Forming machine and method for producing substantially two-dimensional bent parts

Abstract

The invention relates to a forming machine (1), comprising a feed device (2) for feeding wire (W) into a forming region (3), a forming device (4) for bending the wire (W) in the forming region (3), a support device (5) for supporting the wire (W) leaving the forming region (3), and a pivot drive device (6) for pivoting the support device (5) about a vertical pivot axis (S), wherein the feed device (2) and the forming device (3) can be controlled in a coordinated manner such that the wire (W) can be bent to produce a substantially two-dimensional bent part (100), and wherein the pivot drive device (6) and two actuating drive devices (9, 10) of the support device (5) can be controlled such that a depositing device (7) of the support device (5) moves together with the wire (W) of the substantially two-dimensional bent part (100) leaving the forming region (3).

Description

[0001] P 62309 WO 8 September 2025

[0002] - 1 - TK / TK

[0003] Forming machine and method for manufacturing essentially two-dimensional bent parts

[0004] SCOPE OF APPLICATION AND STATE OF THE ART

[0005] The invention relates to a forming machine for producing essentially two-dimensional bent parts, in particular for producing shaft winding components for electric motors, from wire. The invention also relates to a method for producing such an essentially two-dimensional bent part, in particular for producing a shaft winding component for an electric motor, using such a forming machine.

[0006] Forming machines are computer numerically controlled machine tools that, using suitable tools, can produce small or large series of shaped parts with sometimes complex geometries from elongated semi-finished products such as wire, tube, strip, or the like in an automated manufacturing process, primarily by forming. A complex bent shaped part is a shaped part that has more than one bend, where bends are relatively close together and / or merge into one another and / or may also lie partially in different planes. Shaped parts that are manufactured predominantly or exclusively by means of bending operations are referred to as "bent parts" within the scope of this disclosure.

[0007] In the case of "essentially two-dimensional bent parts," the formed bent part material, in particular the formed wire, can run essentially parallel to exactly one, in particular virtual, plane. An essentially two-dimensional component can have a thickness extent, in particular corresponding to a wire diameter, where the thickness extent is comparatively small compared to the longitudinal and transverse extents of the component. In particular, the material of the bent part can only be bent about, in particular virtual, bending axes that are oriented essentially perpendicular to the, in particular virtual, plane.It is understood that such an essentially two-dimensional bent part can be used as an intermediate product, which intermediate product can optionally be subjected to further forming in a subsequent forming process, in particular to produce a three-dimensional bent part on the basis of the two-dimensional intermediate product.

[0008] A substantially two-dimensional bent part as defined in this disclosure can be a wave winding component for an electric motor. Such a wave winding component can be intended for a wave winding of the electric motor in question. A wave winding can be synonymously referred to as a "continuous hairpin winding" and typically has a meandering shape. In the wave winding concept, so-called winding mats are manufactured based on several wave winding components. These winding mats can be attached to the inside of a stator lamination stack of the electric motor's stator. The wave winding components of the winding mat attached to the stator can then be electrically interconnected and / or soldered and / or welded together to form the wave winding and thus provide the electrical wave winding of the stator.Such a wave winding can advantageously allow for a relatively low winding head height on both sides and a particularly low contacting effort, especially compared to conventional hairpin and / or plug-in coil technology. Challenges arise in the production of wave winding components for the shaft winding of an electric motor, particularly due to their comparatively complex meandering geometry. Furthermore, wave winding components can be susceptible to unintentional deformation and / or bending due to the use of relatively thin wire material, especially in combination with the meandering geometry.

[0009] Wave-wound parts can be manufactured conventionally using the so-called "sword winding technique," in which a wire is formed around a sword-shaped body that is usually not adjustable. Alternatively, it is common to manufacture wave-wound parts using the so-called "flat winding technique," in which typically several or even all bends of the meandering wave-wound part are created simultaneously and / or with bending tools that are precisely matched to the required bending radius of each bend and are not adjustable.

