METHOD FOR PRODUCING A COIL WINDING AND WINDING FORMER

Abstract

The invention relates to a method for producing a wave winding for forming a coil winding (30) with at least one wave winding layer (33a, b) in a stator or rotor element (100), wherein a winding former (10) is provided with at least two winding sections (13a, b, c) and such that it can be rotated about a longitudinal axis (11), comprising the following method steps: Applying parallel coil wires to a first side (15) of the winding former (10) in a winding section (13) of the winding former (10); forming winding heads (31a, b) by alternately axially shifting the parallel coil wires on the winding former (10) and winding same about the rotated winding former (10); repeating steps a and b until the wave winding has reached a length of a first wave winding layer (33a) of the coil winding (30), wherein, according to the invention, the steps a to c are repeated in another winding section (13b) with a different winding width (12b). The invention also relates to a winding former (10) for producing a wave winding of this type which is suitable for introduction into grooves of a stator or rotor element (100).

Claims

1. A method for producing a wave winding for forming a coil winding (30) having at least one wave winding layer (33a,b) in a stator or rotor element (100), with a winding former (10) that can be rotated about a longitudinal axis (11) and has at least one winding section (13a) with a winding width (12a), having the method steps: a. Feeding parallel coil wires onto a first side (15) of the winding former (10) in a winding section (13) of the winding former (10); b. Forming winding heads (31a,b) by alternately axially shifting the parallel coil wires on the winding former (10) and winding them around the rotated winding former (10); c. Repeating steps a and b until the wave winding has reached a length of a first wave winding layer (33a) of the coil winding (30), characterized in that the winding former is formed with at least one further winding section (13b,c) with a different winding width (12b,c) and steps a to c are repeated at least in the further winding section (13b,c) with different winding widths (12b,c).

2. The method according to claim 1, additionally having the method step: Axially shifting the winding former (10) along its longitudinal axis (11) for transferring the coil wires to be wound into the further winding section (13b,c).

3. The method according to any one of the preceding claims, characterized in that an intermediate step having an intermediate winding in an intermediate section (14a,b) is provided in the transfer from one winding section (13a) to the next winding section (13b,c), wherein a winding width of the intermediate section (14a,b) lies between the winding widths (12a,b,c) of the winding sections (13a,b,c).

4. The method according to any one of the preceding claims, additionally having the method step: Repeating the steps until a desired number of wave winding layers (33a,b) is reached for insertion into the stator or rotor element (100).

5. The method according to any one of the preceding claims, wherein steps a to c are repeated in winding sections with increasing winding widths.

6. The method according to any one of the preceding claims, additionally having the method step: Feeding the wave winding into a transfer tool for insertion of the wave winding (30) into grooves of a stator or rotor element (100).

7. The method according to any one of the preceding claims, additionally having the method step: Completely stripping the coil winding (30) from the winding former (10) and transfer of the coil winding (30) to a transport device.

8. A winding former (10) for producing a wave winding from parallel coil wires suitable for insertion into grooves of a stator or rotor element (100), wherein the winding former (10) is rotatable and has an essentially rectangular cross-section, characterized in that the winding former (10) axially has at least two winding sections (13a,b,c) with different winding widths (12a,b,c).

9. The winding former (10) according to claim 8, characterized in that the winding widths (12a,b,c) of the winding sections (13a,b,c) increase in steps along the longitudinal axis (11).

10. The winding former (10) according to claim 9, characterized in that the winding widths (12a,b,c) of the winding sections (13a,b,c) increase alternately from a free end of the winding former (10) along the longitudinal axis (11).

Description

[0026] Further features, details and advantages of the invention result from the wording of the claims and from the following description of exemplary embodiments with reference to the drawings. In the figures:

[0027] FIG. 1a shows a schematic view of a coil winding drawn into a stator or rotor element which has been produced according to the prior art or has been produced with a winding former according to the prior art;

[0028] FIG. 1b shows a schematic view of a coil winding drawn into a stator or rotor element which has been produced by the method according to the invention or has been produced with a winding former according to the invention, and

[0029] FIG. 2 shows a schematic representation of a winding former according to the invention.

