Method for producing rotors or stators of electric machines

Abstract

A method to produce rotors or stators of electric machines having radial grooves into which webs of flat windings having parallel webs and winding heads connecting said webs being pulled, wherein a winding is produced on a rotating, strip-shaped flat former shorter than the winding such that windings are pulled off the former and transferred into a linear transfer device, which transports the windings to a removal position at which the windings are transferred into radial grooves of a rotor or of the transfer tool for transfer into radial grooves of a stator, wherein the former, the transfer device, and the rotor or the transfer tool being jointly rotated about an axis of rotation of the former when rotated to form windings.

Claims

1. A method for producing rotors or stators of electric machines, wherein the rotors or stators have radial grooves into which webs of flat windings with parallel webs and winding heads connecting the webs are inserted, the method comprising: inserting windings prefabricated on a former and being initially flat into radial grooves of a rotor or a transposing tool configured for passing on the windings into grooves of a stator, the former being a rotating, strip-shaped, flat former shorter than the windings such that first turns of the windings generated are removed from the former before production of the windings is complete; transposing turns of the windings removed from the former into a linear transfer device configured for transporting the turns to a removal position; and transposing the turns from the removal position into the radial grooves of the rotor or into the radial grooves of the transposing tool for transposition of the winding into the radial grooves of the stator, wherein the former, the transfer device and the rotor or the transposing tool are jointly rotated about an axis of rotation of the former whenever the former is rotated in order to form turns.

2. The method of claim 1, wherein each of the winding is generated by wire webs, lying on the former of a respective turn being displaced alternately with respect to fed wires and the former being rotated by 180°, and the transfer device is adjusted during displacement by a corresponding amount of travel parallel to the axis of rotation of the former, and the rotor or the transposing tool is rotated synchronously about a central axis of rotation thereof.

3. The method of claim 1, wherein the winding heads of the windings are clamped between displacement procedures after leaving the former.

4. The method of claim 1, wherein the winding heads are formed in the transfer device between displacement between two forming halves.

5. The method of claim 1, wherein the turns are transposed from the transfer device into the radial grooves of the transposing tool or the rotor by means of first cams.

6. The method of claim 5, wherein the turns are pressed radially inward into the radial grooves of the rotor or the transposing tool by means of second cams.

7. The method of claim 5, wherein the first and/or second cams are moved back and forth in a transposition direction and/or have slopes with respect to a direction of movement of the windings.

8. The method of claim 1, wherein the turns of the windings are deposited in the transfer device in holders which are designed on and/or between links of a link chain, wherein the link chain is guided linearly over a region between the former and the transposing tool or the rotor.

9. The method of claim 1, wherein the turns are guided with aid of transposing pins engaging between the turns during transposition into the transfer device.

10. The method of claim 9, wherein the transposing pins are moved in engagement with the turns during displacement with the turns, and are moved out of engagement with the turns between displacement procedures and returned to a starting position thereof.

11. The method of claim 1, wherein insulating strips are inserted between stages of the turns between generation of the turns on the former and transposition of the turns into the transfer device.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) Further features, details, and advantages of the invention become apparent from the text of the claims and from the following description of exemplary embodiments with the aid of the drawings, in which:

(2) FIG. 1 shows a schematic plan view and side view of a device for equipping a transposing tool in a starting position;

(3) FIG. 2 shows an enlarged detail of the transition point of the device from FIG. 1;

(4) FIG. 3 shows a further enlarged detail from FIG. 1;

(5) FIG. 4 shows a view of the device after a shifting/forming process of the winding;

(6) FIG. 5 shows a view of the device with retracted transposing pins;

(7) FIG. 6 shows a view of the device with repositioned transposing pins;

(8) FIG. 7 shows a view of the device with re-engaging transposing pins, retracted former, and activated winding head forming device;

(9) FIG. 8 shows a view of the device with opened winding head forming device;

(10) FIG. 9 shows a view of the device after a winding process with a transfer unit rotated by 180°;

(11) FIGS. 10, 11, 12, 13 and 14 show the working steps illustrated in FIGS. 4 to 8 with a transfer unit rotated by 180°.

DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

(12) A device for producing a rotor or stator for an electric machine is shown in FIG. 1, wherein, when a stator is produced, in fact a further method step which is not shown needs to take place, in which the winding is transposed into the stator of the machine from a transposing tool 44 which is equipped with the winding in the device shown. Such a method is known in principle, for example, from EP 1 639688 B1 which at this point is expressly included in the disclosed content of this application.

(13) The schematically illustrated device 10 has a bearing housing 12 in which a transfer unit 14 is mounted so that it can rotate concentrically with a winding head 16, wherein the latter is likewise mounted in the bearing housing 12 or a separate bearing block 18, as illustrated in the drawings.

(14) A former 20 is guided in a torsionally rigid but axially adjustable fashion in the winding head 16, wherein the axis of rotation runs through the center of the strip-like former 20. Furthermore, two wire holders/shifters 22, 24 are held in the winding head 16 so that they can be adjusted axially and radially with respect to the axis of rotation, which in each case are associated with a flat side of the former 20 and are arranged correspondingly excentrically with respect to the axis of rotation, as can be clearly seen in each case from the lower view in the drawings. In this respect, the winding device corresponds to known embodiments, with the exception that the former 20 is here designed so that it is considerably shorter than the length of the winding 20 which is to be generated as a whole, only two turns of which in the region of the former are shown schematically in all the drawings in order to make the views clear.

(15) In order to transfer the windings generated on the former into a transfer device 28, transposing pins 32 arranged on a common support 30 are provided. The transposing pins 32 with its support 30 are also associated with the rotatable transfer unit 14, and the whole transfer device 28. The support 30 can be adjusted radially and axially with respect to the axis of rotation, as will be described in detail below.

(16) The transfer device 28 has a circulating link chain 34 which is deflected over in this case three deflecting rollers 36, 38, and 40. The link chain 34 is tensioned linearly between a first deflecting roller 36 and a second deflecting roller 36 so that the winding 26 can be flattened and transported without being bent in a region between the former 20 and a transition point 42 to a transposing tool 44. In order to be able to hold the winding securely, rigid and variable holders 48 and 50 are designed on and between chain links 46 of the chain 34. The rigid holders 48 in each case take the form of inner walls 52 of the respective chain links 46 which are formed so that they are rigid relative to one another, whilst the variable holders 50 are designed so that they are between outer walls 54 of adjacent chain links 46 when the link chain 34 is stretched linearly (see also here FIGS. 2 and 3). The link chain 34 is carried along in a form-fitting fashion, wherein this happens in the exemplary embodiment shown by means, for example, of transport pins 56 which engage in suitable recesses 57 on the chain links 46. Any of the deflecting rollers shown are suitable in principle as the driven deflecting roller, preferably the third driving roller 40, wherein a plurality of driven rollers can also be considered. A separate drive which interacts in a form-fitting fashion with the link chain 34 at a point between the deflecting rollers is, of course, also possible.

(17) A cam track 58, which ensures that the level of the winding 26 in the holders 48, 50 of the transfer device 28 corresponds approximately to the middle level of the former 20, is provided in the transition region between the former 20 and the transfer device 28.

(18) A winding head forming device 60, which has a movable forming tool 62 and a template 64 arranged below the link chain 34, is provided between the former 20 and the transposing tool 44.

(19) The winding head forming device 60 is also designed so that it rotates together with the transfer unit 14. A clamping device 66 for the winding heads of the winding is moreover provided in the region of the template, wherein said clamping device holds the winding in place with respect to the transfer device 28 when the transposing pins 32 are retracted and cannot stabilize the winding 26 themselves. The clamping device 66 rotates with the transfer device 28 but, like the winding head forming device 60, cannot move axially.