[0010] TASK AND SOLUTION

[0011] It is an object of the present invention to provide a forming machine for producing essentially two-dimensional bent parts, in particular for producing winding components for electric motors, from wire, and a method for producing such an essentially two-dimensional bent part, in particular for producing such a shaft winding component, for an electric motor, using such a forming machine, each exhibiting improved properties. In particular, the invention aims to counteract or even completely prevent unintentional deformation of the formed wire of an essentially two-dimensional bent part during the production of the bent part, especially deformation caused by friction and / or its own weight. This object is achieved by the subject matter of the independent claims. Preferred embodiments are the subject matter of the dependent claims.The wording of all claims is made by express reference to the content of this description.

[0012] A forming machine according to the invention is used for the production of essentially two-dimensional bent parts made of wire. In particular, the forming machine is used for the production of wire shaft winding components for electric motors.

[0013] The forming machine according to the invention has a feed device for advancing wire in a feed direction. The wire can be advanced in the feed direction into a forming area of ​​the forming machine by means of the feed device. The forming machine has a forming unit that is designed and / or arranged for bending the wire within the forming area. The forming machine also has a support device designed to support wire exiting the forming area. By means of the support device, an already formed section of the wire, in particular a free end section of the formed wire, of a partially formed bent part can be supported. In particular, the support device is designed to counteract unintentional deformation of the wire section protruding from the forming area due to its own weight and / or friction.

[0014] The forming machine according to the invention has a swivel drive device by means of which the support device can be swivelled about a vertical swivel axis of the forming machine relative to the forming area, in particular in a controlled manner. In particular, the forming device is designed to generate a bend in the wire about a bending axis that runs coaxially to the swivel axis, in particular a virtual one.

[0015] The support device of the forming machine according to the invention has a storage device on which wire can be stored after it has left the forming area. In particular, the formed free end section of the wire can be stored on the storage device. The support device also has a base for coupling it to the rotary drive device. In particular, the base is directly connected to the rotary drive device. The base can be non-rotatably connected to a rotatable drive shaft of the rotary drive device. The base can have a rotary table or be implemented by a rotary table. The support device of the forming machine according to the invention has a first actuator, which is designed and / or controllable for adjusting the storage device relative to the base along a horizontal first adjustment direction of the support device.Furthermore, the support device has a second actuator device which is designed and / or controllable for adjusting the storage device relative to the base along a second adjustment direction of the support device, wherein the second adjustment direction is oriented orthogonally to the first adjustment direction.

[0016] The feed unit and the forming unit of the forming machine according to the invention are coordinated and controllable in such a way that the wire can be bent to produce the essentially two-dimensional bent part. In particular, the wire can be bent sequentially multiple times and / or in opposite directions to produce the essentially two-dimensional bent part by coordinated control of the feed unit and the forming unit. "Sequentially multiple times" means that several bends of the same or opposite directions occur one after the other along a longitudinal extension of the formed wire. As a result of the production of opposite bends, the free end section of the formed wire, which protrudes from the forming area, can undergo a back-and-forth movement around the pivot axis.For example, a number of bends in the same direction along the longitudinal extent of the formed wire can alternate with a number of bends in opposite directions to achieve a meandering shape of the bent part. Between bends, the wire can be advanced without deformation, creating straight wire sections between the bends. As a result of the creation of a straight wire section, the free end of the formed wire can move away from the forming area in the feed direction.

[0017] According to the invention, the rotary drive unit of the forming machine and the two actuator units of the support unit are controllable such that the depositing unit moves together with the wire of the essentially two-dimensional bent part leaving the forming area. In particular, the rotary drive unit and the actuator units of the support unit are controllable depending on the feed unit and / or the forming unit such that the depositing unit moves together with the wire of the essentially two-dimensional bent part leaving the forming area. The joint movement is preferably implemented such that the depositing unit and the wire leaving the forming area move in the same direction and magnitude, so that the wire resting on the depositing unit does not displace relative to the depositing unit.In particular, a wire section protruding from the forming area, especially a free and / or already formed section, can be supported by the support device in such a way as to counteract unintentional deformation of this wire section, which is located outside the forming area and has already been given its final shape. Specifically, the support device serves, firstly, to absorb the weight of the wire section, and secondly, through the combined movement of the support device and the wire section, to prevent sliding friction between the wire section and the support device.

