WINDING MACHINE

Abstract

The invention relates to a winding module (2) for a winding device for automatically winding coils for an electric machine, comprising a module structure (20), a needle carriage (24) having a needle (25), wherein the needle carriage (24) is mounted in the module structure (20) such that it can move along a first direction (R). The winding module (2) has a winding material clamping device (240) for clamping the winding material (8), which is designed to secure the winding material (8) against rotation and against shifting along the needle axis (250), wherein the winding material clamping device (240) is arranged in or on the needle carriage (24). The invention also relates to a module frame and a winding device having a module (2) of this type.

Claims

1. A winding module for a winding device for automatically winding winding material, in order to produce a coil for an electrical machine, wherein the winding module comprises: a module stand; a needle carriage with a needle, wherein the needle carriage is supported in the module stand in a displaceable manner in a first direction, wherein the winding module further has a winding material clamping device for clamping the winding material; wherein the winding material clamping device is configured in order to secure the winding material to prevent torsion about and to prevent displacement along the needle axis; and wherein the winding material clamping device is arranged in or on the needle carriage.

2. The winding module as claimed in claim 1, wherein the winding material clamping device has a clamping lever which is supported on or in the needle carriage and which is movable between: a clamping position, in which the winding material clamped by the clamping lever during correct use of the winding module; a release position, in which the clamping lever releases the winding material during correct use of the winding module for movement relative to the needle.

3. The winding module as claimed in claim 2, wherein the clamping lever is movable via a lever actuator, and wherein the lever actuator has a movably supported eccentric element.

4. The winding module as claimed in claim 1, wherein the needle carriage has a winding material channel in order to guide the winding material through the needle carriage to the needle.

5. The winding module as claimed in claim 1, wherein the module stand has a guide device, and wherein the needle carriage is guided on the guide device in the first direction.

6. The winding module as claimed in claim 3 which further has a torque shaft in order to rotate the eccentric element.

7. A module frame for a plurality of winding modules as claimed in claim 1, comprising at least one winding module, wherein the module frame has a plurality of receiving members to releasably fix the plurality of winding modules.

8. The module frame as claimed in claim 7, further comprising a single rotation element or at least a pair comprising a first and a second rotation element, wherein the first and second rotation elements of the pair are supported in a rotatable manner on or in the module frame with spacing from each other in the first direction, wherein the module frame further comprises a coupling device; wherein the coupling device is connected in terms of movement to the single rotation element or connected in terms of movement to at least one rotation element of the at least one pair comprising a first and second rotation element; and wherein the coupling device is further connected in terms of movement to the needle carriage; so that the needle carriage can be moved in the first direction via the rotational movement of the single rotation element or the at least one rotation element of the at least one pair comprising a first and second rotation element.

9. The module frame as claimed in claim 8, wherein the first rotation element is a first shaft or a first disk which is supported on a first shaft and the second rotation element is a second shaft or a second disk which is supported on a second shaft; and wherein the connection device has a carriage belt for forming a belt drive with the first and second rotation elements.

10. The module frame as claimed in claim 9, wherein the carriage belt is open.

11. The module frame as claimed in claim 9, wherein the carriage belt is releasably fixed to the needle carriage.

12. The module frame as claimed in claim 8, wherein at least one of i) all the single rotation elements and ii) the first and second rotation elements are driven.

13. A winding device for automatically winding winding material in order to produce a coil for an electrical machine, wherein the winding device comprises: a machine frame, a table plate having at least one switching unit for receiving and switching the winding member, and a module frame as claimed in claim 8.

14. The winding device as claimed in claim 13, wherein the module frame is movable relative to the table plate in a second direction and thus all the winding modules which are fixed in the module frame are movable in the second direction.

15. The winding device as claimed in claim 13, wherein at least one of i) there are provided 2, 3, 4, 5, 6, 7, 8 or more removable winding modules in the same module frame; and ii) one or more third servo motors are provided, wherein with each third servo motor at least one switching unit(s) can be switched.