(20) A short distance upstream from the second deflecting roller 38 in the transporting direction, first disk-like cams 68 engage with slopes 70 (see FIG. 2) through slots 72 in the link chain 34 and lift up the winding 26 during an advancing movement of the transfer device 28 such that the corresponding windings are lifted out of the holders 48, 50 of the link chain and pressed into radial grooves 74 in the already described transposing tool 44.

(21) The transposing tool 44 essentially consists of an annular support 76 with the already mentioned radial grooves 74 which are widened axially. The radial grooves 74 are interrupted by slots 78 oriented perpendicularly thereto and in which adjustable, second disk-like cams 80 can engage. The transposing tool 44 is clamped in a driven rotational guide 81 which is designed so that it can rotate together with the transfer unit 14. It furthermore has a rotational drive (not shown) which rotates the transposing tool 44 synchronously with the advance of the transfer device 28.

(22) A main shaft 82 is provided in order to synchronize the movements of all of the interacting pieces of equipment inside the device and in particular synchronize the rotating movement between the winding head 16 and the transfer unit 14, wherein the mechanical synchronization can also be replaced by electronic synchronization with sensors for position detection and electronically activated servomotors.

(23) A wire guide 84, which does not rotate together with the former 20 and the transfer unit 14, is arranged which extracts the wires 86 for the winding 26 from a wire supply (not shown) and leads them toward the former 20. The wire guide also has the function of a clamping device and can be moved at least in two degrees of freedom of a notional radial plane with respect to the axis of rotation of the former.

(24) An insulating station, which introduces electrical insulation between wires with different phases, can be provided between the wire shifters 22, 24 and the transposing pins 32, this being possible at this point without extending the cycle times. The former may need to be configured so that it is slightly longer in order to free up sufficient axial space to install the insulating station.

(25) Starting from FIG. 1, a cycle for producing a winding is described below which is repeated multiple times until the complete winding is generated. The particular steps at the beginning of the production process and the end are not explained in detail. The winding is shown schematically with connecting wires 88 and just two generated windings but the description refers to a winding 26 which has already been generated with a sufficiently large circumference that it extends into the radial grooves 74 of the transposing tool 44, and the connecting wires are actually already situated correspondingly in a position protruding laterally above the transposing tool 44. Accordingly, the positions shown should be disregarded in the following considerations.

(26) In the situation shown in FIG. 1, the wires 86 are oriented so that they are flush with the former 20, wherein the wire guide 84 is arranged at a certain distance from the former 20 and the wires are also clamped there. A first wire shifter 22 on the upper side of the former 20, according to the view, holds the wires on the former, whilst on the underside of the former the second wire shifter 24 is extended further axially with respect to the winding head 16 and also holds the wires which run there on the former 20.

(27) Further in the process, the transposing pins 32 are situated in the transition region to the transfer device 28 engaging with the windings on the upper side of the former, i.e. the pins engage between the turns and stabilize them. The clamping device 66 is opened and the winding head forming device 60 is situated in a rest position.

(28) Further in the process axially, the winding 26 is held in the holders 48, 50 of the link chain 34 and then runs further in the radial grooves 74 of the transposing tool 44, wherein the turns initially lie radially on the outside and are then arranged further inward, after the second cams 80 in the direction of rotation, wound radially one over the other.

(29) In a first step, the end state of which is shown in FIG. 4, the first and second wire shifters 22, 24 are moved axially out of the winding head 16 by an amount of travel corresponding to the width of half a turn. The transposing pins 32, the link chain 34, and the transposing tool 44 move synchronously, the latter being rotated by an angle which corresponds to a travel of the outer circumference that is equal to the axial advancing travel. The former 20 is also moved by a corresponding amount of travel such that there are no relative movements between the already wound wires 86 and the former 20 in this step.

