Method and manufacturing apparatus for producing a wave winding, and wave winding

Abstract

The invention relates to a method for producing a wave winding (1), the method comprising winding electrical conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) around a stepped winding blade (4) with steps (71, 72, 73) in order to form a winding mat (2), the steps (71, 72, 73) being configured to reduce height deviations between radially inner and outer conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) in the rolled state of the winding mat (2), wherein at least two adjacent steps (71, 72, 73) are used for conductors (34, 56) which have different circumferential positions in the rolled state of the winding mat (2).

Description

[0001] Method and manufacturing apparatus for the production of a wave winding as well as wave winding

[0002] The present invention relates to a method and a manufacturing device for producing a wave winding, in which electrical conductors are wound around a stepped winding blade with steps to form a winding mat, the steps being configured to reduce height deviations between radially inner and outer conductors in the wound state of the winding mat. The invention further relates to a wave winding.

[0003] Methods and manufacturing devices for producing wave windings in which electrical conductors are wound around a stepped winding blade are known. In particular, a rolled mat of conductors is used, which is wound around a winding blade with steps to precisely arrange the conductors in radial positions. The steps of the winding blade serve to reduce height deviations between radially inner and outer conductors. Typically, the conductors are arranged uniformly in a flat mat with a constant foot-to-foot distance. However, as soon as the mat is rolled around the winding blade, this foot-to-foot distance changes depending on the radial position of the conductors. Conductors located in radially outer positions sink deeper into the rolled state than conductors in inner positions, leading to significant height deviations.

[0004] It is therefore known in principle to use a stepped winding blade, in which the wires are wound on different steps of the winding blade according to their radial positions. This arrangement helps to compensate for the geometric differences between the radial positions of the conductors and to make the winding more uniform.

[0005] Nevertheless, the known methods and devices have significant problems and disadvantages. In particular, contact marks can form between the wires during the rolling and expansion process if they are at the same or a similar height in the rolled state. This occurs especially when the radially inner and outer wires reach a similar height due to the winding around the steps of the blade. These contact marks occur primarily at the overlapping points of the mat and can penetrate so deeply into the conductors that the insulating material of the wires is damaged and the underlying copper is exposed. This poses a significant risk for high-voltage applications, as exposed copper can lead to safety problems, especially short circuits or breakdowns.

[0006] Another disadvantage of known methods lies in the difficulty of designing a compact winding head without causing mechanical damage during the winding process. The uniform winding head height achieved by the stepped winding blades often results in suboptimal winding compactness. This leads to increased space requirements for the wave winding, which inefficiently utilizes machine space and thus increases the overall size and material costs. Furthermore, the uneven arrangement of the wires, particularly in the overlap areas, contributes to mechanical stress and material fatigue, which can negatively impact the winding's service life.

[0007] Furthermore, the problems described lead to increased material usage, particularly for conductive materials like copper, as additional installation space is required to compensate for the geometric and mechanical deficiencies. This not only increases material costs but also results in inefficient electrical performance, since larger winding heads can lead to higher resistance losses and thus reduced energy efficiency.

[0008] The object of the invention is therefore to avoid or at least reduce the problems known from the prior art and to provide an improved method and an improved manufacturing device for producing a wave winding. A further object of the invention is to realize an optimized wave winding. This object is achieved by a method for producing a wave winding in which electrical conductors are wound around a stepped winding blade with steps to form a winding mat, wherein the steps are configured to reduce height deviations between radially inner and outer conductors in the wound state of the winding mat, wherein at least two adjacent steps are used for conductors with different circumferential positions in the wound state of the winding mat.

[0009] This combination of features offers the advantage that, by using adjacent steps for conductors with different circumferential positions in the rolled state of the mat, the formation of additional local contact indentations between the wires is minimized, especially at the points where the mat overlaps. The adapted step configuration prevents the conductors from pressing against each other in different circumferential and / or radial positions, which can lead to deep contact indentations in conventional winding processes. These indentations are problematic because they can be so deep that the copper is exposed, leading to significant high-voltage safety risks. With the solution described here, the winding head remains compact while simultaneously ensuring that no damage occurs to the conductors during the winding process, thereby improving the safety and reliability of the overall system.

[0010] For the purposes of this patent application, a wave winding is an arrangement of electrical conductors wound in the form of a flat mat around a winding blade to create a winding for electrical machines. When winding the blade, the wave winding consists of several parallel conductors that are wound onto the blade and then rolled.

