Method for producing stator or rotor with interlaced wire groups forming an intertwined wave winding

1. A method for producing a wave wound electrical element of an electrical machine,

the produced electrical element having a distributed wave winding of intertwined wire groups which wire groups have interlaced wires,

the wires of which wave winding are

i) shaped continuously in wavelike fashion into

a) straight segments which are introduced into slots of the electrical element and

b) head portions with each head portion joining two adjacent straight segments of one wire and protruding past an associated first or second end face of the electrical element, and

ii) associated in pairs whose straight segments occupy the same slots but whose head portions protrude from opposite ends of the slots receiving two successive straight segments of the associated wires,

said method comprising the steps of:

forming two interlaced wire groups separately, said forming step for each wire group including the steps of

winding up n parallel wires with intermediate spacing onto a striplike former that is rotatable about a longitudinal axis thereof, said winding up step, for an electrical element having a number of slots divisible by 2 n that are to be occupied by the wave winding, including the steps of

(i) spacing each of the parallel wires on the former with a predetermined intermediate spacing corresponding to a spacing of the slots of the electrical element,

(ii) bending over so as to be doubled over one straight segment and forming a first end turn for one head portion of each of the parallel wires; and

(iii) pausing of the rotational winding movement and axially displacing the straight segments of each wire group formed in said spacing and bending steps while maintaining the intermediate spacing thereof, together with the adjoining first end of the respective associated end turn relative to a second end of the respective associated end turn, along the axis of rotation of the former by n times the predetermined intermediate spacing in a predetermined direction so that the end turns form head portions; and

(iv) repeating steps (i), (ii) and (iii) for the straight segments for any intermediate slots and finally for last n slots on the former to form each of the two individually interlaced wire groups;

winding the two individually interlaced wire groups onto one another in an axial relative position in which the straight segments, created from associated wires on opposite sides of the striplike former, are made to coincide in a relative position in which the straight segments of the wires associated in pairs, in successive slots to be occupied thereby, alternatingly assume a radially outer position and a radially inner position so that the two interlaced wire groups form an intertwined wave winding; and

introducing the intertwined wave winding into the slots of the electrical element in a direction transversely to a longitudinal extent of the slots to form the wave wound electrical element.

2. The method as claimed in claim 1 ,

wherein each of the two individually interlaced wire groups has from two to five times as many straight segments as the electrical element has slots, and

wherein the winding step of the two individually interlaced wire groups with one another includes the step of continuously shaping and putting together the two interlaced wire groups such that between the respective second and next-to-last straight segments the head portions of two associated wires that are intended for the same slots intersect, upon each progression from one slot to the next, in projection onto a plane located transversely to the longitudinal direction of the slots.

3. The method as claimed in claim 1 , further including the step of pressing flat the interlaced wire groups one of individually before the winding step or together after the winding step to form the intertwined wave winding.

4. The method as claimed in claim 3 , wherein the pressing flat step separately presses flat each interlaced wire group only to such an extent that in an end view of each interlaced wire group, two straight segments joined by a head portion rest side by side with one of no intermediate spacing or with only minimal intermediate spacing.

5. The method as claimed in claim 1 ,

wherein in said winding up step the interlaced wire groups are formed from parallel, identically oriented wires of rectangular cross section,

wherein said bending over step includes the step of

(i) placing the wires with a side face thereof onto the former, and

(ii) bending the wires on the former by 180° about a first bending axis located parallel to the longitudinal center axis of the former to form end turns, and

wherein said axially displacing step includes the step of bending the legs thus formed in a region of this bend and at ends of each of the end turns about bending axes that are transverse to the first bending axis such that in a side view of the striplike former gable-shaped head portions are formed.

6. The method as claimed in claim 5 , wherein the placing step includes the step of selecting the rectangular wires used to have an overall width measured in the longitudinal direction of the former, taking into account slot or wire insulators and a play necessary for the introduction of the wires into the slots, that fits a slot width of the former.

7. A method for producing a wave wound electrical element of an electrical machine, said method comprising the steps of:

forming two interlaced wire groups separately, said forming step for each wire group including the steps of

shaping n parallel wires with intermediate spacing into a wavelike pattern including straight segments which are to be introduced into slots of the electrical element and head portions which join two adjacent straight segments of one wire and which are to protrude past an associated first or second end face of the electrical element, and

repeatedly bending over the n parallel wires so that each wire is doubled over a preceding straight segment thereof to form an end turn of a head portion therebetween, and then axially displacing one end of each end turn of each wire relative to the other end so that relative to successive slots to be occupied thereby radially inner and outer ones of the straight segments are formed;

intertwining the two individually interlaced wire groups by winding the longitudinal center axes thereof around one another and with an axial relative position in which the radially inner straight segments of each of the interlaced wire groups are made to coincide with and be positioned inwardly from the radially outer straight segments of each of the interlaced wire groups to form an intertwined wave winding; and

introducing the intertwined wave winding into the slots of the electrical element in a direction transversely to a longitudinal extent of the slots to form the wave wound electrical element.

8. The method as claimed in claim 7 , further including the step of pressing flat the interlaced wire groups one of individually before the winding step or together after the winding step to form the intertwined wave winding.

9. The method as claimed in claim 8 , wherein the pressing flat step separately presses flat each interlaced wire group only to such an extent that in an end view of each interlaced wire group, two straight segments joined by a head portion rest side by side with one of no intermediate spacing or with only minimal intermediate spacing.