[0018] In particular, the forming machine allows the production of bent parts with a wide variety of shapes and / or different wire cross-sections and / or thicknesses. Therefore, the forming machine can prove to be particularly flexible, which is especially advantageous for small-batch production and / or prototype manufacturing. Despite its exceptional flexibility, the forming machine is capable of producing a wide range of bent parts with exceptional precision. This can be advantageous for the production of shaft winding components, as these are often subject to very tight manufacturing tolerances that must be met to ensure that a shaft winding mat with such a shaft winding component can be precisely mounted onto the stator of an electric motor.

[0019] Advantageously, the wire leaving the forming area of ​​the forming machine can undergo further forming, particularly outside the forming area, especially embossing, for example to create a step, particularly a so-called S-shaped cut, on the shaft winding section. In this respect, the essentially two-dimensional component can be further formed into a three-dimensional component, especially directly following the forming area.

[0020] In an embodiment of the invention, the forming machine comprises a control device, in particular an electronic one. The control device is designed and / or programmed to control the feed device and the forming device in a coordinated manner such that wire fed into the forming area is bent by the forming device to produce the essentially two-dimensional bent part, in particular sequentially multiple times and / or in opposite directions. In particular, the control device is designed to execute an NC program defining a target geometry of the bent part to be produced for controlling the feed device and the forming device.

[0021] In a further embodiment of the invention, the control unit of the forming machine is designed and / or programmed to control the rotary drive unit and the two actuator units of the support unit depending on the feed unit and / or the forming unit. In this way, the adjustment of the support unit and the bending process for producing the essentially two-dimensional bent part can be coordinated and / or synchronized.

[0022] In a further embodiment of the invention, the wire can be bent by means of the forming device essentially parallel to a plane, in particular a horizontal and / or virtual plane, in two opposite bending directions. Alternatively or additionally, the wire can be bent by means of the forming device in two opposite bending directions, depending on the control system. This can, in particular, enable the production of meandering, essentially two-dimensional bent parts with opposing bends.

[0023] In a further embodiment of the invention, the first actuator device is a linear actuator device, in particular an electrical and / or hydraulic and / or pneumatic one.

[0024] In a further embodiment of the invention, the depositing device comprises a conveyor belt which can be driven, in particular circumferentially, by means of the second actuator device. Wire leaving the forming area, in particular the free formed wire section, can be deposited on an upper run of the conveyor belt. The upper run of the conveyor belt defines the second direction of adjustment. In particular, the upper run of the conveyor belt forms the depositing device.

[0025] In a further embodiment of the invention, the storage device includes a winding device for winding wire after it has left the forming area. The winding device can be configured to wind the essentially two-dimensional bent part around a winding axis of the winding device. The second actuator is configured to drive the winding device in rotation around the winding axis of the winding device, with the second adjustment direction extending along and / or tangentially to a circumferential direction of the winding device. The circumferential direction of the winding device extends, in particular, around the winding axis of the winding device. The winding axis can be horizontal. The winding device can be connected to a conveyor belt of the storage device.Alternatively, it is conceivable that the storage device only includes the winding device, in particular without a conveyor belt.

[0026] In a further embodiment of the invention, the forming device includes a forming section for bending interaction with the wire. The forming section is adjustable transversely to the feed device in a controlled manner in order to deflect or redirect the wire, which is advanced into the forming area in the feed direction, relative to the feed direction, thereby generating a bend in the wire. This deflection or redirection of the wire is particularly transmitted to the wire segment protruding from the forming area, which is supported by the support device.

[0027] In a further embodiment of the invention, the forming device comprises a bending mandrel, in particular one that is rotatably adjustable and / or arranged coaxially to the pivot axis, and a tool part with a bending pin that is rotatably adjustable around the bending mandrel and / or a bending axis coaxial to the pivot axis. The bending pin and / or the bending mandrel can form a forming section of the forming device for bending interaction with the wire to be bent.

