Device and method for attaching phase separators to winding bodies of electric machines

Abstract

The invention relates to a device for receiving and attaching phase separators (PT) to a winding body (W) of electric machines, comprising a cylindrical application head (K) which can be pivoted and rotated about the axis thereof. The application head (K) has, on the circumference thereof, a support surface (A) for receiving a phase separator (PT), on which surface the phase separator (PT) comes to rest in a planar manner with a non-adhesive side as soon as the application head (K) has received the phase separator (PT) from a dispensing device (S). Furthermore, the application head has a fixing apparatus (F1, F2) for mechanically fixing the phase separator (PT) to the support surface (A), wherein the fixing apparatus (F1, F2) is designed such that, when the phase separator (PT) provided by the dispensing device (S) is received, the fixing apparatus (F1, F2) engages into at least one predefined region (B1, B21, B22) without adhesive on the adhesive side of the phase separator (PT) facing the winding body (W) and thus fixes the phase separator (PT) to the support surface (A) of the application head.

Description

[0001] Device and method for attaching phase separators to winding bodies of electrical machines

[0002] The invention relates to a device and a method for receiving and attaching phase separators to winding bodies of electrical machines according to claim 1 and claim 7, and a suitably designed phase separator according to claim 10.

[0003] Electric machines are used to convert electrical energy into mechanical energy or vice versa. An electric machine designed as a drive machine for a motor vehicle is particularly suitable for use within the powertrain of a hybrid or fully electric vehicle.

[0004] The winding bodies of electrical machines typically consist of multiple coils with several phases. To isolate the phases from each other, self-adhesive insulating papers are generally used, applied to the winding bodies at appropriate points according to the required insulating effect. Such insulating papers are also known as phase separators.

[0005] The phase separators are often still applied manually. This means that the adhesive insulating papers are applied and pressed down by hand after the respective coil windings have been inserted. A disadvantage of this method is the difficulty in manually reproducible positioning and pressing of the self-adhesive insulating paper onto the winding core. Furthermore, this process is time-consuming.

[0006] From DE 102019 105308 B4, a device and a method are known in which the phase separators are removed from a dispenser or carrier material by suction and then applied with their adhesive side to the coils of the winding body and subsequently pressed down. During suction, the insulating papers can become crumpled. Furthermore, additional air is required for suction, and the suction itself generates noise emissions. The object of the invention is to provide a device and a method for picking up and attaching phase separators to the winding bodies of electrical machines, as well as a suitably designed phase separator, with which the aforementioned disadvantages are overcome.

[0007] According to the invention, this problem is solved by the device with the features of claim 1, the method with the features of claim 7, and the phase separator with the features of claim 10.

[0008] Advantageous further developments of the invention are defined in the respective dependent claims.

[0009] The device according to the invention for receiving and subsequently attaching phase separators to a winding body of electrical machines comprises a pivotable and rotatable cylindrical application head, wherein the application head has at least one support surface on its circumference for receiving a phase separator and the phase separator comes into contact with the support surface with a non-adhesive side as soon as the phase separator has been received by the device from a dispensing device.Furthermore, the application head features a fixing device for mechanically fixing the phase separator to the contact surface. This fixing device is designed such that, when the phase separator is picked up from the dispensing device, it engages one or more predefined areas without adhesive on the adhesive side of the phase separator facing the winding body, thus holding and fixing the phase separator to the contact surface of the application head. The device according to the invention thus provides an automatable mechanical solution for clamping the phase separator from the moment it is picked up from a dispensing device until it is attached to the winding body. It is also characterized by its simple mechanical design and low energy consumption, making it cost-effective overall.In addition, unlike known automated solutions, it has reduced noise emissions and is safer in handling the phase separators, as the suction-type pickup of the phase separators is dispensed with.