16. The winding device as claimed in claim 13, wherein a plurality or all of the winding material clamping devices are coupled to each other, and are actuatable via one, hydraulic device.

17. A method of using a winding module, of a module frame as claimed in claim 7 comprising winding coils for an electrical machine.

18. The winding module as claimed in claim 3, wherein at least one of: i) at least one of the clamping lever and the eccentric element is/are pretensioned, by means of a tensioning device; and ii) the lever actuator is actuatable via a hydraulic device for moving the clamping lever.

19. The winding module as claimed in claim 5, wherein the guide device has at least one guide rail which is at least one of i) opposite with respect to the needle carriage transversely to the first direction and ii) extends in the first direction.

20. The winding module as claimed in claim 6, wherein the torque shaft at least one of i) extends parallel with the at least one guide rail and ii) extends over the length of the at least one guide rail.

21. The module frame as claimed in claim 10, wherein first and second belt ends are fixed via clamping plates to the first or second rotation element; and wherein the open carriage belt extends in the first direction.

22. The module frame as claimed in claim 11, wherein the carriage belt is releasably fixed to the needle carriage via a clamping plate which is fitted to the needle carriage.

23. A method of using a winding device as claimed in claim 13, comprising winding coils for an electrical machine.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0054] Preferred embodiments of the invention are described below with reference to the drawings, which are merely explanatory and which are not intended to be interpreted in a limiting manner. In the drawings:

[0055] FIG. 1 shows an embodiment of a winding device according to the invention having a module frame and winding modules inserted;

[0056] FIG. 2 is a first detailed cross-section of the winding device according to FIG. 1;

[0057] FIG. 3 is a perspective front view of an embodiment of the module frame according to the invention according to FIG. 1 with 6 winding modules each having a displaceable needle carriage;

[0058] FIG. 4 is a perspective rear view of the module frame according to FIG. 3;

[0059] FIG. 5 is a second detailed cross-section of the winding device according to FIG. 1;

[0060] FIG. 6 is a perspective front view from above of a detail of the winding module with the needle carriage according to FIG. 1;

[0061] FIG. 7 is a side view of the winding module according to FIG. 6;

[0062] FIG. 8 is a cross-section through the needle carriage according to FIG. 6;

[0063] FIG. 9 shows an embodiment of a winding material clamping device which is arranged in the needle carriage according to FIG. 8;

[0064] FIG. 10 shows an embodiment of a hydraulic device which is fitted in the module frame for actuating the winding material clamping device of the winding modules; and

[0065] FIG. 11 shows an embodiment of a switching device having two switching units which are connected via a belt drive to a servo motor.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0066] With reference to FIGS. 1 to 11, preferred embodiments of the present invention will now be described. In this instance, metal wire 8 is used as the winding material.

[0067] FIG. 1 shows a winding device 1 having a machine frame 10. The winding device 1 further has a control cabinet 41, a wire supply 42, a wire clamping and cutting unit 43 for suspending the wire in commutators 7, a loading handling unit 44 and a switching unit 6. Furthermore, the winding device 1 has a module frame 12 having a large number of winding modules 2.

[0068] The machine frame 10 is welded and assembled from square steel pipes. A table plate 11 which acts as a base for additional functional groups is fitted in the machine frame 10. The machine frame 10 is partially provided with a safety sheeting 101. The safety sheeting 101 may comprise grooved profiles of aluminum. Doors are secured with door protection retention members. Other constructions are possible.

[0069] The control cabinet 41 has an operating panel for operating the winding device 1. The control cabinet 41 is integrated at the rear side in the machine frame 10. The operating panel 411 is rotatably suspended on a boom 412 in front of the winding device 101.

