METHOD AND DEVICE FOR PRODUCING ROTORS AND STATORS INCLUDING THE PRODUCTION OF CONNECTION WIRES

Abstract

A method used for producing rotors and stators of electric motors, including the production of connection wires, and comprises the following steps: Winding the coil windings (12), which comprise a plurality of individual wires (14), on a wire winder (28) to which the individual wires (14) are fed from a wire supply unit (16) via a wire guide 18, 20, 22), Depositing the coil windings (12) in a draw-in tool (36), Drawing the coil windings (12) into grooves of a stator (84) or rotor body, Combining the individual wires (14) in phases by means of slide-on tubes (52) to produce the connection wires of the stator or rotor in question. In order to be able to automate the production of the connection ends, which was previously carried out manually, it is proposed that the individual wires (14) of each coil winding (12) are fastened to each other in the region of the wire guide (18, 20, 22) in order to form winding ends (46) and winding beginnings (32), after the winding and before or during the depositing, the winding ends (46) and winding beginnings (32) of each coil winding (12) are fastened in first position holders (42, 44) arranged in certain positions with respect to the draw-in tool, and during the drawing of the coil windings (12) into the stator or rotor, the winding ends (46) and winding beginnings (32) are transferred from the first position holders (42, 44) into second position holders (90, 92) arranged in certain positions with respect to the stator body (84) or rotor body. The present invention also relates to a device for carrying out the aforesaid method.

Claims

1. A method for producing rotors and stators of electric motors, including the production of connection wires, comprising the following steps: Winding the coil windings (12), which comprise a plurality of individual wires (14), on a wire winder (28) to which the individual wires (14) are fed from a wire supply unit (16) via a wire guide 18, 20, 22), Depositing the coil windings (12) in a draw-in tool (36), Drawing the coil windings (12) into grooves of a stator (84) or rotor body, Combining the individual wires (14) in phases by means of slide-on tubes (52) to produce the connection wires of the stator or rotor in question, characterised in that the individual wires (14) of each coil winding (12) are fastened to one another in the region of the wire guide (18, 20, 22) in order to form winding ends (46) and winding beginnings (32), after the winding and before or during the depositing, the winding ends (46) and winding beginnings (32) of each coil winding (12) are fastened in first position holders (42, 44) arranged in certain positions with respect to the draw-in tool, and during the drawing of the coil windings (12) into the stator or rotor, the winding ends (46) and beginnings (32) are transferred from the first position holders (42, 44) into second position holders (90, 92) arranged in certain positions with respect to the stator body (84) or rotor body.

2. The method according to claim 1, characterised in that the slide-on tubes (52) are slid onto the winding ends (46) and/or beginnings (32) before the coil windings (12) are drawn into the stator (84) or rotor body.

3. The method according to claim 1, characterised in that the individual wires (14) of the winding ends (46) and/or beginnings (32) are compacted to a diameter which is smaller than the inner diameter of the slide-on tubes (52) before the slide-on tubes (52) are slid on.

4. The method according to claim 1, characterised in that the individual wires (14) are twisted with each other to form the winding ends (46) and/or beginnings (32).

5. The method according to claim 1, characterised in that the individual wires (14) in the region of the wire supply device (16) are guided by a single wire guide (22) which can be rotated about an axis of rotation parallel to the wire guide direction.

6. The method according to claim 1, characterised in that the inner diameter of the slide-on tubes (52) is widened on the slide-on side before being slid onto the winding ends (46) and/or beginnings (32).

7. The method according to claim 1, characterised in that the slide-on tubes (52) are aligned with the winding ends (46) and/or beginnings (32) by means of a centring device (54) which engages in the slide-on tube (52) in question.

8. The method according to claim 7, characterised in that the centring device (54) has a movable gripper (68) with which the winding ends (46) or beginnings (32) are gripped and compacted.

9. The method according to claim 7, characterised in that the slide-on tubes (52) are produced at a certain length before being slid on and are received in a magazine (64) by means of which the position of the slide-on tubes (52) is defined relative to the centring device (54).

