Distributed winding and winding method

Abstract

The invention relates to a distributed winding comprising: a first winding assembly having a first winding device and a first coil having a first partial coil and a second partial coil, the first coil being arranged around the first winding device; and a second winding assembly having a second winding device and a second coil, the second coil being arranged around the second winding device, wherein the first coil and the second coil are galvanically isolated from one another, wherein a coil axis of the first partial coil and of the second partial coil is arranged coaxially with respect to the coil axis of the second coil, and wherein the second winding assembly is arranged between the first partial coil and the second partial coil.

Description

[0001] R.415325

[0002] - 1 -

[0003] Description

[0004] title

[0005] Distributed winding and winding methods

[0006] State of the art

[0007] The present invention relates to a distributed winding and a method for producing the distributed winding.

[0008] Distributed and intersecting windings, as currently practiced, typically require several intermediate steps, winding interruptions, and changeovers for their production, which is why they are wound manually or semi-automatically. A distributed winding design that enables a simple, automated, and cost-effective winding process would be desirable.

[0009] Disclosure of the invention

[0010] The distributed winding according to the invention with the features of claim 1 and the method for producing the distributed winding with the features of claim 8 have the advantage that crossings of the windings during the actual winding process are avoided and fully automatic production of the distributed winding is enabled.

[0011] This is achieved according to the invention by the distributed winding comprising a first winding assembly and a second winding assembly. The first winding assembly has a first winding device and a first coil with a first partial coil and a second partial coil, the first coil being arranged around the first winding device. The second winding assembly has a second winding device with a second coil, the second coil being arranged around the second winding device. The second coil is R.415325

[0012] - 2 -

[0013] A winding assembly is arranged between the first and second partial coils, with the first and second coils being galvanically isolated from each other. Furthermore, a coil axis of the first and second partial coils is arranged coaxially with the coil axis of the second coil. By dividing the distributed winding into a first winding assembly and a second winding assembly, with the winding assemblies arranged on different winding devices, the winding assemblies can be manufactured fully automatically and cost-effectively, independently of each other in terms of space and time. The second winding assembly can be arranged within the first winding assembly to form a distributed winding, which can be used, for example, to form a transformer. The first coil is, in particular, made of a single electrical conductor.

[0014] The dependent claims describe preferred embodiments of the invention.

[0015] Preferably, the first winding device is multi-part and comprises a first coil former and a second coil former. The first partial coil is arranged around the first coil former, and the second partial coil is arranged around the second coil former. This allows the partial coils to be wound independently onto the coil formers using standard winding machines and subsequently aligned with each other. Due to the split design of the coil formers, they can, for example, be wound parallel to each other and then aligned coaxially.

[0016] Preferably, the first winding device has a receiving space configured to receive the second winding assembly. The receiving space allows the second winding assembly to be easily positioned within the first winding assembly, between the first and second partial coils.

[0017] One coil end of the second coil is preferably arranged radially outside the first or second sub-coil. This allows for easy contact of the distributed winding. The arrangement of the coil end of the second coil radially outside the first or second sub-coil results in a crossing of the windings, which, according to R.415325,

[0018] - 3 -

[0019] Winding technology can only be performed manually or semi-automatically. The distributed winding according to the invention, with a first winding assembly and a second winding assembly, can also enable fully automated winding even with crossed windings.

[0020] Preferably, the second winding assembly is attached to the first winding assembly in a way that allows for non-destructive removal. This enables easy repair of the distributed winding.

[0021] The second winding assembly is preferably attached to the first winding assembly by means of a snap connection. This snap connection allows for a quick and easy, reliable connection between the second and first winding assemblies, which can be easily automated.

[0022] The first winding device and the second winding device preferably have a recess for a magnetic core. The recess is particularly cuboid in shape to accommodate a cuboid magnetic core. Thus, the distributed winding enables the formation of a compact and efficient transformer.

[0023] Furthermore, the invention relates to a method for producing a previously described distributed winding. In a first step of the method, a first coil is wound with a first sub-coil and a second sub-coil around a first winding device to produce a first winding assembly. In a further step, a second coil is wound around a second winding device to produce a second winding assembly. The winding of the first winding assembly and the second winding assembly can be carried out simultaneously or sequentially. In a subsequent step of the method, the second winding assembly is arranged between the first sub-coil and the second sub-coil of the first winding assembly. Thus, the first winding assembly can be produced independently of the second winding assembly in order to subsequently produce a crossed and distributed winding.The steps can be fully automated to enable fast and cost-effective production of the distributed winding. R.415325.

[0024] - 4 -

[0025] Preferably, the winding of the first coil comprises the step of winding the first partial coil around a first coil former and the step of winding the second partial coil around a second coil former. In the arranging step, the second winding assembly is arranged on the first coil former, and the second coil former is arranged on the second winding assembly. This allows the coil formers to be wound independently of each other, which, for example, enables a modular design of the distributed winding.