[0030] FIG. 1a shows a schematic view of a coil winding 20 drawn into a stator or rotor element 100 which has been produced according to the prior art or has been produced using a winding former according to the prior art.

[0031] In the detailed view it can be seen that the winding heads 21a, b have a greater axial extent with each wave winding layer 23a,b lying radially further inwards. The coil winding 20 used piles up in such a way that the winding heads in the stator or rotor element 100 form a frustoconical structure. This results in an increased space requirement, wherein the axial distance between the radially outer wave winding layer 23a in this exemplary embodiment of the prior art and the radially inner wave winding layer 23b is unused.

[0032] FIG. 1b shows a schematic view of a coil winding 30 drawn into a stator or rotor element which has been produced from a wave winding by the method according to the invention or has been produced with a winding former 10 according to the invention. It can be seen here that the winding heads 31a, b, unlike FIG. 1a, which describes the prior art, all lie in one plane when viewed axially. Consequently, the wave winding layers 33a,b of the coil winding 30 are also completely overlapping. As a result, the space available for the coil winding 30 of the stator or rotor is optimally used.

[0033] FIG. 2 shows a schematic representation of a winding former 10 according to the invention in a plan view of the first side 15 of the winding former 10. The winding former 10 is elongated and has a flat cross section. The winding former 10 thus has a sword-like shape, wherein the winding former 10 has a large length-to-width ratio in relation to its overall length and its overall width. The thickness of the winding former 10 is chosen to be as small as possible.

[0034] The winding former 10 can be rotated about a longitudinal axis 11 by at least 180° in both directions. The winding former 10 can be shifted axially along the longitudinal axis 11.

[0035] The winding former 10 has several winding sections 13a,b,c, each of which has a constant winding width 12a,b,c. The winding widths 12a,b,c of the winding sections 13a,b,c increase steadily from left to right in the illustration in FIG. 2. However, it is equally possible to provide a winding former 10 in which, viewed from left to right, a winding width 12a,b,c is provided that decreases in each case for the winding sections 13a,b,c. The left-hand end of the winding former 10 can represent an open end, while a right-hand end with a stop and a swivel joint can have a closed end.

[0036] Intermediate sections 14a,b are provided between the winding sections 13a,b,c and can be wound when the length of the coil winding 30 produced has reached the circumference of a specific wave winding layer 33a,b of the coil winding 30 to be drawn into a stator element or rotor element 100. For the transition between the wave winding layers 33a,b, the coil winding 30 can take place in the respective intermediate section 14a,b.

[0037] The increase in the winding width 12a,b,c of the winding sections 13a,b,c takes place in stages along the longitudinal axis. The winding can be started in the winding section 13a with a small winding width 12a at the open end of the winding former 10. Alternatively, it is also possible to start at the closed end of the winding former 10 in a winding section 13c with a large winding width 12c. It is also conceivable that if there are more than two winding sections 13a,b,c on the winding former 10, the winding starts at an inner winding section 13b.

[0038] It can be seen in FIG. 2 that the increase in the winding width 12a,b,c of the winding sections 13a,b,c takes place from a free end of the winding former 10 alternately at a changing distance. The winding sections 13a,b,c can have different lengths along the longitudinal axis 11 of the winding former 10.

[0039] An intermediate section 14a,b is arranged between two winding sections 13a,b or 13b,c, which can have a winding width that differs from the winding sections 13a,b or 13b,c. The intermediate sections 14a,b can be used to produce intermediate windings which allow a transition from one wave winding layer 33a of the coil winding to another wave winding layer 33b lying radially further inwards or outwards in the stator or rotor element.

List of Reference Numerals

[0040] 10 Winding former

[0041] 11 Longitudinal axis

[0042] 12a,b,c Winding width

[0043] 13a,b,c Winding section

[0044] 14a,b Intermediate section

[0045] 15 First side

[0046] 20 Coil winding (prior art)

[0047] 21a,b Winding head (prior art)

[0048] 22a,b Wire web (prior art)

[0049] 23a,b Wave winding layer (prior art)

[0050] 30 Coil winding

[0051] 31a,b Winding head

[0052] 32a,b Wire web

[0053] 33a,b Wave winding layer

[0054] 100 Stator or rotor element