A METHOD AND DEVICE FOR POSITIONING AND CLAMPING WIRE ENDS FOR ELECTRIC MACHINES
20200153319 · 2020-05-14
Inventors
Cpc classification
H02K15/08
ELECTRICITY
H02K3/50
ELECTRICITY
International classification
H02K15/00
ELECTRICITY
H02K3/50
ELECTRICITY
Abstract
To enhance process reliability when processing wire ends during the course of a production of a machine element of an electric machine, a positioning and clamping device configured to position and clamp one or several wire ends for further processing during the course of the production of the machine element of the electric machine, comprises a capturing device for capturing and positioning the at least one wire end, wherein the capturing device has at least one oblique guide for the relative positioning of the at least one wire end. Furthermore, a corresponding clamping and positioning method is described.
Claims
1-15. (canceled)
16. A positioning and clamping device for positioning and clamping at least one wire end for further processing during production of a machine element of an electric machine, the positioning and clamping device being movable relative to the machine element from which the at least one wire end protrudes and comprising: a capturing device configured to capture and position the at least one wire end, wherein the capturing device has at least one oblique guide for the relative positioning of the at least one wire end, wherein the capturing device has a first element with a first recess and a second element with a second recess, wherein the first and second elements can be moved relative to each other, wherein the first and second recesses overlap each other at least partially in such a way that the at least one wire end can be received within the recesses and rims of the recesses move closer towards or apart from each other during the relative movement of the first and second elements, wherein at least one rim at at least one of the recesses extends at least partially obliquely.
17. The positioning and clamping device according to claim 16, wherein at least one of: the at least one oblique guide, during a relative movement in a circumferential direction of the positioning and clamping device, causes the at least one wire end to be guided in a radial direction, or one first oblique guide, which extends in the circumferential direction of the positioning and clamping device and in a radial direction, and another oblique guide, which extends in an axial direction and in a radial direction, are provided.
18. The positioning and clamping device according to claim 16, wherein at least one of: opposite rims of one or at least one of the recesses form a funnel-shaped oblique insertion region, at least one first rim of the first recess extends at least partially obliquely and at least one first rim of the second recess overlapping with the first rim extends at least partially obliquely, wherein inclination directions of the obliquely extending regions of the first rim of the first and second recesses are opposite, opposite rims of the first recess form a first funnel-shaped oblique insertion region and opposite rims of the second recess form a second funnel-shaped oblique insertion region, wherein the oblique insertion regions are disposed opposite to each other, or the at least one rim that extends at least partially obliquely is a rim extending in a circumferential direction.
19. The positioning and clamping device according to claim 16, wherein at least one of: at least one of the first or the second element are configured as a disk or annular disk or as a disk segment or annular disk segment, the first and second elements can be rotated relative to each other about a common rotation axis, or a plurality of first and second recesses is disposed distributed about an axis, wherein several at least one of first or second elements are provided, which, relative to each other, can be moved radially with respect to the axis.
20. The positioning and clamping device according to claim 16, wherein the capturing device is configured as a single-item device for handling one wire end or one wire end pair or as a multiple-item device for simultaneously handling a plurality of wire ends or a plurality of wire end pairs.
21. The positioning and clamping device according to claim 16, wherein at least one of the capturing device is configured for fixing and clamping the at least one wire end, in addition to the capturing device, a fixing and clamping device for fixing and clamping the at least one wire end pre-positioned by means of the capturing device is also provided, or an insertion aid to axially insert wire ends into recesses of the positioning and clamping device is provided, with at least one insertion aid at least one of extending in an axial direction, with an oblique insertion portion extending in the axial direction, or an insertion funnel extending in the axial direction.
22. The positioning and clamping device according to claim 21, wherein at least one of the fixing and clamping device has a fixing and clamping member, which is movable relative to the capturing device, for fixing and clamping the at least one wire end between the capturing device and the fixing and clamping member, the fixing and clamping device has a fixing and clamping member and a counter-holder, which can be moved relative to each other for fixing and clamping the at least one wire end between them, the fixing and clamping device has, as a fixing and clamping member, a movably driven plunger, the fixing and clamping device is configured as a single-item device for handling one wire end or one wire end pair or as a multiple-item device for simultaneously handling a plurality of wire ends or a plurality of wire end pairs, the capturing device and the fixing and clamping device are provided with a common drive unit or coupled drive units for performing the capturing, pre-positioning, fixing and clamping during a movement, or that the capturing device and the fixing and clamping device can be moved independently of each other, the insertion aid is configured in a stationary manner, and at least one of the capturing device or the fixing and clamping device have at least one element that can be moved or rotated relative to the insertion aiding means, or the insertion aiding means is configured as a single-item device for handling one wire end or one wire end pair or as a multiple-item device for simultaneously handling a plurality of wire ends or a plurality of wire end pairs.
23. A production device for producing a machine element of an electric machine, comprising a positioning and clamping device according to claim 16, and a machining device configured to process the at least one clamped wire end.
24. The production device according to claim 23 wherein the machining device comprises at least one of a welding device, a cutting device or a forming device.
25. A positioning and clamping method for positioning and clamping at least one wire end for further processing during production of a machine element of an electric machine, comprising the step of a) capturing and positioning the at least one wire end via at least one oblique guide directly guiding the at least one wire end and bringing the at least one wire end into an exact position.
26. The positioning and clamping method according to claim 25, wherein the step a) of capturing and positioning comprises at least one of: a1) capturing the at least one wire end, bringing the wire ends closer to each other in a preliminary position, and holding the at least one wire end in the preliminary position; a2) relatively moving a first element with at least one first recess and a second element with at least one second recess, a3) capturing and positioning between rims of the first and second recesses moving relative to each other, wherein at least one of the relatively moving rims extends at least partially obliquely; a4) capturing and positioning via an oblique inserting portion; a5) capturing and positioning between oblique rims that are opposite to each other in a funnel shape, or a6) capturing and positioning by means of oblique inserting portions or insertion funnels which extend in opposite directions and can be moved relative to each other in opposite directions.