[0010] The inventive method for receiving and attaching phase separators to a winding body of electrical machines comprises the following steps, which do not necessarily have to be carried out in the specified order, but must be carried out in a logical sequence one after the other:

[0011] a) an application head with at least one support surface for receiving a phase separator is moved towards a dispensing device,

[0012] b) the dispensing device provided a phase separator,

[0013] c) The application head is moved over the phase separator provided by the dispensing device,

[0014] d) a fixing device of the application head engages behind the phase separator provided by the dispensing device in such a way that the fixing device engages in at least a predefined area without adhesive on the adhesive side of the phase separator facing the winding body,

[0015] e.) The application head performs a rolling movement, so that as the application head moves, the phase separator comes into full contact with the support surface along its entire length and is fixed to the support surface by means of the fixing device.

[0016] f) The application head is moved towards an inside of the winding body and presses the phase separator with its adhesive side against a designated location on the winding body,

[0017] g) the fixing device is returned to a starting position and thus the phase separator is no longer fixed to the contact surface of the application head, h) the application head is moved away from the winding body path.

[0018] The aforementioned steps can then be repeated by picking up another phase separator from the dispensing device and then attaching it to another predefined location on the winding body.

[0019] The inventive method and device allow for the optimization of cycle times in automation. The device is designed with low wear, and the method and device are also optimized for setup, as the fixing unit can process several different sizes of phase separators. Furthermore, the functionality of the phase separators is not impaired because the inventive device and method ensure that the insulating papers are picked up from the dispensing device without creases and attached to the winding body. Since the fixing unit engages the phase separators in areas without adhesive, the elements of the fixing unit are not contaminated by adhesive. Thus, the invention achieves high process reliability and positioning accuracy.

[0020] According to the invention, the fixing device with fixing element is designed such that it engages behind the phase separator provided by the dispensing device as soon as the application head has pivoted over the phase separator provided by the dispensing device. Preferably, the fixing device comprises a first and a second finger-like fixing element, wherein the second fixing element can engage behind the phase separator provided by the dispensing device at a different location within the predefined area without adhesive or in a different area without adhesive than the first fixing element, after the application head with its contact surface has completed a rolling movement over the length of the provided phase separator.According to the invention, the fixing device can also consist of only one fixing element, which is designed in such a flat and ramp-like manner in the circumferential direction that, as the rolling movement of the application head progresses, it increasingly engages behind the phase separator along its length. Such a rear engagement of the fixing element would then be designed in a shell-like manner with a radius adapted to the contact surface.

[0021] If the contact surface of the application head has a radius smaller than the radius on the inside of the winding body, a phase separator is first attached centrally to the inside of the winding body. This can be achieved if the radius of the contact surface corresponds, for example, to 80% of the radius of the inside of the winding body, although any other radius of the contact surface is also conceivable as long as it can be implemented on the application head.Further embodiments of the invention, such as the application head performing a rolling movement in the circumferential direction as soon as the device is guided towards the inside of the winding body so that the phase separator comes into contact with the winding body with its adhesive side, or by extending pressure elements on the application head as soon as the phase separator comes into contact with the winding body with its adhesive side, ensure that the phase separator is first attached centrally and then applied stress-free along the inner circumference of the winding body. This guarantees a crease-free and therefore reliable attachment and function of the phase separators at the designated locations on the winding body. In a further embodiment of the invention, the application head can comprise not only one contact surface, but also two or more corresponding contact surfaces extending in the circumferential direction.

[0022] The phase separator designed according to the invention has a non-adhesive side facing away from the winding body and an adhesive side facing the winding body, the adhesive side having at least one area without adhesive. This allows a phase carrier to be easily detached from a carrier material of the dispensing device during the execution of the inventive method or when using the inventive device, and thus removed for further processing, namely, attachment to predetermined locations on the winding body. The area(s) without adhesive on the otherwise fully adhesive side of the phase separator can be created, for example, by not applying adhesive, and / or

[0023] - by the presence of carrier material, and / or

[0024] - by folding the adhesive area inwards, and / or

[0025] - by applying an additional strip.

