail is movable, while the second telescopic rail is movable relative to the first. These telescopic rails are arranged so that they can be telescopically moved into one another, thus allowing their length to be reduced or increased as needed. This makes it possible to fix the winding templates in different positions during the winding process and thus to achieve the winding of multiple coil chambers in a compact design.

[0048] The function of the telescopic rail is to hold the winding templates in the desired position during the winding process while simultaneously allowing flexible adjustment of the template length. By sliding the first and second telescopic rails, the template is moved into the appropriate position to wind the different coil chambers sequentially. The guide rail serves as a stabilizing element along which the telescopic rails move and align themselves. The telescopic rails can preferably be locked in the desired position using a clamping or locking unit to ensure secure fixation.

[0049] The telescopic rail is advantageously designed such that the first telescopic rail is guided within the guide rail, while the second telescopic rail is movable within the first. Both rails are preferably made of a strong and durable material, such as steel or aluminum, to ensure high stability and longevity. The connection points between the telescopic rails and the guide rail are designed to ensure low-friction and precise movement. Preferably, the telescopic rails have a U-shaped cross-section.

[0050] chamber

[0051] For the purposes of this patent application, a chamber is a defined section or area of ​​the telescopically movable winding template, designed to accommodate a specific number of turns of a winding wire. Each chamber is responsible for the precise winding of the wire and ensures that the turns are applied without overlaps or crossings.

[0052] CONFIDENTIAL P240427

[0053] - 9 -

[0054] Several chambers are arranged one after the other on a winding template, with each chamber being activated and wound in a separate operating position.

[0055] The chamber's function is to hold the wire in a defined space during the winding process and stabilize the windings. Once a chamber is fully wound, the next chamber is activated by telescopically extending from its previous position. This allows for the crossover-free winding of multiple coils in a continuous process. The compact arrangement of the chambers on a winding template enables a greater number of winding steps to be performed without significantly increasing the length of the feeder tool.

[0056] Advantageous embodiments of the invention

[0057] According to an advantageous embodiment of the invention, it can be provided that the winding templates each comprise a guide unit arranged inside a winding template, by means of which the first telescopic rail and the second telescopic rail are guided.

[0058] The guide unit inside the winding templates offers the advantage of precisely guiding and stabilizing the telescopic rails. This contributes to smooth movement of the telescopic rails and prevents them from tilting or shifting unevenly during the winding process. The internal guide also keeps the system compact and saves valuable machine space.

[0059] According to a further preferred embodiment of the invention, the guide unit may also include a clamping unit and / or a locking unit, which enables the telescopic rails to be guided in series. The integration of a clamping unit and / or a locking unit, which enables the telescopic rails to be guided in series, has the advantage that the templates are held stably in position during operation. This ensures precise positioning of the templates and improves the accuracy of the winding process. The firm fixation ensures that

[0060] CONFIDENTIAL P240427

[0061] - 10 - prevents the templates from shifting during winding, resulting in better winding quality and a reduced likelihood of wire crossings. This also facilitates smooth transitions between chambers.

[0062] Furthermore, according to another advantageous embodiment of the invention, the clamping unit or the locking unit can be pneumatically operated and actuated by means of a pneumatic cylinder. Pneumatic actuation of the clamping unit or the locking unit offers the advantage of automated control and increased reliability of the locking mechanisms. Pneumatic systems are known for their durability and low maintenance requirements, which leads to improved operational reliability of the device. In addition, the use of a pneumatic cylinder enables fast and powerful locking, making the entire winding process more efficient. This contributes to a reduction in cycle times and thus to higher productivity.

[0063] According to a further particularly preferred embodiment of the invention, the locking unit may have an actuable bolt which, in a locked position, engages a corresponding positive locking element of the first telescopic rail and / or the second telescopic rail. The use of an actuable bolt engaging a corresponding positive locking element of the telescopic rails creates a mechanically very stable locking mechanism. This ensures precise and secure positioning of the templates during the winding process. An advantage here is that the bolt is mechanically secured in its locked position, thus preventing unintentional movement or loosening of the templates during operation. This increases operational reliability and further improves winding quality.

[0064] Furthermore, the invention can also be further developed in that the guide unit comprises a first, essentially U-shaped bridge, the free legs of which are connected to the first telescopic rail, the bridge being guided on the guide rail. The U-shaped bridge, the free legs of which are connected to the first telescopic rail,

[0065] CONFIDENTIAL P240427

[0066] The connection of the first telescopic rail to the U-shaped bridge ensures robust and stable guidance of the telescopic rails. This offers the advantage that the templates are guided precisely and evenly during adjustment. The U-shaped bridge design also provides high strength and resistance to mechanical stress, increasing the system's durability. At the same time, this design keeps the system compact.

