Compact production station for assembling a stator for an electric motor from stator segments

Abstract

A device for producing a stator for an electrical machine includes a segment feed for feeding stator segments, a cylindrical press for pressing the stator segments, a housing feed for feeding stator housings, and a mandrel for receiving the stator segments. The mandrel includes an axial direction, a first region with a first radius, a second region arranged axially below the first region with a second radius that is less than the first radius, and a third region arranged axially below the second region with a third radius that is less than the second radius. In an example embodiment, the mandrel is movable from the segment feed to the cylindrical press, from the cylindrical press to the housing feed, and from the housing feed to the segment feed.

Claims

1-10. (canceled)

11. A device for producing a stator for an electrical machine, comprising: a segment feed for feeding stator segments; a cylindrical press for pressing the stator segments; a housing feed for feeding stator housings; a mandrel for receiving the stator segments, comprising: an axial direction; a first region comprising a first radius; a second region arranged axially below the first region, the second region comprising a second radius that is less than the first radius; and a third region arranged axially below the second region, the third region comprising a third radius that is less than the second radius.

12. The device of claim 11 wherein the mandrel is movable: from the segment feed to the cylindrical press; from the cylindrical press to the housing feed; and from the housing feed to the segment feed.

13. The device of claim 12 further comprising: a tower arranged centrally between the segment feed, the cylindrical press, and the housing feed; and a movable mandrel arm arranged on the tower.

14. The device of claim 13, wherein the mandrel further comprises: a longitudinal axis; and an axial drive for rotating about the longitudinal axis.

15. The device of claim 14, wherein the mandrel further comprises: a rotational axis arranged orthogonal to the longitudinal axis; and a tilt drive for rotating about the rotational axis.

16. The device of claim 15 wherein: the tower comprises a main direction of extension; and the mandrel is movable parallel to the main direction of extension.

17. The device of claim 11, wherein: the first region is configured for: receiving the stator segments in the segment feed; and feeding the stator segments to the cylindrical press; the second region is configured for: receiving the stator segments in the cylindrical press after pressing; and feeding the stator segments to the housing feed; and the third region is configured for avoiding excessive pressing of the stator segments in the cylindrical press.

18. The device of claim 17 wherein: the first region has a first electromagnet, or a surface structure, configured as an alignment contour for aligning the stator segments on the first region; and the second region has a second electromagnet.

19. The device of claim 11, wherein the third region comprises a measuring device for detecting an electrical contact between a surface of the third region and the cylindrical press.

20. A method for manufacturing a stator for an electrical machine from stator segments using the device of claim 11, comprising: a first step comprising: receiving the stator segments in the segment feed from the first region; arranging the stator segments in a cylindrical shape on a first surface of the first region; feeding the stator segments to the cylindrical press; a second step comprising: pressing the stator segments in a cylindrical shape with the cylindrical press; arranging the third region in the cylindrical press to prevent an overpressing of the stator segments; arranging the stator segments on a second surface of the second region after pressing; and feeding the stator segments to the housing feed; and a third step comprising: feeding a housing to the housing feed; heating the housing in the housing feed; and arranging the stator segments in the housing using the mandrel.

21. The method of claim 20 wherein: the mandrel comprises a longitudinal axis; and the first step further comprises: rotating the mandrel about the longitudinal axis; arranging the stator segments on the first surface; feeding the stator segments to the mandrel; and winding the stator segments onto the first region.

22. The method of claim 21 wherein the first step further comprises aligning the stator segments with an alignment contour of the first region during winding.

23. The method of claim 20, wherein: the first step further comprises holding the stator segments on the first region by a first electromagnet during the receiving the stator segments and the feeding the stator segments to the cylindrical press; the second step further comprises holding the stator segments on the second region by a second electromagnet during the feeding to the housing feed; or the third step further comprises: holding the stator segments on the second region by the second electromagnet during the arranging in the housing; releasing the stator segments by switching off the second electromagnet after the arranging in the housing; and moving the mandrel away from the stator segments.

24. The method of claim 20 wherein: the second step further comprises: pressing the stator segments by the cylindrical press to form a cylinder; exerting a radial force on the stator segments with the cylindrical press; and terminating the radial force on the stator segments when an electrical contact between the third region and the cylindrical press is detected.

25. The method of claim 24 wherein the second step further comprises spacing a pressing tool of the cylindrical press apart from the stator segments after the pressing the stator segments.

26. The method of claim 20, wherein: the mandrel comprises a longitudinal axis; the stator segments comprises a first main direction of extension; the cylindrical press comprises a second main direction of extension; and the first step further comprises: aligning the longitudinal axis parallel to the first main direction of extension; and aligning the longitudinal axis parallel to the second main direction of extension during the feeding to the cylindrical press.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Further details and advantages of the disclosure will be explained below with reference to the exemplary embodiment shown in the drawings. In the figures:

[0032] FIG. 1 schematically shows an exemplary embodiment of a device according to the disclosure for producing a stator;

[0033] FIG. 2 schematically shows a mandrel of a device for producing a stator according to an exemplary embodiment of the present disclosure;

[0034] FIG. 3 schematically shows a part of the first step of the method for manufacturing a stator according to an exemplary embodiment of the present disclosure;

[0035] FIG. 4 schematically shows a part of the second step of the method for manufacturing a stator according to an exemplary embodiment of the present disclosure; and

[0036] FIG. 5 schematically shows the method for manufacturing a stator according to an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION

[0037] In FIG. 1, an exemplary embodiment of a device 1 according to the disclosure for producing a stator is shown schematically. The device 1 has a segment feed A, a press B and a housing feed C. The segment feed A, the press B and the housing feed C are arranged around a tower 5 and form an equilateral triangle. The tower 5 is designed as a rotating tower.