10. The method according to claim 1, characterised in that the winding ends (46) and/or beginnings (32) covered with the slide-on tubes (52) are fixed, with reference to the rotor or stator body (84), in one of a plurality of second position holders (90a, 90b, 90c, 92a, 92b, 92c).

11. A device for carrying out a method according to claim 1, with the following features: a wire supply unit (16) for parallel feeding of individual wires (14) which together form a coil winding (12) for a stator or rotor of an electric motor, a wire winder (28) with winding templates (30) on which the coil windings (12) are successively wound, a template wire gripper (34) being provided for holding the beginnings of the individual wires on the wire winder (28), a draw-in tool (36) for receiving the coil windings (12) after winding, a stator (86) or rotor carrier for receiving a stator (84) or rotor body, a transfer device for transferring the coil windings (12) from the draw-in tool (36) into the stator (84) or rotor body, characterised in that at least one connecting device is also provided, by means of which the wire beginnings and/or ends of the individual wires (14) are connected to one another to form winding ends (46) or beginnings (32).

12. The device according to claim 11, characterised in that the connecting device comprises a single wire guide (22) in the region of the wire supply unit (16) which can be rotated about an axis of rotation parallel to the feed direction of the individual wires (14) to the wire winder (28).

13. The device according to claim 11, characterised in that first position holders (42, 44) for the winding ends (46) and winding beginnings (32) are provided in a defined position with respect to the draw-in tool (36) and second position holders (90, 92) for the winding beginnings (32) and winding ends (46) are provided in a defined position with respect to the transfer device.

14. The device according to claim 11, characterised in that a centring device (54) for aligning and a slide-on device (56) for drawing on slide-on tubes (52) are provided on the respective winding end (46) or the respective winding beginning (32).

15. The device according to claim 14, characterised in that the centring device (54) comprises a gripper (68) for gripping and compacting the winding ends (46) or winding beginnings (32) and can be passed through the inner diameter of the slide-on tubes (52).

16. The device according to claim 14, characterised in that the centring device (54) comprises at least one carrier (74) for gripping and drawing or sliding the slide-on tubes (52) onto the winding ends (46) or beginnings (32).

17. The device according to claim 15, characterised in that the gripper (68) comprises a pincer-like device (78) and an actuating tube (80) that is movable axially relative to the pincer-like device (78) and that moves the pincer-like device (78) into a closed position by means of an axial adjustment.

Description

[0040] Additional 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 drawings:

[0041] FIG. 1 is a schematic view of a device for producing coil windings;

[0042] FIG. 2 is an elevation of a draw-in tool for receiving coil windings;

[0043] FIG. 3 is a schematic view of the process for transferring the coil windings from the wire winder to the draw-in tool;

[0044] FIG. 4 is a schematic plan view of a coil plate of the draw-in tool with a transferred coil winding;

[0045] FIG. 5 is a schematic side view of a device for fitting the winding ends and beginnings with slide-on tubes;

[0046] FIG. 6 is a detailed view of a centring device of the fitting device;

[0047] FIG. 7 is a schematic plan view of the centring device;

[0048] FIG. 8 is a schematic section of a first embodiment of a gripper of the centring device;

[0049] FIG. 9 is a schematic section of a second embodiment of a gripper of the centring device in the semi-closed position;

[0050] FIG. 10 is a section of the gripper according to FIG. 9 in the open position;

[0051] FIG. 11 is a schematic of a further embodiment of a gripper of the centring device;

[0052] FIG. 12 is a schematic view of the coil windings being drawn into a stator body;

[0053] FIG. 13 is a view from below of the stator carrier from FIG. 12 with a positioning gripper.