[0067] In a further preferred embodiment of the invention, the guide unit may also include a second, essentially U-shaped bridge, the free legs of which are connected to the second telescopic rail, with the bridge being guided on the guide rail or the first telescopic rail. The second U-shaped bridge, connected to the second telescopic rail, enables parallel and independent guidance of the telescopic rails, resulting in flexible and precise control of the stencil movements. This ensures that the stencils move smoothly and without tilting, which is particularly advantageous in more complex winding processes with multiple chambers. The use of two separate bridges also increases the structural stability of the entire system and minimizes the risk of mechanical malfunctions.

[0068] It can also be advantageous to further develop the invention by providing a wire start clamping device on the guide rail and / or the first telescopic rail and / or the second telescopic rail, which secures the winding wire during the winding process. The wire start clamping device offers the advantage that the wire remains firmly fixed throughout the entire winding process, which significantly reduces the risk of wire slippage or tangling. This leads to higher precision during winding and improves the quality of the finished coil windings. Furthermore, the clamping device enables an automated process start, thereby reducing operator effort and accelerating the winding process.

[0069] According to a further preferred embodiment of the invention, the winding templates may be designed to be essentially identical. The identical design of the winding templates offers the

[0070] CONFIDENTIAL P240427

[0071] - 12 -

[0072] Advantages include simplified manufacturing and maintenance. Because all templates are identical in design, the same components can be used, reducing production costs and simplifying inventory management. Furthermore, defective parts can be easily replaced without the need for special spare parts. This increases efficiency and reduces downtime in the production process, as repairs and maintenance can be carried out more quickly.

[0073] Finally, the problem of the invention can also be solved by a method for cross-free winding of coils comprising the following steps:

[0074] • Providing a device according to any one of claims 1-9,

[0075] • Transferring the device to the first operating position of the winding templates

[0076] • Fixing the wire start of a winding wire to one of the guide rails using a wire start clamping device and starting the winding process, whereby the winding templates rotate around a common axis of rotation to wind a predetermined number of turns onto the first chamber;

[0077] • Transferring the device to the second operating position of the winding templates

[0078] • Continuing the winding process, with the winding templates rotating around the common axis of rotation to wind a predetermined number of turns onto the second chamber,

[0079] • Transferring the device to the third operating position of the winding templates

[0080] • Continuing the winding process, with the winding templates rotating around the common axis of rotation to wind a predetermined number of turns onto the third chamber,

[0081] • Inserting the winding chambers into a feeder after completion of the winding process and transferring the winding,

[0082] • Cutting off the winding wire and

[0083] • Returning the winding chambers to the first operating position of the winding templates.

[0084] CONFIDENTIAL P240427

[0085] - 13 -

[0086] The method for cross-free winding of coils offers the advantage of a more efficient and precise winding process. By precisely moving the device into different operating positions, the winding templates can be loaded automatically and sequentially without manual intervention. This significantly reduces the wiring effort on the coils and results in a faster and error-free winding process. The precise control of the winding process ensures high winding quality and minimizes wire crossovers or wire routing errors, thus increasing the overall reliability of the winding and reducing manufacturing costs.

[0087] For the purposes of this patent application, "fixing the wire start of a winding wire to one of the guide rails by means of a wire start clamping device" is also understood to mean that the wire start clamping device need not necessarily be directly attached to one of the guide rails. Rather, the wire start clamping device can also be attached to a separate component, with the wire start clamping device and the guide rail being fixed relative to each other. The crucial point is that the position of the clamping device relative to the guide rail is fixed so that the function of securely fixing the wire start during the winding process is guaranteed, regardless of whether the clamping device is mounted directly or indirectly on the guide rail.

[0088] The invention will now be explained in more detail with reference to figures, without limiting the general concept of the invention.

[0089] It shows:

[0090] Figure 1 shows a device for cross-free winding of coils with two winding templates in a first operating position in a longitudinal side view.

[0091] Figure 2 shows a device for cross-free winding of coils with two winding templates in a second operating position in a longitudinal side view.

[0092] CONFIDENTIAL P240427

[0093] - 14 -

[0094] Figure 3 shows a device for cross-free winding of coils with two winding templates in a third operating position in a longitudinal side view.

[0095] Figure 4 shows a device for cross-free winding of coils with two winding templates in their first, second and third operating positions, each in a longitudinal side view.