[0038] In FIG. 2, a mandrel 3 of the device 1 for producing a stator according to an exemplary embodiment of the present disclosure is shown schematically. The mandrel 3 is fastened to the tower 5 by a mandrel aim 4 and is rotatably mounted on a connection to the mandrel arm 4 about a rotational axis D with a tilt drive 7. The mandrel 3 can also be rotated about the longitudinal axis L thereof with an axial drive 6. In the radial direction R, the mandrel 3 has three different regions. A first region 3.1 of the mandrel has a first radius, a second region 3.2 of the mandrel 3 has a second radius which is smaller than the first radius. A third region 3.3 of the mandrel 3 has a third radius, which in turn is smaller than the second radius. A first electromagnet 8 is arranged in the first region 3.1, and a second electromagnet 9 is arranged in the second region 3,2. The third region 3.3 does not have an electromagnet.

[0039] In FIG. 3, a part of the first step 100 of the method for manufacturing a stator according to an exemplary embodiment of the present disclosure is shown schematically. The mandrel 3 is aligned here with the longitudinal axis L thereof parallel to the main direction of extension of a plurality of stator segments 2, which are fed to the mandrel 3 by a conveyor belt 12 and wound by the first region 3.1 of the mandrel 3. For this purpose, the mandrel 3 rotates about longitudinal axis L thereof. The first electromagnet (not shown for the sake of clarity, see FIG. 2) attracts the stator segments 2 and holds them on the surface of the first region 3.1.

[0040] In FIG. 4, a part of the second step 200 of the method for manufacturing a stator according to an exemplary embodiment of the present disclosure is shown schematically. FIG. 4 (a) shows a section through the press B with the stator segments 2 and the mandrel 3. The stator segments 2 are arranged inside the press B and are enclosed by a pressing tool 11. The pressing tool 11 has a static pressing tool part 11.1 and a movable pressing tool part 11.2. The movable pressing tool part 11.2 is pressed down with an axial force F.sub.1. Because the movable pressing tool part 11.2 touches the static pressing tool part 11.1 on a contact surface which is inclined relative to the radial force F.sub.1, and which is inclined in the direction of the stator segments 2, the downward movement caused by the radial force F.sub.1 simultaneously leads to an axial force F.sub.2 in the direction of the stator segments 2, which are pressed by the axial force F.sub.2.

[0041] The stator segments 2 enclose the third region 3.3 of the mandrel 3. If the stator segments 2 are pressed, they move in the direction of the third region 3.3. As soon as the stator segments 2 come into contact with the third region 3.3, a measuring device 10 registers a current flow between the press B, more precisely between the pressing tool 11 and the third region 3.3. As soon as a current is measured by the measuring device 10, the press B switches off the axial force F.sub.1 and thus also the radial force F.sub.2 and moves the pressing tool 11 back from the stator segments 2. The pressed stator segments 2 relax and the inner diameter of the hollow cylinder formed by the stator segments 2 increases to the nominal size of the inner diameter of the stator to be manufactured. FIG. 4 (b) shows a further section in a plan view of the press B with the stator segments 2 and the mandrel 3. The pressing tool 11 encloses the stator segments 2 and the third region of the mandrel 3.

[0042] The method for producing a stator according to an exemplary embodiment of the present disclosure is shown schematically in FIG. 5. In the first step 100, the stator segments 2 are received from the first region 3.1 of the mandrel 3 (see FIG. 3) and transported to the press B. In the second step 200, the stator segments 2 are pressed in the press B (see FIG. 4). The third region 3.3 of the mandrel 3 prevents the stator segments 2 from being overpressed too much. The stator segments 2 are then transported to the housing feed C. There, in the third step 300, a housing is supplied and heated. The mandrel 3 then introduces the pressed stator segments 2 into the housing.

REFERENCE NUMERALS

[0043] 1 Device [0044] 2 Stator segment [0045] 3 Mandrel [0046] 3.1 First region [0047] 3.2 Second region [0048] 3.3 Third region [0049] 4 Mandrel arm [0050] 5 Tower [0051] 6 Axial drive [0052] 7 Tilt drive [0053] 8 First electromagnet [0054] 9 Second electromagnet [0055] 10 Measuring device [0056] 11 Pressing tool [0057] 11.1 Static pressing tool part [0058] 11.2 Movable pressing tool part [0059] 12 Conveyor belt [0060] 100 First step [0061] 200 Second step [0062] 300 Third step [0063] A Segment feed [0064] B Press [0065] C Housing feed [0066] D Rotational axis [0067] L Longitudinal axis [0068] R Axial direction [0069] F.sub.1 Axial force [0070] F.sub.2 Radial force