[0054] FIG. 1 illustrates a device 10 for winding coil windings 12 made of individual wires 14. In the exemplary embodiment shown, six individual wires 14 each form a coil winding 12. The six individual wires 14 are fed via a suitable wire supply unit 16, known per se, which draws the individual wires 14 from wire supply coils, not shown. The individual wires 14 are guided via a first fixed wire guide 18 and a second fixed wire guide 20, a single wire guide 22 which can be rotated with respect to the feed direction being arranged between the two fixed wire guides 18, 20. The drive is illustrated schematically by a drive shaft 24 which drives the rotatable single wire guide 22 via a gear drive 26. Furthermore, the wire supply device 16 comprises a separating device, which is itself known and therefore not shown, in the region of the rotatable individual wire guide 22.

[0055] The winding coils themselves are wound using a wire winder 28, which is itself known, with an adjustable winding template 30 and about which the individual wires are wound by a rotary movement of the entire wire winder 28. A winding beginning 32 of the coil winding is fixed to a template wire holding element 34 rotating with the wire winder 28.

[0056] FIG. 2 illustrates a movable draw-in tool 36 which comprises a plurality of draw-in lamellae 38 arranged in a ring-shape and into which the coil windings 12 are deposited. The draw-in tool 36 also comprises a bobbin plate 40 which, in contrast to known embodiments of such draw-in tools, is designed to have first position holders 42, 44 for winding ends 46 and the winding beginnings 32 already mentioned. The entire draw-in tool 36 is rotatable and axially movable relative to the wire winder 28, in which case the bobbin plate 40 may be axially adjustable relative to the draw-in lamellae 38. The drive mechanism 46 for adjusting the bobbin plate 40 and/or the draw-in lamellae 38 shall not be discussed in greater detail here.

[0057] FIG. 2 also shows a first handling gripper 48 which can remove the winding beginnings 32 initially held there in the template wire holding element 34 and transfer them to a first position holder 44 for a winding beginning 32.

[0058] The winding process takes place in such a way that a winding beginning 32 produced by the rotatable individual wire holding element 22 is first clamped in the template wire holding element 34. The wire winder 28, of which there may also be two or more for simultaneously winding a plurality of coil windings 12, is then rotated until the desired number of turns of the six individual wires 14 is wound on the winding template 30. The rotatable individual wire holding element 22 can be rotated 180 once or several times between the individual turns, so that the arrangement of the adjacent individual wires 14 is switched.

[0059] Once the winding process has concluded, the rotatable individual wire holding element 22 is rotated about a suitable angle of rotation, which can be 360 or more, to twist the wires. The individual wires are then rotated in the region of the rotatable individual wire holding element 22, so that a winding end 46 of the coil winding 12 which has just been wound and a winding beginning 32 of the coil winding 12 to be wound next are produced at the same time. The coil winding 12 produced is then transferred to the draw-in tool 36, this transfer being illustrated in FIG. 3.

[0060] FIG. 3 also illustrates the two fixed wire guides 18, 20 and the rotatable individual wire guide 22 arranged therebetween, which in this case holds the already separated, twisted winding beginning 32 of the subsequent coil winding 12. The winding end 46 of the previously wound coil winding 12 will have already been gripped by a second handling gripper 50 which clamps the winding end 46 in a first position holder 42 provided in front of it, while the first handling gripper 48 removes the winding beginning 32 from the template wire holding element 34 and clamps it in the first position holder 44 for the winding beginning 32. The position of the two position holders 42, 44 for the winding end 46 and the winding beginning 32 on the bobbin plate 40 may be seen in the plan view according to FIG. 4, which also shows the two handling grippers 48, 50. In addition, the coil winding 12 illustrated in FIG. 4 shall be construed only as an example. Using suitable axially-adjustable winding templates, it is also possible, with a corresponding wire winder, for example to wind two coil windings 12 which are already wired to one another, and these are then deposited together in the draw-in tool. This means that the winding beginnings and ends of these coil windings are already connected, so that only the winding end of one of the two coil windings and winding beginning of the other coil winding have to be clamped in the first position holders 42, 44. These are then generally at a greater angular distance from one another than is illustrated in FIG. 4.