[0070] FIG. 2 is a cross-section through the winding device 1 according to FIG. 1. In the foreground (bottom right), one of the winding modules 2 can be seen and is fitted in the module frame 12. The module frame 12 is itself supported on the table 11 in the machine frame 10. The module frame 12 is arranged in a linearly displaceable manner on a guide device 46 (Y stroke). A first guide rail 461 of the guide device 46 can be seen in FIG. 2, which rail 461 extends in the Y direction.

[0071] The loading handling unit 44 is shown above the module frame 12. The loading handling unit 44 has two laterally arranged supports 441 on which there is provided a runner 441 which extends transversely relative to the support 441. The loading handling unit 44 has two supports 441 which are arranged laterally in the winding device 1 on the table 11 and which each have an extension arm 442. The extension arms 442 are arranged parallel with each other and are freely movable via two servo motors in two axes. The synchronization of the two extension arms 442 is carried out via a drive rod in the drive axle of the motors. The movement of the extension arms 442 is brought about via a circumferential toothed belt 443 in a crosswise arrangement. This drive concept is also referred to as T-bot. A pneumatic rotary unit 444 is flange-mounted on the extension arm 442 at both sides. The receiving bar 445, which is rotatably supported by means of the rotary units 444 for the product grippers 446, is located between these rotary units 444. Two grippers 446 are always arranged opposite each other per winding module 2. This double gripper system allows loading and unloading in a state released from the winding process. The sequence is as follows: after a product 7 is completely wound with the coil 5, one gripper 446 approaches, a tension unit is released, the handling unit 44 travels away upward, rotates through 180 and inserts the unwound product 7 with the other gripper 446 in the tension unit. This is carried out simultaneously for all the winding modules 2. After the handling unit 44 has moved away, the winding process can be started. At the same time, the unloading of the wound stators onto a support 45 (waiting position) or a material carrier is now carried out.

[0072] FIG. 2 further shows a portion of the wire clamping and cutting unit 43 for suspending the wire 8 on commutators. The unit 43 is arranged above the winding module 2. The unit 43 contains two main functions, that is to say (i) a clamping sleeve presses the start wire 8 via a vertical, pneumatic drive into a groove base of the first hook on the commutator so that the first windings can be wound; and (ii) via a horizontal, pneumatic drive, a blade receiving sleeve is moved in rotation via a toothed rack. Via a cutting edge of the outer sleeve, the wire 8 is separated and bent around the hook by the blade member. The wire end is thereby prevented from touching the wire 8 in the adjacent hook.

[0073] FIG. 3 shows the module frame 12 in a front view. The module frame 12 has two trapezoidal side walls which are connected to each other via a base plate and a strut which is arranged opposite and parallel with respect to the base plate. A first shaft 121 extends in the upper region between the side walls over the entire length of the module frame 12. A second shaft 122 which also extends over the entire length of the module frame 12 is arranged with spacing from the first shaft 121 in the Z direction. The first shaft and second shaft 121, 122 are connected to each other in a rotationally secure manner laterally via a synchronization drive 128. To this end, disks which are arranged in a rotationally secure manner are fitted to each shaft 121, 122 at the end in each case. Toothed disks of the synchronization drive 128 which are spaced apart from each other in the Z direction are now coupled in terms of movement via a closed toothed belt. A tension disk which ensures the correct tension of the belt of the belt drive 128 is provided centrally between the toothed disks which are connected via the belt drive.

[0074] Six equidistantly distributed winding modules 2 are arranged over the length of the frame 12. The first shaft 121 and the second shaft 122 each have for each winding module 2 a first toothed disk 123 and second toothed disk 124 which are fitted in a rotationally secure manner on the shaft 121, 122, respectively. Therefore, there are provided on the first and second shafts 121, 122 six first toothed disks 123 and six second toothed disks 124. In embodiments having more or fewer receiving members for winding modules 2, naturally a corresponding number of first and second toothed disks 123, 124 can be provided. The receiving members on the module frame are therefore distinguished by the toothed disks and corresponding fixing means for fixing the respective module stand 20.

