Granted Patent B2

US 12,738,820 · App. 18/152,886 · Granted Sep 15, 2026

Inventors: Stefan Wiedemann (Scherstetten, DE); Markus Schmölz (Rieden, DE); Manfred Ziegler (Hiltenfingen, DE)

Assignee: GROB-WERKE GmbH & Co. KG

H02K15/0433

Abstract

Claims (30)

1 . A method of producing a plugged wave winding configured to form at least part of a coil winding for a component of an electrical machine by plugging together a first wave winding part with a second wave winding part, wherein the first wave winding part is formed by at least one first wave winding wire and the second wave winding part is formed by at least one second wave winding wire, wherein the wave winding wires each extend in a longitudinal direction and have straight wire sections extending in a first transverse direction running transverse to the longitudinal direction and roof-shaped winding heads therebetween such that adjacent straight wire sections are interconnected by a winding head bent in a roof shape, the method comprising:

providing the first wave winding part and first guide elements for guiding straight wire sections of the first wave winding part during a plugging operation,

providing the second wave winding part and second guide elements for guiding straight wire sections of the second wave winding part during the plugging operation,

bending portions of at least one of the wave winding parts such that one or more of the winding heads directed towards the other wave winding part are displaced in a second transverse direction extending transversely to the longitudinal direction and transversely to the first transverse direction for plugging the wave winding parts into one another, and

plugging the first and second wave winding parts of the wave winding into one another under guidance of the first and second guide elements by pushing,

wherein the first and second guide elements, for passing winding heads during plugging into one another, are moved from a guide position, in which they guide the straight wire sections, to a release position for releasing a path of the winding heads.

2 . The method according to claim 1 , further comprising at least one of:

guiding a movement of at least one of the wave winding parts during the plugging into one another with primary guide elements extending from one side into the wave winding part to be guided, and secondary guide elements extending from the other side into the wave winding part to be guided, wherein the primary and secondary guide elements are transferred into the release position at different times of the plugging operation so that guiding is permanently provided, or

guiding the movement of at least one of the wave winding parts during the plugging into one another with the first and second guide elements as primary guide elements and additionally with secondary guide elements, the primary and secondary guide elements being transferred into the release position at different times of the plugging operation so that guiding is permanently provided.

3 . The method according to claim 1 , further comprising guiding a movement of at least one of the wave winding parts during the plugging into one another with front guide elements located closer to the other wave winding part and rear guide elements located further away from the other wave winding part, wherein the front and rear guide elements are transferred into the release position at different times of the plugging operation.

4 . The method according to claim 1 , further comprising that each straight wire section, or at least each half-wave with two adjacent straight wire sections and a winding head in between, is guided by at least one guide element at each time of the plugging operation.

5 . The method according to claim 1 , further comprising at least one of the following steps:

providing one or more individual wires or partial mats as the first wave winding part and the second wave winding part so that the first and second wave winding parts lie next to each other in the first transverse direction and are aligned with their longitudinal directions relative to each other;

raising or lowering a first portion or a first half of the winding heads of the first wave winding part;

optionally lowering or raising or holding in position a second portion or a second half of the winding heads of the first wave winding part;

pushing the second wave winding part in the first transverse direction into the first wave winding part;

releasing the respective bent portion of the first wave winding part so that the respective bent portion moves back again towards an initial position or moving the respective bent portion of the first wave winding part back towards an initial position;

holding the first wave winding part and guiding the movement of the second wave winding part with the guide elements;

guiding the wave winding part to be guided with several rows of pins movable in a direction of which at least one direction component runs along the center axis of the pin.

6 . The method according to claim 1 , further comprising aligning at least one of the wave winding parts or the plugged wave winding by moving at least some of the guide elements in the first transverse direction.

7 . The method according to claim 5 , wherein pushing the second wave winding part guided with the guide elements into the release position only when passing the winding head.

8 . A method of producing a plugged wave winding configured to form at least part of a coil winding for a component of an electrical machine by plugging together a first wave winding part with a second wave winding part, wherein the first wave winding part is formed by at least one first wave winding wire and the second wave winding part is formed by at least one second wave winding wire, wherein the wave winding wires each extend in a longitudinal direction and have straight wire sections extending in a first transverse direction running transverse to the longitudinal direction and roof-shaped winding heads therebetween such that adjacent straight wire sections are interconnected by a winding head bent in a roof shape, the method comprising:

providing the first wave winding part and first guide elements for guiding straight wire sections of the first wave winding part during a plugging operation,

providing the second wave winding part and second guide elements for guiding straight wire sections of the second wave winding part during the plugging operation,

bending portions of at least one of the wave winding parts such that one or more of the winding heads directed towards the other wave winding part are displaced in a second transverse direction extending transversely to the longitudinal direction and transversely to the first transverse direction for plugging the wave winding parts into one another, and

pushing the first and second wave winding parts of the wave winding with the guide elements so as to plug the wave winding parts into one another,

wherein the first and second guide elements, for passing winding heads during plugging into one another, are moved from a guide position, in which they guide the straight wire sections, to a release position for releasing a path of the winding heads,

and the method further comprising at least one of:

guiding a movement of at least one of the wave winding parts during the plugging into one another with primary guide elements extending from one side into the wave winding part to be guided, and secondary guide elements extending from the other side into the wave winding part to be guided, wherein the primary and secondary guide elements are transferred into the release position at different times of the plugging operation so that guiding is permanently provided, or

guiding the movement of at least one of the wave winding parts during the plugging into one another with the first and second guide elements as primary guide elements and additionally with secondary guide elements, the primary and secondary guide elements being transferred into the release position at different times of the plugging operation so that guiding is permanently provided.

Assignments (1)

Priority Claims (2)

Continuity (1)

References Cited (18)