[0026] In a preferred embodiment according to the invention, the phase separator has an elongated area without adhesive, essentially a strip, at its upper end, which, when attached, is located at the level of the winding head of the winding body. This allows for a full-surface bond with a large portion of the coil of the winding head to be insulated. In a further embodiment according to the invention, two areas without adhesive can be provided, wherein the first and second areas without adhesive are the two upper corner regions of the phase separator. Such an embodiment can be particularly advantageous if a device according to the invention comprises a fixing device with a first and a second finger-like fixing element, wherein the first fixing element engages the phase separator in one region and the second fixing element engages the phase separator in the other region.This gives the phase separator a maximum available adhesive surface without any limitations in fixing the phase separator to the mounting surface.

[0027] Other embodiments according to the invention are also conceivable, for example, laterally non-adhesive surfaces in the lower central area of ​​the phase separator, wherein the fixing device of the application head is then designed in such a way that it engages behind the phase separator to be received at the correspondingly designed areas without adhesive.

[0028] The invention will now be explained in more detail using the figures as examples. They are shown schematically and not to scale:

[0029] Figs. 1a, 1b show two possible embodiments of phase separators.

[0030] Fig. 2 Mounting of a phase separator using a first fixing element. Fig. 3 Mounting of the phase separator using a second fixing element. Fig. 4 Application head with fixed phase separator.

[0031] Fig. 5 Application head during attachment of the phase separator to the winding body

[0032] Figures 1a and 1b show two possible embodiments of phase separators according to the invention for use with the device and method according to the invention. The phase separator PT has one or more areas B1, B21, and B22 without adhesive on the adhesive side shown. This means that the adhesive effect was deliberately omitted at these points B1, B21, and B22, and these areas cannot be used to attach the phase separator to the winding body.

[0033] Fig. 2 shows partial sections of the application head K according to the invention, which is positioned above a dispensing device S to receive a phase separator PT. A fixing element F1 of the fixing device engages behind the phase separator PT provided by the dispensing device S such that the fixing element engages in at least one of the predefined areas without adhesive on the adhesive side of the phase separator PT, which will later face the winding body. Subsequently, the application head K performs a rolling movement, as indicated by the arrow in Fig. 3, so that with increasing movement of the application head K, the phase separator PT comes into complete contact with a support surface A along its entire length and is then additionally fixed to the support surface A by means of the fixing element F2 of the fixing device.In the embodiment shown in Figures 2 and 3, the two fixing elements are designed in a finger-like manner, which can be independently positioned both radially and axially for gripping. An application head K with a phase separator PT fixed to the contact surface A by means of the fixing elements F1 and F2 is shown in Figure 4. The finger-like fixing elements F1 and F2 grip and engage the phase separator PT exclusively in the elongated upper non-adhesive area B1 on the outwardly facing side of the phase separator PT.

[0034] Figure 5 shows the application head K with the phase separator PT fixed to the support surface A during application to a winding body W. For this purpose, the application head K is moved in the direction of the arrow towards the inside of the winding body W to press the phase separator PT, with its adhesive side, against a designated location on the winding body W, thus attaching it. (Not shown) Once the phase separator PT is adhered to the coil of the winding body, the fixing elements are returned to their initial position. Optionally, further measures can then be taken to optimally adhere the phase separator PT to the winding body W. For this purpose, the application head K can perform a rolling movement in the circumferential direction of the winding body to increase the adhesive force between the phase separator and the coil. In addition, further pin-like pressure elements E, indicated in Figure 4, can be extended towards the winding body.This additional movement allows the phase separator PT to nestle against the coil within the inner coil legs. These pressure elements are then retracted. Finally, the application head returns to its starting position and the cycle begins again. (See list of reference symbols.)

[0035] A contact surface

[0036] B1, B21, B22 area without adhesive

[0037] E pressure elements

[0038] F1, F2 Fixing device with fixing element K Application head

[0039] PT phase separator

[0040] S dispenser

[0041] W Wrap body

Claims

Patent claims 1. Device for receiving and attaching phase separators (PT) to a winding body (W) of electrical machines, with a pivotable and rotatable cylindrical application head (K) about its axis, wherein the application head (K) - has a contact surface (A) on its circumference for receiving a phase separator (PT) and the phase separator (PT) comes into contact with the contact surface (A) with a non-adhesive side as soon as the application head (K) has received the phase separator (PT) from a dispensing device (S), - and has a fixing device (F1,F2) for mechanically fixing the phase separator (PT) to the support surface (A), - and wherein the fixing device (F1,F2) is designed such that when the phase separator (PT) provided by the dispensing device (S) is picked up, the fixing device (F1,F2) engages on the adhesive side of the phase separator (PT) facing the winding body (W) in at least one predefined area (B1,B21,B22) without adhesive and thus fixes the phase separator (PT) to the support surface (A) of the application head.