[0075] Via a first servo motor 51, which engages on the first shaft 121 via a first belt drive 126 and on the second shaft 122 via a second belt drive 127, both shafts 121, 122 are driven by motor and coupled in terms of movement via the synchronization drives 128.

[0076] FIG. 4 shows the module frame 12 in a rear view. It can be seen that module stands 20 of the winding modules 2 are each screwed to the base plate and to the upper strut of the frame 12 in the receiving members.

[0077] FIGS. 3 and 4 further show that the module frame 12 is supported on the guide device 46, which has the first guide rail 461 and the two additional rails 462, 463. The module frame 12 has travel units 465 which are associated with the guide rails 461 to 463 and on which the module frame 12 can then be moved on the rails 461 to 463. In principle, fewer rails would naturally also be sufficient, in particular the two outer rails 461, 462 provide a stable guide and the third guide rail 463 reduces the play further.

[0078] The module frame 12 is now moved in the Y direction via a second servo motor S2 which engages on the module frame 12 via a rod 464 which extends in the Y direction and which makes it movable in the Y direction (Y stroke).

[0079] FIG. 5 is a cross-section through the winding device 1. The wire supply 42, which is arranged on the table 11 of the machine frame 10, can be seen. The wire supply 42 is provided with wire brakes and a wire compensation mechanism. The wire supply 42 supplies the wire via a guide hose. After a preliminary brake 432, the wire 8 is wound around a Vulkollan-coated braking roller 433 of the magnetic powder brake (540) and guided in a vertical direction around a first redirection roller 434 after a 90 redirection around a second redirection roller 435 and, from there, back to the compensation roller 436. The compensation roller 436 is pressed against the winding module 2 on a guide carriage 437 in a horizontal direction by a pneumatic cylinder 438 with free-running properties. This compensation pressure is adjusted via a proportional valve via a control unit. Thus, it is ensured that during the winding process loose wire 8 is never produced and the wire drawing remains constant. The individual wire unrollers (not shown) are screwed behind the winding module 2 on the table plate 11 of the winding device 1 and are thus accessible for changing the wires in an optimum manner.

[0080] Furthermore, on the left-hand side, FIG. 5 shows the module frame 12 and a winding module 2 with a module stand 20, the first shaft 121 having the first toothed disk 123 is again arranged in the upper region of the winding module 2 and the second shaft 122 having the second toothed disk 124 is arranged in the lower region. The two toothed disks 123, 124 are coupled in terms of movement via an open toothed belt 1250 of a connection device 125, which belt extends in the Z direction. The toothed belt 1250 is fixed on the needle carriage 24. The needle carriage 24 is further arranged between two guide rails 261, 262 which are provided in the winding module 2 and are thus displaceable via movement of the shafts 121, 122 along the guide rails 261, 262 in the Z direction. The guide rails 261, 262 are guided through the recesses 246 (through-openings) through the needle carriage 24. The needle carriage 24 is provided in the region of the recesses 246 with bearings 2460 so that it is possible for the needle carriage 24 to slide along the guide 26 with as little friction as possible.

[0081] The winding member 7, which is tensioned on the switching unit 6, is located in front of the module 2. The winding member 7 has a large number of teeth 72 which are separated via grooves 72. The winding module 2 has a needle carriage 24 which is displaceable in the Z direction and which has a needle 25, from which the wire 8 is inserted in the grooves 71 for winding round the teeth 72, whereby the coil 5 is formed.

[0082] FIG. 6 shows the winding module 2 in a perspective view from above. FIG. 7 shows the winding module 2 in the frame 12 in a side view.

[0083] The substantially parallelepipedal module stand 20 having the central through-opening can be seen. The two guide rails 261 and 262 are laterally fitted. The needle carriage 24 is arranged so as to be displaceable in the Z direction between these rails 261, 262.

[0084] The needle carriage 24 has an additional through-opening for the introduction of a torque shaft 2421. The torque shaft 2421 engages on a winding material clamping device 240 which is arranged in the needle carriage 24. FIG. 6 shows how the wire 8 is guided through an opening into the interior of the needle carriage and is discharged again at the opposite end by the needle 25 along the needle axis 250 (see FIG. 7).

