System and method for producing a winding bar for a stator winding

Abstract

A system for producing a winding bar for a stator winding of a stator of a rotating electric machine, in particular a turbine generator, having two machining units which can be arranged at a variable distance to each other. Each machining unit has machining device for machining an end portion of the winding bar, and each machining device is arranged on the respective machining unit in a pivotal manner about a pivot axis via at least one respective pivot arm. The pivot axis is identical to a longitudinal central axis of the rotating electric machine, and the radial distance between each machining device can be varied relative to the pivot axis.

Claims

1. A system (1) for producing a winding bar (17, 18) for a stator winding of a stator of a rotating electric machine, comprising: two processing units (2, 3) which are arranged at a variable distance from one another, wherein each processing unit (2, 3) comprises a plurality of processing means (8, 9, 10, 11) for processing an end portion of the winding bar (17, 18), wherein each processing means (8, 9, 10, 11) of the plurality of processing means: comprises a respective pivot arm (12); and is pivotable about a pivot axis (13) via the respective pivot arm (12), wherein the pivot axis (13) coincides with an axis of rotation of the rotating electric machine when the winding bar is disposed in the rotating electric machine, wherein a radial distance between each processing means (8, 9, 10, 11) is variable relative to the pivot axis (13), wherein a first processing means (8) of the plurality of processing means (8, 9, 10, 11) is configured to: first bend the end portion of the winding bar (17, 18) radially outwardly at a predetermined cone angle () of an opening cone (20) of a winding head of the stator with respect to the pivot axis (13) to form an angled-off portion of the winding bar; and second to bend the angled-off portion of the winding bar about a first bending axis (15) extending transversely to the pivot axis (13) in order to form a winding head portion of the winding bar comprising a profile that tapers radially outward relative to the pivot axis (13) in a direction toward a tip portion of the angled-off portion, and wherein a second processing means (10) of the plurality of processing means (8, 9, 10, 11) is configured to bend the tip portion of the angled-off portion of the winding bar about a second bending axis (21) which extends transversely to the pivot axis (13).

2. The system as claimed in claim 1, wherein at least one processing unit (14) of the two processing units (2, 3) comprises at least one lifting crane (14) by means of which the end portion of the angled-off portion of the winding bar is lifted when bending the angled-off portion about the first bending axis 15.

3. The system as claimed in claim 1, wherein at least one processing unit of the two processing units (2, 3) comprises a plurality of grippers (9) in which is deposited and clamped the angled-off portion of the winding bar so that the angled-off portion comprises a profile which is curved about the pivot axis (13), and wherein each gripper (9) of the plurality of grippers is functionally connected to a respective actuator by means of which the respective gripper is moved back and forth on the respective pivot arm (12) radially and/or parallel to the pivot axis (13).

4. The system as claimed in claim 1, wherein in at least one processing unit of the two processing units (2, 3) the plurality of processing means (8, 9, 10, 11) comprises a separating unit (11) by means of which a part of the tip portion is severed off.

5. The system as claimed in claim 1, further comprising: system electronics configured to arrange the two processing units (2, 3) with respect to one another and to arrange individual processing means (8, 9, 10, 11) of the plurality of processing means (8, 9, 10, 11) relative to the pivot axis (13) and also to control the individual processing means (8, 9, 10, 11) in dependence on predetermined structural parameters of the rotating electric machine.

6. The system as claimed in claim 1, wherein the rotating electric machine is a turbogenerator.

7. The system as claimed in claim 3, wherein each gripper (9) is functionally connected to the respective actuator by means of which the respective gripper (9) is moved back and forth on the respective pivot arm (12) radially and/or parallel to a cone angle () of the opening cone (20).

8. The system as claimed in claim 1, wherein the plurality of processing means (8, 9, 10, 11) comprise: an angle deformer (8) adapted to bend the end portion to produce the angled-off portion of the winding bar, grippers (9) adapted to clamp the angled-off portion of the winding bar, a deformer (10) adapted to bend the tip portion of the angled-off portion of the winding bar about the second bending axis (21), and a separating unit (11) adapted to sever a part of the tip portion off.

9. A method for producing the winding bar for a stator winding of a stator of the rotating electric machine, comprising: providing a winding bar blank; determining parameters of the rotating electric machine with respect to the pivot axis of the rotating electric machine; arranging the processing means (8, 9, 10, 11) of the system of claim 1 with consideration to the determined parameters of the rotating electric machine; bending the end portion of the winding bar (17, 18) radially outwardly at the predetermined cone angle () of the opening cone (20) of the winding head of the stator with respect to the pivot axis (13) to form the angled-off portion of the winding bar by means of the system of claim 1; bending the angled-off portion of the winding bar about the first bending axis (15) extending transversely to the pivot axis (13) in order to form a winding head portion of the winding bar by means of the system of claim 1, and bending the tip portion of the angled-off portion of the winding bar about the second bending axis (21) which extends transversely to the pivot axis (13) by means of the system of claim 1.