[0028] In a further embodiment of the invention, the support device, in particular the storage device of the support device, can be pivoted by 150° to 210°, in particular by 180°, relative to the forming area. This can facilitate the design freedom of essentially two-dimensional bent parts that can be produced using the forming machine.

[0029] In a further embodiment of the invention, the forming machine has a controllable cutting device designed to cut the wire of the essentially two-dimensional bent part, in particular at an exit point of the wire from the forming area. In particular, the cutting device can be automatically controlled by the control unit of the forming machine.

[0030] A method according to the invention serves to produce a substantially two-dimensional bent part using a forming machine according to the invention as described above. In particular, the method serves to produce a shaft winding part for an electric motor using the forming machine. Specifically, the substantially two-dimensional bent part, especially the shaft winding part, is produced according to the method. The method comprises a step in which wire is advanced in the feed direction while the depositing device is being adjusted along the first adjustment direction and / or along the second adjustment direction. The method also comprises a step in which the wire is bent in the forming area while the depositing device is being pivoted about the pivot axis.

[0031] In a further embodiment of the invention, the storage device is adjusted along the first adjustment direction and / or the second adjustment direction primarily, and in particular exclusively, during the feeding of the wire in the feed direction, especially without bending. During feeding of the wire in the feed direction without bending, the wire can be conveyed through the forming area and out of the forming area in the feed direction. Alternatively or additionally, the storage device pivots about the pivot axis exclusively during the bending of the wire, especially without or with feed.

[0032] "Feed-driven" bending can mean that wire is fed and / or advanced during the bending process. Feed-driven bending can be rotary bending, particularly rotary draw bending. With feed-driven bending, slight adjustment of the support device along the first adjustment direction and / or along the second adjustment direction may be advantageous. Alternatively, with "feed-free bending," it is conceivable that the wire is not advanced by the feed device while and / or as long as a bend is being produced by the forming device. Feed-free bending can be pin-and-mandrel bending.

[0033] In a further embodiment of the invention, the steps of the method are repeated several times in succession to produce the two-dimensional bent part. In particular, the essentially two-dimensional bent part is produced in a meandering shape. Alternatively or additionally, the essentially two-dimensional bent part with a repeating bending pattern can be produced by repeatedly performing the steps of the method in succession. This can be particularly advantageous if the essentially two-dimensional bent part to be produced is a shaft winding component for an electric motor.

[0034] In a further embodiment of the invention, the control device of the forming machine is adapted and / or programmed for the, in particular, automatic execution of the process. Specifically, the control device is adapted and / or programmed to control the feed device, the forming device, the rotary drive device, the first actuator device, and the second actuator device of the forming machine in a coordinated manner for carrying out the process.

[0035] BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Further advantages and features of the invention will become apparent from the claims and from the following description of preferred embodiments of the invention, which are illustrated with reference to the drawings. In this context, identical reference numerals refer to identical, similar, or functionally equivalent components. It is understood that the features mentioned above and those to be explained below can be used not only in the combinations specified, but also in other combinations or individually, without departing from the scope of the present invention.

[0037] Fig. 1 shows in schematic perspective a formation of a forming machine according to the invention, which is designed to carry out an embodiment of a method according to the invention.

[0038] Fig. 2 shows a schematic perspective view of a detail of the forming machine according to

[0039] Fig. 1,

[0040] Figures 3 to 6 show a schematic top view, each detail of the forming machine according to Figures 1 and 2, in the form of successive snapshots taken during the execution of an embodiment of the method according to the invention, and

[0041] Fig. 7, a schematic top view, shows a further detail of the forming machine according to the

[0042] Figs. 1 to 6.

[0043] DETAILED DESCRIPTION OF THE EXECUTION EXAMPLES

[0044] A forming machine 1 is designed for the production of essentially two-dimensional bent parts 100. The bent part 100 can be essentially planar. In principle, the forming machine 1 enables the precise production of bent parts 100 with very different shapes, especially wire bending profiles. Several bent parts 100 with a selected shape can be produced serially with high repeatability using the forming machine 1. In this case, the forming machine 1 is configured for the production of shaft winding parts 200 from wire W. The shaft winding parts 200 are used to create a shaft winding for an electric motor.