[0026] Preferably, for winding, the first coil former and the second coil former are arranged at a defined distance from each other. This ensures that a connecting piece, which electrically connects the first partial coil to the second partial coil, has a defined length. The length of the connecting piece preferably corresponds essentially to the height of the second winding assembly measured along the coil axis.

[0027] Preferably, the second winding assembly is attached to the first winding assembly in a non-destructively detachable manner, in particular by means of a snap connection. This allows the first winding assembly to be quickly and easily connected to the second winding assembly, and the connection can be disconnected again if necessary.

[0028] Brief description of the drawings

[0029] Preferred embodiments of the invention are described in detail below with reference to the accompanying drawings. The drawing shows:

[0030] Figure 1 shows a perspective view of the distributed winding according to a first embodiment of the invention,

[0031] Figure 2 shows a perspective view of the distributed winding during a process section of the process for manufacturing the distributed winding according to the first embodiment of the invention and R.415325

[0032] - 5 -

[0033] Figure 3 shows a view of a distributed winding according to a second

[0034] Exemplary embodiment of the invention during a process step for the production of the distributed winding.

[0035] Embodiments of the invention

[0036] Preferably, all identical components, elements and / or units in all figures are provided with the same reference numerals.

[0037] Below, with reference to Figures 1 to 3, a distributed winding 1 and a method for producing the distributed winding 1 are described in detail.

[0038] Figure 1 shows the distributed winding 1 for a transformer. The distributed winding 1 comprises a first winding assembly 10 and a second winding assembly 20, wherein the second winding assembly 20 is arranged within the first winding assembly 10.

[0039] The first winding assembly 10 comprises a first winding device 11 around which a first coil 12 is arranged. The first coil 12 has a first sub-coil 13 and a second sub-coil 14. Furthermore, the first coil 12 has a connecting piece 17 which electrically connects the first sub-coil 13 to the second sub-coil 14. The first sub-coil 13 and the second sub-coil 14 share a common coil axis XX around which they are wound.

[0040] The second winding assembly 20 has a second winding device 21 around which a second coil 22 is arranged. The second winding assembly 20 is located within the first winding assembly 10 between the first partial coil 13 and the second partial coil 14. The first coil 12 of the first winding assembly 10 and the second coil 22 of the second winding assembly 20 are galvanically isolated from each other. Furthermore, the second coil 22 is arranged coaxially with the coil axis XX of the first partial coil 13 and the second partial coil 14. The second winding assembly 20 is preferably attached to the first winding assembly 10 by means of a snap connection that allows for non-destructive detachment. The first winding device 11 and the second winding device 21 are flush against each other, parallel to the coil axis XX. R.415325

[0041] - 6 -

[0042] The second coil 22 has a coil end 23 which is arranged radially outside the first partial coil 13. The first winding assembly 10 is arranged crossed with the second winding assembly 20 via the connecting piece 17 and the coil end 23.

[0043] The first winding device 11 has a receiving space 3 in which the second winding assembly 20 is arranged. The receiving space 3 is radially bounded by webs 18 of the first winding device 11, the webs 18 extending parallel to the coil axis XX and connecting an upper part of the winding device 11 with a lower part of the winding device 11. Preferably, snap connections are integrated into the webs 18 to attach the second winding assembly 20 to the first winding device 11.

[0044] The distributed winding 1 has a cuboid-shaped recess 2 along the coil axis XX, which is configured to receive a magnetic core. Thus, the distributed winding 1 can, for example, form a transformer, wherein a changing electric current through the first coil 12 of the first winding assembly 10 can induce an electric voltage in the second coil 22 of the second winding assembly 20, or conversely, the second winding assembly 20 can induce a voltage in the first winding assembly 10.

[0045] Figure 2 shows the distributed winding 1 in a process step after the first coil 12, with the first sub-coil 13 and the second sub-coil 14, has been wound around the first winding device 11 to produce the first winding assembly 10, and the second coil 22 has been wound around the second winding device 21 to produce the second winding assembly 20. The first winding assembly 10 can be produced spatially and temporally independently of the second winding assembly 20.

[0046] In the step shown in Figure 2, the second winding assembly 20 is arranged between the first partial coil 13 and the second partial coil 14 of the first winding assembly 10. For this purpose, the second winding assembly 20 is inserted into the receiving space 3 of the first winding device 11 along a first insertion direction R1. The first insertion direction R1 is oriented perpendicular to the coil axis XX. R.415325

[0047] - 7 -

[0048] By inserting the second winding assembly 20 into the receiving space 3 of the first winding assembly 10, the second winding assembly 20 is preferably attached to the first winding assembly 10 by means of a snap connection. The snap connection is implemented in particular by means of snap hooks on the first winding device 11.