10. The method as claimed in claim 9, wherein at least one position of the opening cone (20) of the winding head of the stator relative to the pivot axis and a cone angle () of the opening cone (20) of the winding head are determined as parameters of the rotating electric machine.

11. The method as claimed in claim 9, wherein the plurality of processing means (8, 9, 10, 11) comprise: an angle deformer (8) adapted to produce the angled-off portion of the winding bar, grippers (9) adapted to clamp the angled-off portion of the winding bar, a deformer (10) adapted to bend the tip portion of the angled-off portion of the winding bar about the second bending axis (21), and a separating unit (11) adapted to sever a part of the tip portion off.

12. The method as claimed in claim 11, further comprising: producing the angled-off portion of the winding bar with the angle deformer (8), clamping the angled-off portion of the winding bar with the grippers (9), bending the tip portion of the angled-off portion of the winding bar about the second bending axis (21) with the deformer (10), and severing the part of the tip portion off with the separating unit (11).

13. The method as claimed in claim 9, wherein the rotating electric machine is a turbogenerator.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) An embodiment of a system according to the invention is explained below with reference to the appended schematic drawings, in which:

(2) FIG. 1 shows a schematic illustration of an exemplary embodiment of a system according to the invention;

(3) FIG. 2 shows a schematic illustration of a processing unit of the system shown in FIG. 1;

(4) FIG. 3 shows a further schematic illustration of the processing unit shown in FIG. 2; and

(5) FIG. 4 shows a schematic and perspective illustration of the processing unit shown in FIGS. 2 and 3.

DETAILED DESCRIPTION OF INVENTION

(6) FIG. 1 shows a schematic illustration of an exemplary embodiment of a system 1 according to the invention for producing a winding bar, which is shown in FIGS. 2 to 4, for a stator winding of a stator of a turbogenerator.

(7) The system 1 comprises two processing units 2 and 3 which can be arranged at a variable distance from one another. For this purpose, the processing units 2 and 3 are movably arranged on a linear guide 4. The linear guide 4 has two guide rails 6, of which only one can be seen in FIG. 1, which extend parallel to one another and are fastened on a base structure 5. Each processing unit 2 or 3 comprises a carriage 7 via which the respective processing unit 2 or 3 is displaceably arranged on the linear guide 4. In addition, at least one fixing means (not shown) is present on each carriage 7 and/or on the linear guide 4 and makes it possible to fix the respective processing unit 2 or 3 in its respectively assumed relative position with respect to the linear guide 4.

(8) Each processing unit 2 or 3 has processing means 8 to 11 for processing an end portion of the winding bar. Each processing means 8, 9, 10 or 11 is arranged on the respective processing unit 2 or 3 so as to be pivotable about a pivot axis 13 via a respective pivot arm 12. The pivot axis 13 is identical to a longitudinal center axis of the rotating electric machine. A radial distance between each processing means 8, 9, 10 or 11 is variable relative to the pivot axis 13.

(9) A first processing means 8 is designed first to radially outwardly angle off an end portion of the winding bar at a predetermined cone angle of an opening cone of a winding head of the stator with respect to the pivot axis 13 and then to deform the resulting, angled-off portion of the winding bar about a bending axis which extends transversely to the pivot axis 13 in order to form a winding head portion of the winding bar.

(10) Each processing unit 2 or 3 comprises a lifting crane 14 by means of which an end portion of the angled-off portion of the winding bar can be lifted during the deformation of the angled-off portion of the winding bar.

(11) Each processing unit 2 or 3 comprises a plurality of processing means 9 in the form of grippers in which there can be deposited and clamped the angled-off portion of the winding bar with a profile which is curved about the pivot axis 13. Each gripper is functionally connected to a respective actuator (not shown) by means of which the respective gripper can be moved back and forth on the respective pivot arm 12 radially and/or parallel to the pivot axis 13, in particular parallel to the cone angle .

(12) A second processing means 10 is designed to deform a free end portion of the angled-off portion of the winding bar about a bending axis which extends transversely to the pivot axis 13.

(13) Each processing unit 2 or 3 additionally comprises a processing means 11 in the form of a separating unit by means of which an end portion of the free end portion of the angled-off portion of the winding bar can be severed from the angled-off portion.

(14) Furthermore, the system 1 comprises a system electronics (not shown) which is designed to arrange the processing units 2 and 3 with respect to one another and to arrange the individual processing means 8 to 11 relative to the pivot axis 13 and also to control the processing means 8 to 11 in dependence on predetermined structural parameters of the rotating electric machine.