[0045] For example, the starting material is a wire W, which has an electrically conductive material (for example, copper) with a substantially flat, rectangular, in particular square, cross-sectional shape, and which is encased in an electrically non-conductive insulating layer of lacquer or the like. The starting material is provided in the present case in the form of a wound material supply 51, for example, in the form of a coil 52. The wire supply 51 can be provided to the forming machine 1 by means of a wire storage device 50.The forming machine 1 is, for example, a computer numerically controlled, multi-axis forming machine 1 and has several machine axes controllable via a control device 11 and a drive system with several electric drives for driving the machine axes, wherein the control device 11 is designed for the coordinated control of work movements of the machine axes in a manufacturing process according to a computer-readable control program specific to the manufacturing process.

[0046] The forming machine 1 has a feed device 2. This feed device can include a feed mechanism that engages the wire W, e.g., a roller feed device, a belt feed device, or a gripper feed device equipped with gripping jaws, and the downstream wire guide visible in the figures. The wire W can be fed by means of the feed device 2 in a feed direction V, for example, in a controlled manner. The wire W, fed by means of the feed device 2, can be conveyed in the feed direction V into a forming section 3 of the forming machine 1. A forming unit 4 of the forming machine 1 is arranged in the forming section 3. The forming unit 4 is designed for bending the wire W within the forming section 3, in this case in a controlled manner.

[0047] The feed unit 2 and the forming unit 4 can be controlled in a coordinated manner to produce the essentially two-dimensional bent part 100. By coordinating the feed unit 2 and the forming unit 4, the wire W can be bent sequentially multiple times and / or in opposite directions.

[0048] For example, the wire W can be bent in two opposite bending directions B1, B2 by means of the forming device 4, essentially parallel to a virtual plane E, which in this case extends horizontally. The bending direction B1, B2 of the wire W can be determined by controlling the forming device 4.

[0049] The forming device 4, for example, has a forming section 15 that can interact with the wire W to bend it. The forming section 15 is adjustable transversely to the feed direction V, and in particular perpendicular to the feed direction V. By adjusting the forming section 15, the wire W, which is fed into the forming area 3 in the feed direction V, can be deflected so that, after interacting with the forming section 15, it runs away from the forming section 15 at an angle to the feed direction V. By deflecting and / or redirecting the wire W relative to the feed direction V, a bend B of the wire W, in particular a plastic bending, can be produced, especially around a vertical bending axis. In the present case, the forming device 4 has a bending mandrel 16 and a tool part 17 which can be rotated around the bending mandrel 16 in order to bend the wire W in the horizontal bending plane E by a predetermined bending angle around a vertical bending axis.The tool part 17, for example, has a bending pin 18. The bending mandrel 16 can itself be rotatable or non-rotatable. The bending pin 18 and / or the bending mandrel 16 can, in particular, each form a forming section 15 for interaction with the wire W to be bent.

[0050] The forming machine 1 also has a support device 5. The support device 5 serves to support wire W that has left the forming area 3. By means of the support device 5, a free end section of the wire W can be supported after it has left the forming area 3. The free end section of the wire W has already been formed and, after the production of the essentially two-dimensional bent part 100, is found unchanged in the bent part 100.

[0051] The support device 5 has a storage device 7. The storage device 7 is designed such that the wire W leaving the forming area 3 runs onto the storage device 7 and can then be stored on it. In particular, after leaving the forming area 3, the wire W can be stored on the storage device 7 in such a way that the free end section of the wire W protruding from the forming area 3 rests on the storage device 7 in a gravitational direction G.

[0052] The support device 5 has a base 8, which in this example is designed like a rotary table and is coupled to a swivel drive 6 of the forming machine 1. The swivel drive 6 serves to swivel the support device 5, in particular the entire support device 5, about a vertical swivel axis S of the forming machine 1 relative to the forming area 3. In this case, the swivel axis is coaxial with the bending axis of the forming device. The swivel range of the support device 5 extends over a total of approximately 180° symmetrically to the feed direction V.

