Method for producing a coil winding for inserting into radially open grooves of stators or rotors of electric machines
The method according to the invention is used to produce a coil winding ( 70 ) which can be inserted into the grooves of a stator or rotor of an electric machine. While using a winding template ( 26 ) and a wire handling device ( 14 ), the invention proposes carrying out a displacement process between a first and a second holding region ( 34, 36 ) even before the wires ( 32 ) are initially wound onto the winding template ( 26 ) in order to produce an inclined wire section ( 40 ) which is subsequently shaped into winding heads ( 42 ) by means of a rotating/winding process. The novel method offers the advantage that all of the wires ( 32 ) of a coil winding ( 70 ) can be processed simultaneously using a comparably simple winding device ( 110 ). The projection of the winding heads ( 42 ) over the stator can also be minimized.
1. A method for producing a coil winding ( 70 ) for inserting into radially open grooves ( 82 ) of stators ( 80 ) or rotors of electric machines, wherein the coil winding ( 70 ) consists of a number of wires ( 32 ) which are intertwined together and are bent round multiple times in opposite directions such that legs ( 44 ) of the wires ( 32 ), which lie parallel to one another and are intended for filling out the grooves ( 82 ), are connected by means of winding heads ( 42 ) which protrude at the front end beyond the rotors or stators ( 80 ), wherein a flat and rotatable winding template ( 26 ) and a wire handling device ( 14 ) are used, characterized by the following method steps:
A. feeding all the wires ( 32 ) which are used for the coil winding ( 70 ) in parallel in a direction perpendicular to a rotational axis of the winding template ( 26 );
B. holding the wires ( 32 ) on the winding template ( 26 ) at a fixing point in a first holding region ( 34 ) of the legs ( 44 ) to be realized;
C. holding the wires ( 32 ) at a distance in front of the winding template ( 26 ) with reference to the feed direction at a fixing point in a second holding region ( 36 );
D. prior to a first rotation of the winding template after step E), displacing the first holding region ( 34 ) of the winding template ( 26 ) relative to the second holding region ( 36 ) parallel to the rotational axis of the winding template ( 26 ) such that a distance between the first and the second holding regions ( 34 , 36 ) is equal to half a distance of the outermost wires with reference to all the wires and as a result of the displacing of the first holding region ( 34 ) a wire portion ( 40 ), which is angled with reference to the legs ( 44 ), is formed between the first and the second holding regions ( 34 , 36 );
E. after a preceding displacement according to D), rotating the winding template ( 26 ) by 180° thereby adjusting the wires ( 32 ), wherein the fixing point from the first holding region ( 34 ) is displaced into a third holding region ( 46 ) on the side of the winding template ( 26 ) located opposite the first holding region ( 34 ) and the fixing point from the second holding region ( 36 ) is displaced into the first holding region ( 34 );
F. fixing the adjusted or subsequently fed wires ( 32 ) at the fixing point n the second holding region ( 36 );
G. disengaging the holding action in the third holding region ( 46 ) prior to or after step F);
displacing the first holding region ( 34 ) relative to the second holding region ( 36 ) parallel to the rotational axis of the winding template ( 26 ) such that a distance between the first and the second holding regions ( 34 , 36 ) is approximately equal to or equal to half the distance of the outermost wires, and as a result of the displacing of the first holding region ( 34 ) the wire portion ( 40 ) is formed;
I. rotating the winding template ( 26 ) by 180° thereby adjusting and/or first-time feeding the wires ( 32 ), wherein, once again, the fixing point in the first holding region ( 34 ) is displaced into the third holding region ( 46 ) on the side of the winding template ( 26 ) which is located opposite the first holding region ( 34 ) and the fixing point in the second holding region ( 36 ) is displaced into the first holding region ( 34 );
J. repeating steps F) to I) until the coil winding ( 70 ) is complete;
K. displacing the first holding region ( 34 ) for the last time relative to the second holding region ( 36 ) parallel to the rotational axis of the winding template ( 26 ) by an amount, the length of which is approximately equal to or equal to half the distance of the outermost wires, as a result of which the wire portion ( 40 ) which is angled with reference to the legs ( 44 ) is formed between the first and the second holding region ( 34 , 36 );