[0096] Figure 5 shows a wound winding template in its first, second and third operating positions, each in a longitudinal side view.

[0097] Figure 6 shows a device for cross-free winding of coils with two winding templates in a top view.

[0098] Figure 7 shows a telescopic winding template in perspective top view in a semi-transparent representation.

[0099] Figure 8 shows a detailed view of a telescopic winding template in perspective.

[0100] Figure 9 shows a perspective cross-sectional view through a telescopic winding template with a locking unit in a semi-transparent representation.

[0101] Figure 10 shows a perspective cross-sectional view through a telescopic winding template with a clamping unit in a semi-transparent representation.

[0102] Figure 11 shows a perspective view of a device for cross-free winding of coils with two winding templates and a guide unit arranged on the outside of the winding templates.

[0103] CONFIDENTIAL P240427

[0104] - 15 -

[0105] Figures 1-4 show a device 1 for cross-free winding of coils.

[0106] 2 with several winding steps in a coil group, each comprising two telescopically movable winding templates 3, 4, parallel and rotatable about a common axis of rotation 24, each with a guide rail 5 on which a first telescopic rail 6, which is displaceable relative to the guide rail 5, is guided, and a second telescopic rail 7, which is displaceable relative to the first telescopic rail 6 and guided on it. The winding templates 3, 4 are essentially identical in the embodiment shown.

[0107] In a first operating position 8 of the winding templates 3, 4, in which the first telescopic rails 6 and the second telescopic rails 7 are fully retracted, the guide rails 5 provide a first chamber 9 for winding a first, inner coil 21 with a winding wire 10. This first operating position is shown in Figure 1.

[0108] In a second operating position 11 of the winding templates 3,4, in which the first telescopic rails 6 and the second telescopic rails 7 are offset from the guide rails 5, the first telescopic rails 6 then provide a second chamber 12 for winding a second, middle coil 22 with a winding wire 10, as shown in Figure 2.

[0109] In a third operating position 41 of the winding templates 3,4, in which the second telescopic rails 7 are offset relative to the first telescopic rails 6, the second telescopic rails 7 then provide a third chamber 13 for winding a third, outer coil 23 with a winding wire 10, as shown in the figure.

[0110] 3 can be seen.

[0111] Figure 4 shows the different operating positions 8, 11, 41 again in a comparison, while Figure 5 illustrates the winding of chambers 9, 12, 13 in operating positions 8, 11, 41. This demonstrates that

[0112] CONFIDENTIAL P240427

[0113] - 16 - the first coil 21, the second coil 22 and the third coil 23 are arranged concentrically to each other in the device 1 after winding.

[0114] The winding templates 3, 4 each comprise a guide unit 14 arranged inside the winding template 3, 4, by means of which the first telescopic rail 6 and the second telescopic rail 7 are guided. As can be seen in Figures 9 and 10, the guide unit 14 comprises a clamping unit 16 and / or a locking unit 17, which enables the telescopic rails 6, 7 to be guided in series. The clamping unit 16 or the locking unit 17 is pneumatically operated and actuated by means of a pneumatic cylinder 18.

[0115] The locking unit 17 has an actuable bolt 25 which, in a locking position, engages in a corresponding positive locking means 26 of the first telescopic rail 6 and / or the second telescopic rail 7, which can be clearly seen in Figure 9.

[0116] Figures 7, 9-10 further show that the guide unit 14 comprises a first, essentially U-shaped bridge 20, the free legs 27, 28 of which are connected to the first telescopic rail 6, the bridge 20 being guided on the guide rail 5, and the guide unit 14 further comprises a second, essentially U-shaped bridge 30, the free legs 31, 32 of which are connected to the second telescopic rail 6, the bridge 30 being guided on the guide rail 5 or the first telescopic rail 6. The guide unit 14 also has a rail 33 extending longitudinally along the guide rail 5 and fixed to the guide rail 5, on which the bridges 20, 30 of the telescopic rails 6, 7 are slidably arranged. The sled 34 is arranged between the rail 33 and the bridges 20,30, which is connected to the corresponding bridge 20,30 and slides along the rail 33.To prevent the translational movement of the telescopic rails 6, 7 from tilting, the two linear guides 35, 36 run longitudinally along the guide rail 5 and are attached to it as separate components. The free legs 27, 28 of the first U-shaped bridge 20 and the free legs of the second U-shaped bridge 30 engage with the U-shaped linear guides 35, 36, as can be seen in Figure 7 or Figure 10.