[0061] FIG. 3 also illustrates the usual process of depositing the coil windings 12 in the draw-in tool 36 by moving the draw-in tool 36 axially in the direction of the aligned winding template 30 of the wire winder 28. After the wound coil winding 12 has been deposited in the draw-in tool 36, the next coil winding 12 can be wound by means of the wire winder 28, so that there is time available to cover the individual wires 14 connected to each other by twisting with a slide-on tube 52 over a desired length, which up to now has had to be done manually.

[0062] FIGS. 5 to 11 illustrate the slide-on tubes 52 being slid on. FIG. 5 illustrates the draw-in tool 36 with a coil winding 12 deposited therein, the winding beginning 32 and end 46 of which are deposited in the first position holders 42, 44. A centring device 54 and an attaching device 56 are illustrated and place the slide-on tubes 52 having a certain length onto the winding ends 46 and the winding beginnings 32. For this purpose, the slide-on tubes 52 are first drawn from supply rolls 58, 60, 62, transferred into a magazine 64, and cut to a desired length from the tube stock. During this process, the slide-on tubes 52 thus produced assume a predefined position in the magazine 64. If no colour distinction is desired, for example according to the phase affiliation of the ends of the windings to be covered, a single tube colour can also be used.

[0063] The magazine 64 can be displaced vertically with respect to the orientation of the slide-on tubes 52, so that the desired slide-on tube can move flush with the centring device 54. Refer also to FIG. 6 in the following in this regard. In FIG. 6 the magazine 64 is illustrated in a partial cut-away view, wherein it is supplied with three slide-on tubes having different colour coding. While the lower two slide-on tubes in the illustration are secured in the magazine by a movable locking device 66, the uppermost slide-on tube 52 is aligned flush with the centring device 54 and the twisted winding end 46. The winding end 46 or a winding beginning 32 to be provided with a slide-on tube is also aligned by suitable rotation and, if necessary, adjustment of the height of the bobbin plate 40.

[0064] In the position shown in FIG. 6, a gripper 68 has also already been inserted into the slide-on tube 52 to be drawn on. After the relevant locking device 66 has been opened, a slide 70 has also already advanced the slide-on tube out of the magazine by a distance, whereby the tube end 72 protruding from the magazine 64 can be axially clamped by a carrier 74 of the attaching device 56.

[0065] In the exemplary embodiment shown, the gripper 68 inserted into the slide-on tube 52 has a bearing mandrel 76, a pincer-like device 78 articulated thereon, and an actuating tube 80 comprising the bearing mandrel and acting on the pincer-like device. This gripper is illustrated in greater detail in FIGS. 9 and 10. The actuating tube 80 is axially movable separately from the mandrel 76, for which purpose an actuating device 82 (not explained in greater detail) is provided and works, for example, with pneumatic actuating cylinders. In FIG. 6, the pincer-like device 78 is illustrated in a closed position in which it fixes the winding end 46 shown here and compresses the individual wires 14 so that their diameter is smaller than the inner diameter of the slide-on tube 52 seated on the actuating tube 80 with slight clearance.

[0066] When it is pushed into the slide-on tube, the pincer-like device 78 is closed and its outer diameter is minimized, the pincer-like device being brought to a maximally open state, for example by a restoring spring, when the actuating tube 80 is retracted by a certain distance (see FIG. 10). The pincer-like device 78 is now closed by axially adjusting the actuating tube 80 relative to the bearing mandrel 76 (see FIG. 9), the pincer-like device gripping the winding end 46 or the winding beginning 32, centring it with respect to the slide-on tube 52 and compacting it.

[0067] After this process, the carrier 74 of the slide-on device 56 is displaced axially, carrying the slide-on tube 52 in a friction fit or by tooth-like projections (not shown) which engage in the fabric or the elastic material of the tube being used in a form fit until the entire slide-on tube 52 is drawn onto the winding end 46. After the winding end 46 has been provided with a slide-on tube 52, the process for the winding beginning 32 is repeated once the bobbin plate 40 has been rotated accordingly (see FIG. 7), and the assembly can also take place in the reverse order.

