Woven Winding Mat Production via Interweaving Partial Mats
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Solution Overview
Problem
Existing methods for producing woven winding mats for electrical machine coil windings are inefficient and often require braiding or looping of wire material, which can be cumbersome and time-consuming.
Innovation Solution
A method and device that involve creating and interweaving two wave-shaped partial winding mats with corrugated bends and straight wire sections, using tool components with clamping receptacles to position and shift the wire sections, allowing for the production of a woven winding mat without braiding or looping, by alternately raising or lowering the bent wire sections to achieve a staggered arrangement for efficient interweaving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional braiding or looping methods are used to produce winding mats, then the structural integrity of the coil winding is maintained, but the production process becomes cumbersome and time-consuming
Solution Approach 1:
The winding mat is divided into multiple partial winding mats, each containing a specific number of wire bends (e.g., five bends per partial mat). These partial mats are produced separately and then assembled together, enabling parallel production and reducing the time required to create large winding mats while maintaining structural integrity through standardized connection points
Solution Approach 2:
The wire bends are pre-formed into corrugated shapes with predetermined geometries before assembly. The partial winding mats are prepared in advance with clamping sections and connection points already in place, allowing for rapid assembly without time-consuming on-site forming operations, thus significantly improving production efficiency
2Adaptability or versatility
If wire sections are rigidly fixed in position, then structural stability is achieved, but flexibility in arranging and swapping wire sections within slots is lost
Solution Approach 1:
The connection between partial winding mats uses dynamic clamping mechanisms rather than rigid fixed connections. The clamping sections allow for adjustable positioning and secure release, enabling wire sections to be easily removed, rearranged, or swapped within slots while maintaining stable connections during operation. This dynamic system provides both flexibility for reconfiguration and stability during use
Data Source
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AI summary
The invention relates to a method and a device for producing a woven winding mat for a coil winding of an electric machine, wherein the method comprises: providing a first partial winding mat (1) with a first wave bend (3) made of wire material, which is formed with first straight wire sections (3b) and first bent winding heads (3a); providing a second partial winding mat (2) with a second wave bend (4) made of wire material, which is formed with second straight wire sections (4b) and second bent winding heads (4a); arranging the first partial winding mat (1) in a first tool component, wherein the first straight wire sections (3b) are clamped in first clamping recesses of the first tool component;Arranging the second partial winding mat (2) in a second tool component, wherein the second straight wire sections (4b) are clamped in second clamping receptacles of the second tool component (51); arranging a respective non-flat side of the first and second partial winding mats (1, 2) arranged in the first and second tool components opposite each other; producing a woven winding mat (10) by weaving the first and second partial winding mats (1, 2), wherein the first and second tool components are brought towards each other and thereby the first and second partial winding mats (1, 2) are pushed into each other in a second transverse direction, so that the opposing first and second curved winding heads (3a, 4a) are guided past each other superimposed; and separating the woven winding mat (10) from the first and second tool components (50, 51).