[0117] CONFIDENTIAL P240427

[0118] - 17 -

[0119] Figure 8 clearly shows that a first gap 37 is provided between the guide rail 5 and the first telescopic rail 6, in which the first coil 21 is received after winding. This gap 37 ensures that the winding templates 3, 4 can be extended telescopically even after winding. The second gap 38 between the first telescopic element 6 and the second telescopic element 7 serves the same function.

[0120] Figure 11 showed an alternative arrangement of the guide units 14, which in this embodiment are not located inside the winding templates 3, 4, but rather on their outer surfaces. The functional principle of the guide units 14 is analogous to the embodiments in which the guide units 14 are positioned inside the winding templates 3, 4. The space freed up inside the winding templates 3, 4 by relocating the guide units to the outside allows for smaller package heights.

[0121] A wire start clamping device can, for example, be provided on the guide rail 5 and / or the first telescopic rail 6 and / or the second telescopic rail 7, which fixes the winding wire 10 during the winding process. It is also conceivable that a wire start clamping device is arranged outside the rails 5, 6, 7, but is fixedly positioned relative to them, so that the wire start clamping device rotates with the rails 5, 6, 7 and thus winds the winding wire 10 around or into the chambers 9, 12, 13.

[0122] A method for cross-free winding of coils 21, 22, 23 can now comprise the following steps: First, a device 1, as shown in Figures 1-10, is provided. Then, the device 1 is moved into the first operating position 8 of the winding templates 3, 4, and the wire start of a winding wire 10 is fixed to one of the guide rails 5 by means of a wire start clamping device, and the winding process is started, whereby the winding templates 3, 4 rotate about a common axis of rotation 24 to wind a predetermined number of turns onto the first chamber 9.

[0123] CONFIDENTIAL P240427

[0124] - 18 -

[0125] To mechanically fix the winding templates 3, 4 in the first operating position 8, a clamping unit 16 or locking unit 17 can be activated. This is then released again after the winding of the first chamber 9 is complete.

[0126] The device 1 is then moved into the second operating position 11 of the winding templates 3,4 and the winding process is continued, with the winding templates 3,4 rotating around the common axis of rotation 24 to wind a predetermined number of turns onto the second chamber 12.

[0127] To mechanically fix the winding templates 3,4 in the second operating position 11, a clamping unit 16 or locking unit 17 can be activated again, which is then released again after completion of the winding of the second chamber 12.

[0128] Now the device 1 is moved into the third operating position 41 of the winding templates 3,4 and the winding process is continued, whereby the winding templates 3,4 rotate around the common axis of rotation 24 in order to wind a predetermined number of turns onto the third chamber 13.

[0129] In the third operating position 41, the winding templates 3,4 can also be mechanically fixed by again activating a clamping unit 16 or locking unit 17, which is then released again after completion of the winding of the third chamber 13.

[0130] After the actual winding process is completed, the winding chambers 9, 12, 13 are inserted into a drawing tool and the winding is transferred.

[0131] Finally, the winding wire 10 is cut off and the winding chambers 9,12,13 are moved back to the first operating position 8 of the winding templates 3,4.

[0132] The invention is not limited to the embodiments shown in the figures. The foregoing description is therefore not intended to be limiting, but rather to be explanatory.

[0133] CONFIDENTIAL P240427

[0134] - 19 - is to be regarded as explanatory. The following patent claims are to be understood as meaning that a mentioned feature is present in at least one embodiment of the invention. This does not preclude the presence of further features.

[0135] If the patent claims and the preceding description define 'first' and 'second' features, this designation serves to distinguish between two similar features without establishing a hierarchy.