[0053] The support device 5 has a first actuator 9, which is designed and controllable for adjusting the storage device 7 relative to the base 8 along a horizontal first adjustment direction V1 of the support device 5. The first actuator 9 can be a linear actuator 12. In this case, the first actuator 9 is supported by the base 8 or the rotary table. By rotating the base 8 about the pivot axis S, the orientation of the storage device 7 or the second feed direction V2 and / or the first feed direction V1 can be changed with respect to the machine coordinate system of the forming machine 1.

[0054] In addition, the support device 5 has a second actuator device 10, which is designed and controllable for adjusting the storage device 7 relative to the base 8 along a second adjustment direction V2 of the support device 5 that is orthogonal to the first adjustment direction V1.

[0055] The rotary drive unit 6 and the two actuator units 9, 10 of the support unit 5 are controllable such that the storage unit 7 moves together with the wire W of the essentially two-dimensional bent part 100 exiting the forming area 3. In this way, relative movement of the wire W exiting the forming area 3, in particular of the free and / or already formed wire section W protruding from the forming area 3, relative to the storage unit 7 can be avoided. Such avoidance of relative movement of the wire section W protruding from the forming area 3 relative to the storage unit 7 enables support of the wire section while preventing unintended friction-induced deformation of the wire section.

[0056] The control device 11 already mentioned is designed and / or programmed to control the feed device 2 and the forming device 4 in a coordinated manner, in particular by executing the control program. As a result of the coordinated control of the feed device 2 and the forming device 4, the wire W fed into the forming area 3 can be bent by means of the forming device 4, producing the essentially two-dimensional bent part 100. The control device 11 is also designed and / or programmed to...

[0057] The rotary drive unit 6 and the actuator units 9, 10 of the support unit 5 are controlled depending on the feed unit 2 and / or the forming unit 4. In this way, the storage unit 7 can be moved in coordination with a bending operation to produce the bent part 100.

[0058] The storage device 7 includes a conveyor belt 13. The conveyor belt 13 can be driven circumferentially by means of the second actuator 10. The conveyor belt 13 has an upper run 14, which, for example, runs essentially horizontally. The wire W leaving the forming area 3 can be placed on the upper run 14. In this case, the upper run 14 defines the second adjustment direction V2. Alternatively or additionally to the conveyor belt 13, the storage device 7 can include a winding device for winding up the wire W leaving the forming area 3, in particular the bent part 100. The second actuator 10 can be configured to drive the winding device in rotation about a winding axis of the winding device. The second adjustment direction V2 can run along and / or tangentially to a circumferential direction of the winding device.The winding device can enable a particularly compact implementation of the storage device 7 and / or be advantageous for the production of relatively long bent parts 100. A winding device can also be arranged at the end of a linear conveying section of a conveyor belt 13.

[0059] The support device 5, in particular its storage device 7, can be pivoted, for example, by 150° to 210° relative to the forming area 3. In this case, the storage device 7 can be pivoted by approximately 180° relative to the forming area 3 about the pivot axis S, as can be seen in particular from the snapshots in Figures 3 to 6. These snapshots show in particular how the storage device 7 moves together with the wire W leaving the forming area 3 when a bent part 100 in the form of a wave-wound part 200 is produced.

[0060] The forming machine 1 has a cutting device 19, which can be controlled, in particular, by means of the control device 11. The cutting device 19 is designed to cut off the section of wire W that protrudes, in particular, from the forming area 3. By means of the cutting device 19, the bent part can be separated from the wire material supply after its final forming. In particular, the section of wire W that protrudes from the forming area 3 can be cut off by means of the cutting device 19 as it exits the forming area 3. The cutting device 19 can be designed and arranged at a boundary of the forming area 3 for cutting off wire W.

[0061] The forming machine 1 is set up to carry out a process by which a substantially two-dimensional bent part 100 is produced. In this case, the shaft winding part 200 is produced according to this process. The process can be understood in particular by reference to the snapshot shown in Figures 3 to 6.