[0011] The electrical conductors of the wave winding are preferably made of copper, as copper is very advantageous in operation due to its electrical conductivity and high strength. Alternatively, other metals such as aluminum can be used if a lower mass is required without compromising the mechanical stability of the winding. Winding mat

[0012] For the purposes of this patent application, a winding mat is a planar arrangement of several parallel electrical conductors wound around a winding blade to create a wave winding. The winding mat consists of a plurality of electrical conductors, preferably made of copper or aluminum, arranged at a uniform distance from one another.

[0013] The construction of the winding mat can advantageously be designed such that it has a constant foot-to-foot distance of the ladder in the unrolled state, which changes in the rolled state to accommodate the different radial positions of the ladder.

[0014] Wrapping sword

[0015] For the purposes of this patent application, a winding blade is a component that serves to guide a winding mat made of electrical conductors during the winding process. The winding blade has one or more steps that serve to compensate for the height differences between the radially inner and outer conductors in the wound state of the mat.

[0016] Electrical conductor

[0017] For the purposes of this patent application, an electrical conductor of a wave winding is a component used for transmitting electric current within a wave winding. The electrical conductor is part of the winding and is wound around the winding blade in such a way as to enable a uniform distribution of the electric currents and magnetic fields.

[0018] Preferably, the electrical conductor is manufactured in a wave winding with a round or rectangular cross-section, depending on the specific requirements of the application. In a preferred embodiment, the conductor is multi-stranded, which provides greater flexibility, particularly in applications where the winding is subjected to dynamic mechanical forces. Furthermore, the conductor can be provided with an electrical insulation layer that protects it from unintentional short circuits and external influences such as mechanical wear or moisture, thereby further increasing the service life and reliability of the wave winding.

[0019] Advantageous embodiments of the invention

[0020] According to an advantageous embodiment of the invention, the steps of the winding blade can be adapted in length and height such that the conductors are inserted asymmetrically into the winding mat in the circumferential direction. This can achieve a further reduction of the mechanical stresses in the wave winding. Furthermore, it prevents conductor damage, which not only extends the service life of the winding but also minimizes high-voltage safety problems that could arise from exposed copper.

[0021] According to a further preferred embodiment of the invention, it can also be provided that the at least two adjacent steps have different lengths. The use of adjacent steps with different lengths offers the advantage that the geometric differences between the radial conductors can be further compensated for. This further reduces the probability of contact marks between the conductors, particularly at the overlapping points of the mat.

[0022] Furthermore, according to another advantageous embodiment of the invention, the length over which a conductor is wound around a first step can differ from the length over which the conductor is wound around the adjacent step. Differentiating the length over which a conductor is wound on two adjacent steps further optimizes the winding geometry. This ensures that the conductors adapt better to one another in the wound state, thereby effectively minimizing the formation of contact marks, which occur particularly at the overlapping points of the mat.The object of the invention can further be achieved by a manufacturing device for producing a wave winding, comprising a stepped winding blade around which electrical conductors are wound to form a winding mat, and a wire feed device for winding the winding blade with the electrical conductors, wherein the manufacturing device uses at least two adjacent steps for conductors during winding, with different circumferential positions in the rolled state of the winding mat.

[0023] The manufacturing device offers the advantage of a more efficient winding process through the targeted use of adjacent stages for conductors with varying circumferences. This configuration reduces local contact marks between the conductors because the mechanical stress in the winding head is distributed more evenly. This prevents the risk of the wires being pressed tightly together in the overlapping areas of the mat, which could lead to damage and copper exposure. This optimized winding not only ensures a compact design but also increases system safety by preventing damage during the winding process.

[0024] Furthermore, the invention can also be further developed such that the steps of the winding blade are adapted in their length and height so that the conductors are immersed asymmetrically in the winding mat in the circumferential direction. This measure ensures that no excessive mechanical stresses arise on the conductors that could lead to contact marks. In particular, at the points where the mat overlaps, the risk of conductor damage is minimized, thereby avoiding exposed copper.

[0025] In a preferred embodiment of the invention, the at least two adjacent steps may also have different lengths. Using steps of different lengths in the manufacturing device offers the advantage that the conductors can be guided precisely according to their radial position, thereby minimizing the risk of contact marks. This variation allows for better control of the winding density and a reduction in mechanical stresses that could otherwise lead to damage to the conductors and exposure of copper.