L. severing the wires ( 32 ) in the region of the second holding region ( 36 );
M. striping the coil winding ( 70 ) from the winding template ( 26 ) completely or in part.
2. The method as claimed in claim 1 , wherein all the wires ( 32 ) are fed synchronously at the same time.
3. The method as claimed in claim 1 , wherein the wires ( 32 ) are gradually fed.
4. The method as claimed in claim 3 , wherein the wires ( 32 ) fed subsequently are first of all introduced corresponding to steps B) to D) between the wires already fed to the rotational axis of the winding template ( 26 ) and are realized with the angled portion ( 40 ) before the wires are incorporated into the recurring method steps with steps E) or I).
5. The method as claimed in claim 1 , wherein in step A), E) or I) the wires ( 32 ) are fed with their wire ends ( 30 ) using a wire drawing device ( 16 ), wherein the wires ( 32 ) are removed from a wire stock.
6. The method as claimed in claim 5 , wherein the free wire ends ( 30 ) of the wires ( 32 ) just fed in step B) or C) are angled in the direction of the rotational axis of the winding template ( 26 ) by means of the wire drawing device ( 16 ), which is clamped with the wire ends ( 30 ), with reference to the first holding region ( 34 ) of the wires ( 32 ) for forming the winding connections.
7. The method as claimed in claim 6 , wherein the forming of the angled wire portion ( 40 ) in step D is carried out as a result of displacing a first holding device ( 18 ) relatively to a second holding device ( 20 ).
8. The method as claimed in claim 6 , wherein the rotating of the winding template ( 26 ) in step E, a first holding device ( 18 ) is displaced to the holding point of the third holding region ( 46 ) and a second holding device ( 20 ) with the clamped wires ( 32 ) is displaced into the first holding region ( 34 ), as a result of which further wire is also removed from a wire store.
9. The method as claimed in claim 1 , wherein the wires ( 32 ) are secured at the holding points on the winding template ( 26 ) in step B by a first holding device ( 18 ) and in step C by a second holding device ( 29 ).
10. The method as claimed in claim 1 , wherein the winding heads ( 42 ) are post formed in the region of the bending region which was realized beforehand in step E or I from the angled wire portion ( 40 ) as a result of the rotating of the winding template ( 26 ).
11. The method as claimed in claim 10 , further comprising a profiled forming tool ( 50 ) is pressed against the winding heads ( 42 ) for the final forming of the winding heads ( 42 ).
12. The method as claimed in claim 1 , wherein the holding of the adjusted wires ( 32 ) in step F) is carried out using a third holding device ( 22 ).
13. The method as claimed in claim 12 , wherein first and third holding devices ( 118 , 122 ) are coupled with the winding template ( 26 ) in the direction of rotation and alternately fix the wires ( 32 ) in first or third holding region ( 34 , 46 ) depending on the rotational state of the winding template ( 26 ).
14. The method as claimed in claim 13 , wherein the first and third holding devices ( 118 , 122 ) are moved axially, and radially between each of the end positions with reference to the rotational axis of the winding template ( 26 ).
15. The method as claimed in claim 13 , wherein the wires between the second and first holding regions ( 34 , 36 ) are entrained by a second holding device ( 20 ) which is moved to and fro between said holding regions.
16. The method as claimed in claim 15 , wherein a wire laying device is used as the second holding device ( 20 ).
17. The method as claimed in claim 12 , wherein three holding devices are moved in a circulating manner between three holding regions ( 34 , 36 , 46 ), wherein with the rotating of the winding template in step I), one of the three holding devices is displaced to the fixing point of the first holding region ( 34 ) and another holding device ( 20 ) of the three holding devices having the clamped wires ( 32 ) is displaced into the first holding region ( 34 ) causing a further wire to be removed from a wire store.
18. The method as claimed in claim 1 , wherein the severing of the wires ( 32 ) in step L) is effected in a rotational position of the winding template ( 26 ) in which the wire beginnings ( 30 ) fed at first are located on the side of the winding template on which the wire feed is effected.
19. The method as claimed in claim 1 , wherein the wires ( 32 ) are swapped in pairs once or multiple times prior to reaching the second holding region ( 36 ) during the feeding of step A.