[0062] The method includes a step in which wire W is advanced in the feed direction V while the storage device 7 is being adjusted along the first adjustment direction V1 and / or along the second adjustment direction V2. In this case, the storage device 7 is adjusted along the first adjustment direction V1 and / or along the second adjustment direction V2 primarily, and in particular only, during the advancement of the wire W in the feed direction V. It is conceivable that no bending of the wire W occurs within the forming area 3 during the adjustment of the storage device 7 along the first adjustment direction V1 and / or along the second adjustment direction V2.

[0063] In a phase with wire feed but without bending movement, the movements of the actuator devices 9, 10 are coordinated, for example, such that the storage device 7 as a whole moves exclusively parallel to the feed direction V, regardless of its orientation in space (transverse or oblique or parallel to the feed direction V).

[0064] Furthermore, the method includes a step in which the wire W is bent within the forming area 3 while the storage device 7 is pivoted about the pivot axis S. It is possible that the storage device 7 is only pivoted about the pivot axis S while the wire W is being bent within the forming area 3. In particular, it is possible that no feed of the wire W in the feed direction V occurs during the bending of the wire W within the forming area 3.

[0065] There are also bending operations in which a certain wire feed occurs simultaneously with the bending operation (i.e., simultaneously with a rotation of the forming section around the bending axis) to advance the wire. This is the case, for example, in rotary draw bending. In this case, too, by coordinating the adjustment movements in the two adjustment directions V1 and V2, it can be ensured that the sectionally bent wire leaving the forming area rests on the support device without slipping and is thus gently supported. The steps of the process are, for example, carried out several times in succession to produce the essentially two-dimensional bent part 100 – as shown here, meandering and with a repeating bending pattern. Accordingly, the snapshots in Figures 3 to 6 can occur several times in succession and / or in reverse sequence when the process is carried out.

[0066] The control unit 11 of the forming machine 1 is adapted and / or programmed for the automatic execution of the process. The control unit 11 can be programmed to control the feed unit 2, the forming unit 4, the rotary drive unit 6, the first actuator unit 9, and the second actuator unit 10 in a coordinated manner in order to carry out the process automatically. In Figures 3, 4, and 7, the drive units provided for the controlled drive of the forming unit 4, which are arranged above the forming unit 4 with respect to the direction of gravity G, have been omitted to allow a better view of the forming unit 4 itself. The illustration in Figure 7 can be understood as an enlarged snapshot, which is to be placed chronologically between the snapshots in Figures 4 and 5 and which is intended to particularly clearly illustrate the structure and / or function of the forming unit 4.

Claims

Patent claims 1. Forming machine (1) for the production of essentially two-dimensional bent parts (100), in particular for the production of shaft winding parts (200) for electric motors, from wire (W), wherein the forming machine (1) comprises: a feed device (2) for advancing wire (W) in a feed direction (V) of the forming machine (1) into a forming area (3) of the forming machine (1), a forming device (4) for bending the wire (W) in the forming area (3), a support device (5) for supporting wire (W) leaving the forming area (3), and a swivel drive device (6) for swiveling the support device (5) about a vertical swivel axis (S) of the forming machine (1) relative to the forming area (3), - wherein the support device (5) has a storage device (7) on which wire (W) leaving the forming area (3) can be stored, a base (8) for coupling the support device (5) to the rotary drive device (6), a first actuator device (9) for adjusting the storage device (7) relative to the base (8) along a horizontal first adjustment direction (V1) of the support device (5), and a second actuator device (10) for adjusting the storage device (7) relative to the base (8) along a second adjustment direction (V2) of the support device (5) orthogonal to the first adjustment direction (V1), - wherein the feed device (2) and the forming device (4) are coordinated and controllable in such a way that the wire (W) can be bent, in particular sequentially multiple times and / or in opposite directions, while producing the essentially two-dimensional bent part (100), - wherein the swivel drive device (6) and the actuator devices (9, 10) of the support device (5) can be controlled in such a way that the storage device (7) moves together with the wire (W) of the essentially two-dimensional bent part (100) leaving the forming area (3).