[0026] The object of the invention can also be achieved by a wave winding in which a rolled mat of conductors is wound around a stepped winding blade with steps, wherein at least two adjacent steps are used for conductors with different circumferential positions in the rolled state of the mat. This arrangement offers the advantage that the mechanical stresses are distributed more evenly in the rolled state of the mat. This significantly reduces the risk of contact marks at the overlapping points of the mat, which in turn reduces the risk of exposed copper that could cause high-voltage safety problems.

[0027] The invention will now be explained in more detail with reference to figures, without limiting the general concept of the invention.

[0028] It shows:

[0029] Figure 1 shows a wave winding in a perspective sectional view and a winding mat in a top view, as they are known from the prior art.

[0030] Figure 2 shows a changing mat in a top view, as known from the prior art.

[0031] Figure 3 shows a first embodiment of a changing mat in a top view,

[0032] Figure 4 shows a second embodiment of a changing mat in a top view.

[0033] Figure 5 shows a third embodiment of a changing mat in a top view.

[0034] Figure 6 shows a fourth embodiment of a changing mat in a top view, Figure 7 shows a fifth embodiment of a changing mat in a top view.

[0035] With reference to Figures 1-4, a method for manufacturing a wave winding 1 is described below, in which electrical conductors 12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56 are wound around a stepped winding blade 4 with steps 71, 72, 73 to form a winding mat 2. Figures 1-4 each show a wave winding 1 with six conductors 12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56 per slot, three holes, three pole pairs, without chords and without a U-shape. Of course, these exemplary parameters can vary without departing from the scope of the invention.

[0036] Figure 1 shows a corresponding configuration of a wave winding 1, as already known from the prior art. The wave winding 1 consists of a mat 2 comprising electrical conductors 12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56. This mat 2 is wound around a winding blade 4, which is stepped. In the flat state of the mat 2, the foot-to-foot distance of each electrical conductor 12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56 is constant. However, in the wound state of the mat 2, this distance changes depending on the radial position of each conductor. Ladders 12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56, which are in a radially outer position, penetrate deeper into the mat 2 when rolled than ladders in a radially inner position. For example, a ladder whose feet are in radial positions 5-6 will penetrate more deeply into the mat 2 than a ladder whose feet are in positions 1-2 (see also Figure 2).

[0037] The winding blade 4, known from the prior art and shown in Figure 4, is equipped with steps 71, 72, 73, which can reduce these height deviations between the conductors 12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56 when the mat 2 is wound. The conductors 12 are wound on step 71 of the winding blade 4, the conductor 34 on step 72, and the conductor 56 on step 73. This stepped arrangement of the conductors 12, 34, 56 achieves a uniform distribution of the conductors in the radial direction, which helps to avoid or at least reduce mechanical stresses and uneven force distributions within the wave winding 1.

[0038] A problem encountered in the prior art is the formation of contact marks between the conductors during the rolling and expanding process. These marks can form when conductors are arranged at the same or similar heights in the rolled state, particularly conductors 12, 34, and 56, which, in the rolled state, are positioned on steps of the winding blade 4 with similar height ratios. These contact marks typically occur at the points where the mat 2 overlaps and can be so deep that the insulating material of the conductors is damaged, exposing the underlying copper. This poses a significant safety risk, especially in high-voltage applications, as exposed copper can lead to short circuits or electrical breakdowns.

[0039] The present invention aims to overcome these disadvantages by providing an improved wave winding 1 in which the geometric height deviations between the conductors in the wound state are further reduced and the mechanical stresses as well as the risk of contact marks are minimized. This is achieved by the specific design of the winding blade 4 and the arrangement of the conductors 12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56 on the steps 71, 72, 73 of the winding blade 4, which is explained in more detail below.

[0040] In the embodiments of the winding blade 4 shown in Figures 3-4, unlike in the prior art, at least two adjacent steps 71, 72, 73 are used for conductors 12, 34, 56 with different circumferential positions when the winding mat 2 is rolled. The steps 71, 72, 73 of the winding blade 4 are adapted in their length 5a, 5b, 5c and height 6 such that the conductors 12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56 are inserted asymmetrically into the winding mat 2 in the circumferential direction. Normally, the conductors in the prior art have a substantially identical axial extent over approximately 360° in the circumferential direction. According to the invention, this is deviated from, so that, for example, a substantially identical first axial extension is present over a circumference of approximately 270° and a substantially identical second axial extension is given in a circumferential range of approximately 90°.This results in the circumferentially asymmetrical distribution of the winding head sections of conductors 12,13,22,24,33,34,35,44,46,55,56.