[0085] FIG. 7 further shows the first belt drive 126, via which the first servo motor S1 engages on the first shaft 121. The tension disk of the first belt drive 126 can also be seen.

[0086] The details of the connection device 125 can further be seen in FIG. 7. The first belt disk 123 having a tooth arrangement 1231 is connected to an upper portion 1251 of the toothed belt 1250 of the belt drive 125 via a clamping plate 1222. The belt 125 is guided through the opening 2470 (see FIG. 8) through the needle carriage 24 and securely clamped with the clamping plate 247 (see also FIGS. 6 and 8). In the lower region 1252, the belt 1250 is connected to the lower second toothed disk 124 with a tooth arrangement 1241 via an additional clamping plate 1222. In the situation according to FIG. 7, it can be seen that the belt 1250 is then already largely wound around the toothed disk 124 and engages with the tooth arrangement 1253 in the tooth arrangement 1241 of the disk 124, and the needle carriage 24 is therefore located in a lower position.

[0087] FIGS. 6 and 7 also show the clamping lever 241 of the winding material clamping device 240.

[0088] FIGS. 8 and 9 show a cross-section through the needle carriage 24, whereby the winding material clamping device 240 can be seen. The winding material clamping device 240 has the clamping lever 241, which can be pivoted as required via a lever actuator 242. The winding material clamping device 42 further has an eccentric element 242. The clamping lever 241 is a two-armed clamping lever having a first arm portion 2411 and a second arm portion 2412. The lever 241 is constructed in an L-shaped manner and is arranged in a substantially L-shaped recess 245 in the needle carriage 24 centrally with respect to the Z direction. The lever 241 is pivotably supported on the lever bearing 2413 in the needle carriage 24.

[0089] The clamping lever 241 interacts with the eccentric element 242 via the first arm portion 2411. The eccentric element 242 is arranged in a rotationally secure manner on the torque shaft 2421, which forms the axis of the eccentric element 242. If the torque shaft 2421 is now rotated, the eccentric element 242 also rotates accordingly. FIGS. 8 and 9 show that the eccentric element 242 is an eccentric disk which can press on the first lever portion 2411 depending on the rotation position with a thickened portion and can thus press the clamping lever 241 which is pretensioned in the clamping position into the release position.

[0090] Via the second arm portion 2412, which extends substantially parallel with the winding material channel 243, the clamping lever 241 can engage in the clamping position with any wire 8 which is introduced in the winding material channel 243 and can securely clamp it at that location so that it does not twist about its own axis or slip in the longitudinal direction thereof. To this end, the lever arm 2412 is provided with a clamping element 2427 which makes direct contact with the wire 8. The abutments 2428 are provided opposite the clamping element 2427 so that an optimum clamping location in the needle carriage 24 can be provided. The second lever portion 2412 tapers toward the free end thereof. Furthermore, the engagement location of a resilient element 2424 is located at the free end of the lever arm 2412 for pretensioning the lever 241 in the clamping position. The resilient element 2424 is constructed as a pressure spring which can be adjusted in terms of the tension thereof via the adjustment screw 2426.

[0091] FIG. 9 also shows an inlet opening into and an outlet opening out of the needle carriage 24, which openings are provided for the introduction of the wire 8. The inlet opening and the outlet opening are connected by the winding material channel 243. The winding material channel 243 extends substantially centrally between the two guide rails 261, 262 and substantially centrally with respect to the Z extent of the needle carriage 24. Torques on the needle carriage 24 are thereby minimized.