2. Forming machine (1) according to claim 1 , characterized in that the forming machine (1) has a control device (11), in particular an electronic one, which is designed and / or programmed to control the feed device (2) and The forming device (4) is coordinated to control in such a way that wire (W) advanced into the forming area (3) is bent by means of the forming device (4) to produce the essentially two-dimensional bent part (100), in particular sequentially several times and / or in opposite directions.

3. Forming machine (1) according to claim 1 or 2, characterized in that a control device (11) of the forming machine (1) is designed and / or programmed to control the rotary drive device (6) and the actuator devices (9, 10) of the support device (5) depending on the feed device (2) and / or the forming device (4).

4. Forming machine (1) according to one of the preceding claims, characterized in that the wire (W) can be bent by means of the forming device (4) essentially parallel to a, in particular horizontal and / or virtual, plane (E) and / or depending on the control in two opposite bending directions (B1 , B2).

5. Forming machine (1) according to one of the preceding claims, characterized in that the first actuator device (9) is a linear actuator device (12).

6. Forming machine (1) according to one of the preceding claims, characterized in that the storage device (7) has a conveyor belt (13) which can be driven by means of the second actuator device (10), in particular in a circumferential manner, - wherein wire (W) leaving the forming area (3) can be laid down on an upper run (14) of the conveyor belt (13) and the upper run (14) defines the second adjustment direction (V2).

7. Forming machine (1) according to one of the preceding claims, characterized in that the storage device (7) has a winding device for winding up wire (W) leaving the forming area (3), - wherein the second actuator (10) is designed to rotate the winding device about a winding axis of the winding device and the second adjustment direction (V2) runs along and / or tangentially to a circumferential direction of the winding device.

8. Forming machine (1) according to one of the preceding claims, characterized in that the forming device (4) has a forming section (15) for interaction with the wire (W), - wherein the forming section (15) is adjustable in a controlled manner transverse to the feed direction (V) in order to deflect the wire (W) fed into the forming area (3) in the feed direction (V) relative to the feed direction (V) by generating a bend (B) of the wire (W).

9. Forming machine (1) according to one of the preceding claims, characterized in that the forming device (4) has a bending mandrel (16), in particular rotatable and / or arranged coaxially to the pivot axis (S), and a tool part (17) rotatable around the bending mandrel (16) and / or a bending axis of the forming device (4) coaxially to the pivot axis (S), with a bending pin (18), in particular wherein the bending pin (18) and / or the bending mandrel (16) forms a forming section (15) for interaction with the wire (W).

10. Forming machine (1) according to one of the preceding claims, characterized in that the support device (5), in particular the storage device (7), is pivotable by 150° to 210°, in particular by 180°, relative to the forming area (3) in a controlled manner.

11. Forming machine (1) according to one of the preceding claims, characterized in that the forming machine (1) has a controllable cutting device (19) which is designed to cut off the wire (W) of the substantially two-dimensional bent part (100), in particular when the wire (W) exits the forming area (3).

12. Method for producing a substantially two-dimensional bent part (100), in particular for producing a shaft winding part (200) for an electric motor, using a forming machine (1) according to one of the preceding claims, wherein the method comprises the steps: Feeding wire (W) in the feed direction (V) during the time the storage device (7) is adjusted along the first adjustment direction (V1) and / or along the second adjustment direction (V2), bending the wire (W) in the forming area (3) during the time the storage device (7) is pivoted around the pivot axis (S).

13. Method according to claim 12, characterized in that the adjustment of the storage device (7) along the first adjustment direction (V1) and / or along the second adjustment direction (V2) takes place mainly, in particular exclusively, during the, in particular without bending, advancement of the wire (W) in the feed direction (V); and / or that the pivoting of the storage device (7) about the pivot axis (S) takes place exclusively during the, in particular without feed or with feed, bending of the wire (W).

14. Method according to claim 12 or 13, characterized in that - the steps of the process are carried out several times in succession to produce the essentially two-dimensional bent part (100), in particular meandering and / or with a repeating bending pattern.

15. Method according to one of claims 12 to 14, characterized in that a control device (11) of the forming machine (1) is adapted and / or programmed for the, in particular automatic, execution of the method.

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