[0136] CONFIDENTIAL P240427

[0137] - 20 -

[0138] List of reference signs

[0139] 1 Device

[0140] 2 coils

[0141] 3 wrapping template

[0142] 4 wrapping template

[0143] 5 guide rail

[0144] 6 telescopic rail

[0145] 7 Telescopic rail

[0146] 8 Operating position

[0147] 9th Chamber

[0148] 10 winding wire

[0149] 11 Operating position

[0150] 12th Chamber

[0151] 13th Chamber

[0152] 14 Command Unit

[0153] 16 clamping unit

[0154] 17 Locking unit

[0155] 18 pneumatic cylinders

[0156] 20 Bridge

[0157] 21 coil

[0158] 22 coil

[0159] 23 coil

[0160] 24 Rotary axis

[0161] 25 bolts

[0162] 26 Positive locking devices

[0163] 27 thighs

[0164] 28 thighs

[0165] 30 Bridge

[0166] 31 thighs

[0167] 32 thighs

[0168] 33 rail

[0169] 34 sleds

[0170] CONFIDENTIAL P240427

[0171] - 21 -

[0172] 35 Linear guide

[0173] 36 linear guides

[0174] 37 gap

[0175] 38 gap

[0176] 41 Operating position

[0177] CONFIDENTIAL

Claims

P240427 - 22 - Claims 1. Device (1) for winding coils (2) without crossing over in several winding steps in a coil group, comprising at least two winding templates (3, 4) that are telescopically movable into one another, parallel to each other and rotatable about a common axis of rotation (24), each with a guide rail (5) on which a first telescopic rail (6) is guided relative to the guide rail (5), and a second telescopic rail (7) that is movable relative to and guided on the first telescopic rail (6), wherein in a first operating position (8) of the winding templates (3, 4), in which the first telescopic rails (6) and the second telescopic rails (7) are fully retracted, the guide rails (5) provide a first chamber (9) for winding a first, inner coil (21) with a winding wire (10), and the first telescopic rails (6) in a second operating position (11) of the winding templates (3, 4),in which the first telescopic rails (6) and the second telescopic rails (7) are offset relative to the guide rails (5), provide a second chamber (12) for winding a second, middle coil (22) with a winding wire (10), and in a third operating position (41) of the winding templates (3,4), in which the second telescopic rails (7) are offset relative to the first telescopic rails (6), provide a third chamber (13) for winding a third, outer coil (23) with a winding wire (10), so that the first coil (21), the second coil (22) and the third coil (23) are arranged concentrically to each other after winding in the device (1). CONFIDENTIAL P240427 - 23 - 2. Device (1) according to claim 1, characterized in that the winding templates (3, 4) each comprise a guide unit (14) arranged inside a winding template (3, 4) by means of which the first telescopic rail (6) and the second telescopic rail (7) are guided.

3. Device (1 ) according to claim 1 or 2, characterized in that the guide unit (14) comprises a clamping unit (16) and / or a locking unit (17) which enables the telescopic rails (6, 7) to be guided in series.

4. Device (1 ) according to claim 3, characterized in that the clamping unit (16) or the locking unit (17) is pneumatically operated and actuated by means of a pneumatic cylinder (18).

5. Device (1 ) according to one of the preceding claims 2-4, characterized in that the locking unit (17) has an actuable bolt (25) which, in a locking position, engages in a corresponding positive locking means (26) of the first telescopic rail (6) and / or the second telescopic rail (7).

6. Device (1) according to one of the preceding claims 2-5, characterized in that the guide unit (14) comprises a first substantially U-shaped bridge (20) whose free legs (27, 28) are connected to the first telescopic rail (6), wherein the bridge (20) is guided on the guide rail (5).

7. Device (1) according to one of the preceding claims 2-6, characterized in that the guide unit (14) comprises a second, substantially U-shaped bridge (30), the free legs (31, 32) of which are connected to the second telescopic rail (7) CONFIDENTIAL P240427 - 24 - are connected, wherein the bridge (30) is guided on the guide rail (5) or the first telescopic rail (6).

8. Device (1) according to one of the preceding claims, characterized in that a wire start clamping device is provided on the guide rail (5) and / or the first telescopic rail (6) and / or the second telescopic rail (7), which fixes the winding wire (10) during the winding process.

9. Device (1) according to one of the preceding claims, characterized in that the winding templates (3,4) are essentially identical.

10. Method for cross-free winding of coils (21 ,22,23) comprising the following steps: • Providing a device (1) according to any of the preceding claims, • Transferring the device (1 ) into the first operating position (8) of the winding templates (3,4), • Fixing the wire start of a winding wire (10) to one of the guide rails (5) by means of a wire start clamping device and starting the winding process, wherein the winding templates (3,4) rotate about a common axis of rotation (24) to wind a predetermined number of turns onto the first chamber (9); • Transferring the device (1 ) into the second operating position (11 ) of the winding templates (3,4), • Continuing the winding process, with the winding templates (3,4) rotating around the common axis of rotation (24) to wind a predetermined number of turns onto the second chamber (12), • Transferring the device (1 ) into the third operating position (41 ) of the winding templates (3,4), • Continuing the winding process, with the winding templates (3,4) rotating around the common axis of rotation (24) to wind a predetermined number of turns onto the third chamber (13), CONFIDENTIAL P240427 - 25 - • Insertion of the winding chambers (9, 12, 13) into a drawing tool after completion of the winding process and transfer of the winding, • Cutting off the winding wire (10) and • Returning the winding chambers (9,12,13) ​​to the first operating position (8) of the winding templates (3,4). CONFIDENTIAL

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