[0092] FIG. 10 shows a hydraulic device 3 for moving the respective torque shafts 2421. The torque shafts 2421 are connected at the lower end via L-shaped pieces 331 to a push rod 33 which extends parallel with the table 11. This push rod 33 is connected via an articulation 34 to an actuation piston rod 32 which is supported in a pneumatic actuation cylinder 31 of the hydraulic device 3. Therefore, with the actuation of the actuation cylinder 31 the push rod 33 is moved forward or backward with respect to the cylinder 31 so that the L-shaped connection pieces 331 and therefore the torque shaft 4421 are rotated. Accordingly, therefore, the eccentric elements 2422 of the mounted winding modules 2 can be rotated by the actuation of the hydraulic device 3.

[0093] FIG. 11 shows the switching unit 6 has a switching axle 62 and is supported by a double-row of ball bearings 63 in a receiving housing which is inserted in the table plate 11. The drive is produced via a toothed belt drive 61. A tension unit comprising a set of tensioning pincers is inserted in the receiving mandrel 64. This set of tensioning pincers is configured for the shaft diameter of the winding member 7 and is tensioned via a disk spring assembly. In order to release this tension, pressure can be applied from below with a mandrel against the disk spring assembly. The set of tensioning pincers thereby opens because it is lifted off a cone. The switching axles 62 are driven in pairs via a toothed belt drive 61. A third servo motor S3 is fitted so as to be offset laterally centrally relative to the axles 62. This switching unit 6 can now be fitted several times and allows machine variants with 4, 6 or 8 winding spindles. In place of tensioning units with sets of tensioning pincers (tensioning of shafts), receiving members for stators can also be provided with tensioning mandrels (tensioning in holes).

TABLE-US-00001 LIST OF REFERENCE NUMERALS 1 Winding device 10 Machine frame 101 Safety sheeting 11 Table plate 12 Module frame 120 Receiving member 121 First shaft 1211 Tooth arrangement of 123 1212 Clamping plate 122 Second shaft 1222 Clamping plate 123 First rotation element, disk 1231 Tooth arrangement of 123 124 Second rotation element, disk 1241 Tooth arrangement of 124 125 Coupling device 1250 Carriage belt 1251 First end of 1250 1252 Second end of 1250 1253 Tooth arrangement of 1250 126 First belt drive 127 Second belt drive 128 Synchronization belt drive 2 Winding module 20 Module stand 24 Needle carriage 240 Winding material clamping device 241 Clamping lever 2411 First lever arm 2412 Second lever arm 2413 Lever bearing 242 Lever actuator 2421 Torque shaft 2422 Eccentric element/disk 2423 Tensioning device 2424 Resilient element 2425 Axle 2426 Adjustment screw 2427 Clamping element 2428 Abutment 243 Winding material channel 244 Recess for 242 245 Recess for 241 246 Recess for 261 or 262 2460 Bearing 247 Clamping plate 2470 Recess in 24 for 247 25 Needle 250 Needle axis 26 Guide device for 24 261 First guide rail of 26 262 Second guide rail of 26 3 Hydraulic device, pneumatic cylinder 31 Actuation cylinder 32 Actuation piston rod 33 Push rod 331 Connection of 2421 and 33 34 Articulation 41 Control cabinet 441 Operating panel 442 Boom 42 Wire supply with wire brakes and wire compensation mechanism 43 Wire clamping and cutting unit for suspending the wire in commutators 431 Guide hose 432 Preliminary brake 433 Braking roller 434 First redirection roller 435 Second redirection roller 436 Compensation roller 437 Guide carriage for 436 438 Pneumatic cylinder 44 Loading handling unit 441 Support 442 Extension arm 443 Toothed belt in crosswise arrangement 444 Pneumatic rotary unit 445 Receiving bar 446 Product gripper 45 Waiting position 46 Guide device for 2 461 First guide rail of 46 462 Second guide rail of 46 463 Third guide rail of 46 464 Rod 465 Travel unit 5 Coil 6 Switching unit 61 Belt drive 62 Switching axle 63 Ball bearing 64 Receiving mandrel 7 Winding member 71 Grooves 72 Winding tooth S1 First servo motor S2 Second servo motor S3 Third servo motor