(15) FIG. 2 shows a schematic illustration of the processing unit 2 of the system 1 shown in FIG. 1. The bending axis 15 which extends transversely to the pivot axis 13 is depicted in FIG. 2, about which bending axis the angled-off portion of the winding bar can be deformed in order to form the winding head portion of the winding bar by means of the processing means 8. Additionally depicted is a reference plane 16 in which the straight part of the winding bar ends. Two windings bars 17 and 18 with different bar geometries are depicted by way of example in FIG. 2 and can be selectively produced by the system 1. Moreover, reference is made to the above description for FIG. 1 in order to avoid repetitions.

(16) FIG. 3 shows a further schematic illustration of the processing unit 2 shown in FIG. 2. An involute circle 19 is depicted which is taken into consideration during the production of the winding bar 18. In addition, an opening angle for the winding bar 18 and an opening angle for the winding bar 17 are depicted. Moreover, reference is made to the above description for FIG. 1 in order to avoid repetitions.

(17) FIG. 4 shows a schematic and perspective illustration of the processing unit 2 shown in FIGS. 2 and 3. FIG. 4 depicts an opening cone 20 of a winding head of the stator of the rotating electric machine, the position and shaping of which is taken into consideration in the setting of the system or of the processing unit 2. Moreover, reference is made to the above description for FIG. 1 in order to avoid repetitions.

(18) A production operation which can be carried out by way of example with the system 1 shown in FIGS. 1 to 4 is described below.

(19) At the start of the production operation, a winding bar blank of straight design can be arranged on the system 1. Here, the actuating means 8, 9 and 10 are opened such that they can each receive a portion of the winding bar. After the winding bar blank has been arranged on the system 1 in such a way, the winding bar blank is oriented axially, which can take place with the aid of markers which are arranged on the winding bar blank and which each mark an end of a straight part of the winding bar to be produced. The straight part can then be fixed in the vicinity of the respective processing means 8 by means of a fixing unit (not shown) of the system 1. The actuating means 8 is closed in order subsequently to be able to bring about the deformation of the winding bar blank. Sliding elements (not shown) may be inserted into the actuating means 8 in advance in order to subsequently facilitate the deformation operation. An end portion of the winding bar blank is fastened to the lifting crane 14 via a crane clamp. The winding bar blank is then angled off by means of the first processing means 8 at the cone angle of the opening cone of the winding head of the stator. The resulting, angled-off portion of the winding bar is then deformed or bent about a bending axis which extends transversely to the pivot axis 13 in order to form a winding head portion of the winding bar by means of the first processing means 8. At the same time, the end portion of the winding bar blank is drawn upward by the lifting crane 14 and the lifting crane 14 is pivoted in order to guide the angled-off portion of the winding bar blank via the actuating means 9 and 10. After the winding bar blank has been deformed by means of the first actuating means 8, the angled-off portion of the winding bar blank is deposited by means of the lifting crane 14 in the actuating means 9 in the form of grippers. The grippers are then closed, which can take place manually or automatically. After the grippers have been closed, the crane clamp is removed from the end portion of the angled-off portion. Displacing the grippers radially and parallel to the pivot axis 13, in particular parallel to the cone angle , results in the involute profile being formed on the angled-off portion. For this purpose, the grippers are moved back and forth to a small degree, with the result that the angled-off portion is expanded such that mechanical stresses in the angled-off portion are eliminated and the involute profile of the angled-off portion is optimally formed. A part of the angled-off portion can then be fixed by means of a holding-down means (not shown) which is arranged adjacently to the second processing means 10. As a result, the tensile forces which are subsequently produced by the deformation by means of the second processing means 10 and act on the remaining part of the angled-off portion which has the involute profile can be reduced. The second actuating means 10 can then be closed in order subsequently to be able to bring abut the deformation of the end portion of the angled-off portion. Sliding elements (not shown) may be inserted into the second actuating means 10 in advance in order to subsequently facilitate the deformation operation. The end portion of the angled-off portion is then deformed by means of the second actuating means 10. The actuating means 11 in the form of a separating unit can then be arranged on a free end portion of the angled-off portion, for example placed thereon. A separating operation is then carried out by means of the separating unit and consequently a free end portion of the angled-off portion of the winding bar is severed from the angled-off portion by the separating unit. The severed part can be collected in a box arranged below. The separating unit can subsequently be removed again. The processing means 8, 9 and 10 can then be opened and the finished winding bar can then be removed from the system 1. For this purpose, the grippers may have been lowered beforehand.

(20) Although the invention has been fully illustrated and described in detail by the preferred exemplary embodiment, the invention is not limited by the disclosed example and other variations can be derived therefrom by a person skilled in the art without departing from the scope of protection of the invention.