[0041] Figures 3-4 clearly show that the at least two adjacent steps 71, 72, 73 can have different lengths 5a, 5b, 5c. Length 7, where a ladder 34, 56 is wound around a first step 71, 72, 73, differs from length 8, where the ladder 34, 56 is wound around the adjacent step 71, 72, 73.

[0042] The winding of the winding blade 2 is carried out in the embodiment shown in Figure 3 as follows: In the embodiment shown in Figure 4, the winding of the winding blade 2 has been carried out as follows: Figure 5 shows an embodiment with only two stages 71, 72, which is wound as follows:

[0043] Figure 6 also shows a variant with two stages 71,72 and the following winding: Another two-stage variant is shown in Figure 7 and has the following winding:

[0044] The wire marks can therefore be reduced by adjusting the steps

[0045] 71, 72, 73 of the winding blade 2 are asymmetrically designed. That is, one step 71, 72, 73, which is normally used exclusively for one conductor in the prior art,

[0046] While steps 12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56 are used with the same radial position, according to the invention they are used for different radial conductor positions. This means that steps 71, 72, 73 not only allow the winding of conductors 12, 34 and 56 respectively.

[0047] The invention is not limited to the embodiments illustrated in the figures. The foregoing description is therefore not to be considered limiting, but rather explanatory. The following claims are to be understood as meaning that a named feature is present in at least one embodiment of the invention. This does not preclude the presence of further features. Insofar as the claims and the foregoing description define 'first' and 'second' features, this designation serves to distinguish between two similar features without establishing a hierarchy. List of reference symbols

[0048] 1 wave winding

[0049] 2 changing mats

[0050] 4 Wrapping sword

[0051] 5 Length

[0052] 6 Height

[0053] 7 Length

[0054] 8 Length

[0055] 9 Manufacturing device

[0056] 12 ladders

[0057] 13 leaders

[0058] 22 leaders

[0059] 24 ladders

[0060] 33 ladders

[0061] 34 ladders

[0062] 35 ladders

[0063] 44 ladders

[0064] 46 ladders

[0065] 55 ladders

[0066] 56 ladders

[0067] 71st level

[0068] Level 72

[0069] Level 73

Claims

Claims 1. Method for producing a wave winding (1) in which electrical conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) are wound around a stepped winding blade (4) with steps (71, 72, 73) to form a winding mat (2), wherein the steps (71, 72, 73) are configured to reduce height deviations between radially inner and outer conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) in the rolled state of the winding mat (2), characterized in that at least two adjacent steps (71, 72, 73) are used for conductors (34, 56) with different circumferential positions in the rolled state of the winding mat (2).

2. Method according to claim 1, characterized in that the steps (71, 72, 73) of the winding blade (4) are adapted in their length (5) and height (6) such that the ladders (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) dip asymmetrically into the winding mat (2) in the circumferential direction.

3. Method according to claim 1 or 2, characterized in that the at least two adjacent steps (71 ,72,73) have different lengths (5).

4. Method according to one of claims 1-3, characterized in that the length (7) at which a conductor (34, 56) is wound around a first stage (71, 72, 73) differs from the length (8) at which the conductor (34, 56) is wound around the adjacent stage (71, 72, 73).

5. Manufacturing device (9) for producing a shaft winding (1) , comprising • a stepped winding blade (4) around which electrical conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) are wound to form a winding mat (2), as well as • a wire feed device for winding the winding blade (4) with the electrical conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56), characterized in that the manufacturing device (9) uses at least two adjacent stages (71, 72, 73) for conductors (34, 56) with different circumferential positions in the rolled state of the winding mat (2) during winding.

6. Manufacturing device (9) according to claim 5, characterized in that the steps (71 ,72,73) of the winding blade (4) are adapted in their length (5) and height (6) such that the ladders (12,13,22,24,33,34,35,44,46,55,56) dip asymmetrically into the winding mat (2) in the circumferential direction.

7. Manufacturing device (9) according to claim 5 or 6, characterized in that the at least two adjacent steps (71 ,72,73) have different lengths (5).

8. Wave winding (1) in which a rolled mat (2) of conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) was wound around a stepped winding blade (4) with steps (71, 72, 73), characterized in that at least two adjacent steps (71, 72, 73) were used for conductors (34, 56) with different circumferential positions in the rolled state of the mat (2).

Images