(30) An inclined wire section 90 is generated with this step between the wire feed 84 and the first wire shifter 22, from which a winding head 92 of the winding is later bent.

(31) After this step is complete, the clamping device 66 is closed and clamps the winding heads 92 lying there, whilst the transposing pins 32 are disengaged from the turns. The corresponding end state is illustrated in FIG. 5, wherein, starting from this state, the transposing pins 32 are moved axially toward the winding head 16 back into their initial position (see FIG. 6).

(32) In order to achieve the state shown in FIG. 7, the transposing pins 32 are reengaged in the turns, the axially stationary clamping device 66 is opened and the winding heads lying in the region between the forming tool 62 and the template 64 are brought into their final form by means of the winding head forming device 60. Furthermore, the former 20 is moved backward counter to the feed direction in the advancing step, wherein the turns are, as it were, stripped off at the end of the former 20 such that they can subsequently be transposed into the holders 48, 50 of the link chain 34. Also, shortly afterwards, the second cams 80 are advanced toward the transposing tool 44 such that the disk-shaped cams 80 engage in the slots 78 and press the turns which run there more deeply into the radial grooves 74 such that, where already present, they lie on the winding layer situated underneath. The turns can also be pressed in radially after the shifting procedure according to FIG. 4 is complete, but in any case there are no strict requirements for a specific time sequence for the individual steps in FIGS. 4 to 8. FIG. 8 shows the device after the winding head forming device 60 has been opened and the second cams 80 retracted. The second cams 80 can alternatively also be guided later such that they remain in the grooves and, according to the layer height of the already introduced winding, are moved slowly radially outward at the same time as the feed movements.

(33) In the transition to FIG. 9, the second (in this case lower-lying) wire shifter 24 is lifted off the former 20 and then pulled backward axially into the winding head such that the former 20 is freed for a further half-turn, which is generated by the former 20 rotating by 180°. At the same time, the whole transfer unit 14 is rotated, with the transposing pins 32, the winding head forming device 66, the transfer device 28 and the rotational guide 81 with the clamped transposing tool 44, about the axis of rotation of the winding head. The rotating procedure can also be carried out at an earlier point in time. With the rotating procedure, the wire guide first moves onto the former in a curve-like fashion, before it is pulled back into the clamping position shown in FIG. 10 and clamped again to the wires 86. The second wire shifter 24, which is now situated in the upper position, is extended axially and takes hold of the wires 86 lying on the former in order to prepare the next displacement procedure. Apart from the transfer unit 14 which stands on the head and the swapped wire shifters 22, 24, the state according to FIG. 10 thus corresponds to the state shown in FIG. 1. After the rotating procedure, the in principle identical sequence of working steps according to FIGS. 11 to 14 accordingly happens next, before, after repeated rotation, the initial state according to FIG. 1 is restored, with the difference that a further turn has been transposed to the transposing tool.

(34) The invention is not limited to one of the abovedescribed embodiments but can be modified in many different manners, wherein all of the features and advantages arising from the claims, the description and the drawings, including structural details, spatial arrangements and method steps, can be essential to the invention both per se and in a wide range of combinations.

LIST OF REFERENCES

(35) 10 device 12 bearing housing 14 transfer unit 16 winding head 18 bearing block 20 former 22 first wire shifter/holder 24 second wire shifter/holder 26 winding 28 transfer device 30 support 32 transposing pins 34 link chain 36 first deflecting roller 38 second deflecting roller 40 third deflecting roller 42 transition point 44 transposing tool 46 chain links 48 rigid holders 50 variable holders 52 inner walls 54 outer walls 56 transport pins 57 recesses 58 cam track 60 winding head forming device 62 forming tool 64 template 66 clamping device 68 first cams 70 slopes 72 slots in link chain 74 radial grooves 76 annular support 78 slots in transposing tool 80 second cams 81 rotational guide 82 main shaft 84 wire guide 86 wires 88 connecting wires 90 inclined wire section 92 winding heads