2. Device according to claim 1 characterized by the fact that the fixing device (F1 ,F2) is designed such that it engages behind the phase separator (PT) provided by the dispensing device (S) as soon as the application head (K) is pivoted over the phase separator (PT) provided by the dispensing device (S).

3. Device according to claim 1 or 2 characterized by the fact that the fixing device (F1,F2) comprises a first finger-shaped fixing element (F1) and a second finger-shaped fixing element (F2), and the second fixing element (F2) provides the dispensing device (S). ten phase separators (PT) can engage at a different point in the area (B1) or in a different area (B22) than the first fixing element (F1) after the application head (K) with its support surface (A) has completed a rolling movement over the length of the provided phase separator (PT).

4. Device according to one of the preceding claims characterized in that the contact surface (A) in the circumferential direction of the application head (K) has a radius that is smaller than the radius on the inside of the winding body (W).

5. Device according to claim 4 characterized by the fact that the application head (K) is designed in such a way that it can perform a rolling movement in the circumferential direction as soon as the device is guided towards the inside of the winding body (W) and the phase separator (PT) comes into contact with the winding body (W) with its adhesive side.

6. Device according to claim 5 characterized by the fact that The application head (K) also has additional pressure elements (E) which are suitable for pressing the phase separator (PT) as soon as the phase separator (PT) comes into contact with the winding body (W) with its adhesive side.

7. Method for picking up and attaching phase separators (PT) to a winding body (W) of electrical machines comprising the steps: a) An application head (K) with a support surface (A) for receiving a phase separator (PT) is moved towards a dispensing device (S), b) the dispensing device (S) provided a phase separator (PT), c) the application head (K) is moved over the area supplied by the dispensing device (S) phase separator (PT) moved, d) a fixing device (F1,F2) of the application head (K) engages behind the phase separator (PT) provided by the dispensing device (S) such that the fixing device (F1,F2) engages on the adhesive side of the phase separator (PT) facing the winding body (W) in at least one predefined area (B1,B21,B22) without adhesive, e) The application head (K) performs a rolling movement, so that the phase separator (PT) comes into full contact with the support surface (A) as the application head (K) moves along its entire length and is fixed to the support surface (A) by means of the fixing device (F1,F2). f) The application head (K) is moved towards an inside of the winding body (W) and presses the phase separator (PT) with its adhesive side against a designated location on the winding body (W), g) the fixing device (F1,F2) is returned to a starting position and thus the phase separator (PT) is no longer fixed to the support surface (A) of the application head (K), h) the application head (K) is moved away from the winding body (W).

8. Method according to claim 7 characterized by the fact that the application head (K) performs a rolling movement in the circumferential direction as soon as the device is guided towards the inside of the winding body (W) in such a way that the phase separator (PT) comes into contact with the winding body (W) with its adhesive side.

9. Method according to claim 7 or 8 characterized by the fact that Pressure elements (E) are extended on the application head (K) to press the phase separator (PT) against the winding body (W) as soon as the phase separator (PT) is in contact with the winding body with its adhesive side. per (W) comes.

10. Phase separator (PT), in particular a non-conductive paper, with a non-adhesive side facing away from a winding body (W) and an adhesive side facing the winding body. characterized by the fact that The adhesive side must have at least one area (B1, B21, B22) without adhesive.

11. Phase separator according to claim 10 characterized by the fact that The area (B1) without adhesive is a strip at the upper end of the phase separator, which in the installed state is located at the level of the winding head of the winding body (W).

12. Phase separator according to claim 10 characterized by the fact that The first and a second area (B21, B22) without adhesive are the two upper corner areas of the phase separator (PT).

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