[0068] FIGS. 8 and 11 illustrate two further exemplary embodiments for grippers 168 and 268, respectively. In the gripper 168 shown in FIG. 8, the pincer-like device 178 is formed integrally with the bearing mandrel 176 as a type of spring fork, the pretensioning of which urges the pincer-like device 178 into the open state. The pincer-like device 178 can then be closed against the restoring force of the spring fork by a relative movement of the actuating tube 180.

[0069] FIG. 11 illustrates a gripper 268 in which the actuating tube 280 acts only on one pincer 279 of the pincer-like device 278, while the second pincer 277 is embodied rigid with the bearing mandrel 276.

[0070] FIG. 12 illustrates the known drawing-in of the coil windings into the grooves (not shown individually) of a stator body 84. While the drawing in itself follows known processes and shall therefore not be explained in greater detail here, a disc-shaped support 88 with second position holders 90, 92 is provided on a stator carrier 86, which holds the stator body 84 in a defined position, and they take over and clamp the winding ends 46 and winding beginnings 32 which are clamped in the first position holders 42, 44 in the stator carrier 84 when the coil winding 12 are drawn in. It is helpful in this case that the winding ends 46 and beginnings 32 are already covered with the slide-on tubes 52, so that it is ensured that all the individual wires 14 are also transferred into the second position holders 90, 92. This can be done by first position holders 42, 44 and/or second position holders 90, 92 that can be actively adjusted between a released position and a clamping position, or by coordinated clamping forces in passive holding elements.

[0071] In FIG. 12 it can also be seen that the bobbin plate 40 of the draw-in tool 36 should be moved very close to the disk-shaped support 88 of the stator carrier 86, for which purpose an axial adjustment of the spool plate 40 separate from the draw-in lamellae 38 can be helpful if necessary. However, it is also possible to transfer the winding ends and beginnings with robotic grippers. Furthermore, it can be seen in FIG. 12 that the diameter of the disk-like support 88 is smaller than the diameter of the bobbin plate 40. With reference to FIG. 13, this is made possible by the fact that there are a plurality of second position holders 90, 92, the winding ends and beginnings being curved such that their radial extension is reduced. A robotic gripping device 94 accomplishes targeted depositing into the three position holders 90a, 90b, 90c and 92a, 92b, 92c for each winding end 46 and each winding beginning 32. In addition to the possible reduced diameter of the disk-shaped support 88 of the stator carrier 86, which simplifies handling of the fitted stator carrier 86 in further process steps, the depositing in three position holders per winding beginning and winding end has the further advantage that the winding ends 46 and beginnings 32 are deposited in an even more precisely defined position, so that gripping is simplified in further process steps, e.g. for welding on electrical connecting lugs.

[0072] The invention is not limited to any of the above-described embodiments, but can be modified in many ways.

[0073] All of the features and advantages arising from the claims, the description, and the drawings, including constructive details, spatial arrangements, and method steps, may be essential to the invention both individually and in many different combinations.

TABLE-US-00001 List of reference numbers 10 Winding device 12 Coil winding 14 Individual wires 16 Wire feed device 18 First fixed wire guide 20 Second fixed wire guide 22 Rotatable single wire guide 24 Drive shaft 26 Gear drive 28 Wire winder 30 Winding template 32 Winding beginning 34 Template wire holding element 36 Draw-in tool 38 Draw-in lamellae 40 Bobbin plate 42 First position holder 44 First position holder 46 Winding end 48 First handling gripper 50 Second handling gripper 52 Push-on tubes 54 Centring device 56 Attaching device 58 First tube roll 60 Second tube roll 62 Third tube roll 64 Magazine 66 Locking device 68 Gripper 70 Slide 72 Tube end 74 Carrier 76 Bearing mandrel 78 Pincer-like device 80 Actuating tube 82 Actuating device 84 Stator body 86 Stator carrier 88 Disc-shaped support 90 Second position holder 92 Second position holder 94 Robotic gripping device 168 Gripper 176 Bearing mandrel 178 Pincer-like device 180 Actuating tube 268 Gripper 276 Bearing mandrel 277 Second pincer half 278 Pincer-like device 279 First pincer half 280 Actuating tube