[0049] The first winding device 11 and the second winding device 21 have a flange area which electrically insulates the first coil 12 axially to the coil axis XX from the second coil 22.

[0050] Figure 3 shows a further process step for producing the distributed winding 1 according to a second embodiment of the invention. The second embodiment of the invention differs essentially from the first embodiment in the design of the first winding device 11.

[0051] The first winding device 11 is composed of several parts and comprises a first coil former 15 and a second coil former 16. The first partial coil 13 is wound around the first coil former 15, and the second partial coil

[0052] 14 is wound around the second coil former 16. For winding the first coil 12, the first coil former 15 and the second coil former 16 are arranged at a defined distance d1 from each other.

[0053] The first partial coil 13 and the second partial coil 14 are electrically connected to each other by means of the connecting piece 17, the length of which essentially corresponds to the defined distance d1 between the first coil former 15 and the second coil former 16. Furthermore, the defined distance d1 between the first coil former corresponds to

[0054] 15 and the second coil body 16 essentially a height h1 of the second winding assembly 20 measured along the coil axis XX.

[0055] To produce the distributed winding 1, the second winding assembly 20 is arranged along a second joining direction R2 onto the first coil former 15 of the first winding assembly 10. Subsequently, the second coil former 16 is arranged along a third joining direction R3 onto the second winding assembly 20, so that the second winding assembly 20 is positioned between the first partial coil 13 and the second partial coil 14. R.415325

[0056] - 8 -

[0057] Furthermore, the first partial coil 13, the second partial coil 14, and the second coil 22 are aligned with each other such that their coil axes XX are coaxially aligned. Thus, by unbundling the first winding assembly 10 and the second winding assembly 20, coils stacked on top of or inside each other can be wound without requiring intermediate steps, winding interruptions, or subsequent steps.

Claims

R.415325 - 9 - Claims 1. Distributed winding comprising a first winding assembly (10) with a first winding device (11) and a first coil (12) with a first partial coil (13) and a second partial coil (14), wherein the first coil (12) is arranged around the first winding device (11), and a second winding assembly (20) with a second winding device (21) and a second coil (22), wherein the second coil (22) is arranged around the second winding device (21), wherein the first coil (12) and the second coil (22) are galvanically isolated from each other, wherein a coil axis (XX) of the first partial coil (13) and the second partial coil (14) is arranged coaxially to the coil axis (XX) of the second coil (22), and wherein the second winding assembly (20) is arranged between the first partial coil (13) and the second partial coil (14).

2. Distributed winding according to claim 1, wherein the first winding device (11) is multi-part and comprises a first coil body (15) and a second coil body (16), wherein the first partial coil (13) is arranged around the first coil body (15) and wherein the second partial coil (14) is arranged around the second coil body (16).

3. Distributed winding according to claim 1, wherein the first winding device (11) has a receiving space (3), wherein the receiving space (3) is configured to receive the second winding assembly (20).

4. Distributed winding according to one of the preceding claims, wherein a coil end (23) of the second coil (22) is arranged radially outside the first partial coil (13) or the second partial coil (14).

5. Distributed winding according to one of the preceding claims, wherein the second winding assembly (20) is attached to the first winding assembly (10) in a non-destructively detachable manner. R.415325 - 10 - 6. Distributed winding according to one of the preceding claims, wherein the second winding assembly (20) is attached to the first winding assembly (10) by means of a snap connection.

7. Distributed winding according to one of the preceding claims, wherein the first winding device (11) and the second winding device (21) have a recess (2) for a magnetic core, in particular for a cuboid magnetic core.

8. Method for producing a distributed winding (1) according to any one of the preceding claims, comprising the steps: Winding a first coil (12) with a first partial coil (13) and a second partial coil (14) around a first winding device (11) to produce a first winding assembly (10), Winding a second coil (22) around a second winding device (21) to produce a second winding assembly (20), and Arranging the second winding assembly (20) between the first partial coil (13) and the second partial coil (14) of the first winding assembly (10).

9. Method according to claim 8, wherein the winding of the first coil comprises the steps of: winding the first partial coil (13) around a first coil former (15) and winding the second partial coil (14) around a second coil former (16), wherein for the arrangement the second winding assembly (20) is arranged on the first coil former (15) and the second coil former (16) is arranged on the second winding assembly (20).

10. Method according to claim 9, wherein for winding the first coil body (15) and the second coil body (16) are arranged at a defined distance (d1) from each other.

11. Method according to one of claims 8 to 10, wherein the second winding assembly (20) is attached to the first winding assembly (10) in a non-destructively detachable manner, in particular by means of a snap connection.

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