27. The positioning and clamping method according to claim 25, wherein either individual wire ends or wire end portions are individually positioned and clamped, or a group of several individual wire ends or several wire end pairs are jointly positioned or clamped.
28. The positioning and clamping method according to claim 25, wherein step a) is carried out for capturing and pre-positioning the at least one wire end, and wherein, further, a step b), fixing and clamping the at least one pre-positioned wire end, is provided.
29. The positioning and clamping method according to claim 28, wherein step b) comprises at least one of: b1) bringing the at least one wire end pre-positioned in step a) into the position thereof desired for further processing, or b2a) applying a clamping force to the at least one wire end between a first and a second element of a capturing device, wherein the elements are moveable relative to each other or rotatable relative to each other, and wherein the at least one oblique guide is provided on at least one of the elements of the capturing device, or b2b) applying a clamping force to the at least one wire end between a capturing device configured for carrying out step a) and a fixing and clamping member movable relative thereto, or b2c) applying a clamping force to the at least one wire end between a fixing and clamping member provided separately from a capturing device for carrying out step a), and a counter-holder provided separately, or the steps a) and b) are carried out in one joint movement or in separate movements.
30. A method for connecting wire ends during the course of the production of an electric machine, comprising the execution of a positioning and clamping method according to claim 25 and the connecting of the clamped wire ends, by means of welding.
31. The method according to claim 30, wherein the wire ends of hairpins are connected during a production of a stator of an electric machine.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0114] Exemplary embodiments will be explained in more detail below with reference to the attached drawings. In the drawings:
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0137] With reference to the attached Figures, embodiments of a positioning and clamping device 10 for positioning and clamping one or several wire ends 12a, 12b, 12c, 12d for further processing during the course of a production of a machine element 14 of an electric machine will be explained below based on the example of the production of a stator 16 of an electric motor.
[0138] Here, a stator 16 of an electric motor is to be produced, for instance, which serves as a driving engine for a vehicle, such as an electric passenger vehicle, and is supposed to have an output power in the range of 10 kW to 500 kW, preferably between 20 kW and 200 kW. In this respect, the goal is to produce a coil winding 18 that is as compact and powerful as possible.
[0139] According to the production step shown in
[0140] The wires of the hairpins have a right-angled cross section, for example, with a width in the range of 2 mm to 8 mm, e.g., 4.7 mm or 6 mm, and a height between 0.75 mm to 4 mm, e.g., 2.36 mm or 1.7 mm.
[0141] The number of wire pairs to be connected is, for example, between 12 and 164, e.g., 36, 58 or 72 wire pairs. One or several rows of hairpins disposed one next to each one another can be disposed on the stator.
[0142] In order to connect them, the protruding wire ends 12a, 12b, 12c, 12d are first pre-bent and then positioned relative to one another and clamped, in order to then be processed further, in particular, formed, cut, and, in particular, connected to one another, in particular, welded to one another. For this purpose, the wire ends 12a, 12b, 12c, 12d have to be positioned very precisely for laser welding; e.g., tolerances of 1/10 mm at most are permitted.
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[0144] On a machine bed or the like, the positioning and clamping device 10 is mounted in a manner movable relative to the bracket 24 in such a way that it can be placed on the machine element 14, which is indicated by the arrow 30.
[0145] The positioning and clamping device 10 has a capturing device 32, which also serves as a fixing and clamping device 34 in some embodiments. In another embodiment, the positioning and clamping device 10 has a capturing device 32 and an optional separate fixing and clamping device 34.
[0146] The capturing device 32 is provided for capturing the wire ends 12a, 12b, 12c, 12d and for positioning them. In particular, the wire ends are at least pre-positioned here.
[0147] The fixing and clamping device 34 serves for fixing and clamping the wire ends 12a, 12b, 12c, 12d, which have at least been prepositioned by the capturing device.
[0148] A separate fixing and clamping device 34 is provided optionally, and may be omitted in other configurations; in that case, the tasks of fixing and clamping are also taken on by the capturing device 32. Tests have shown that fixing and clamping can be carried out, also in a highly precise manner, solely with the capturing device 32 of the embodiment explained with reference to the
[0149] An exemplary embodiment of the capturing device 32 is described in more detail below with reference to the illustrations of
[0150] Preferably, the capturing device 32 has a first element 36 and a second element 40 and a driving device 38 for relative movement of the first 36 and second elements 40.
[0151] The capturing device 32 has at least one oblique guide, in this case, a first oblique guide 44, for instance. In one embodiment, at least one wire end 12a, 12b, 12c, 12d, during a relative movement of the elements 36, 40 of the capturing device 32, can be positioned by means of the oblique guidee.g., the first oblique guide 44both in a direction tangential to a center axis 46 through the capturing device 32 (which, in particular, is to be orientated concentrically with a center axis of the machine element 14) and radial to the center axis 46.
[0152] The elements 36, 40 of the capturing device 32 are configured as disks, particularly as annular disks, in the exemplary embodiment shown in
[0153] The first element 36 has several first cutouts or recesses 48, and the second element 40 has several cutouts or recesses 50. In the exemplary embodiments shown, the first oblique guide 44 is formed by at least one at least partially oblique rim 52 of the respective second recesses 50.
[0154] In the exemplary embodiment of
[0155] The orientation of the oblique rim is such that it is directed, with one of its directional components, in the direction of relative movement of the elements 36, 40 of the capturing device 32, wherein the narrower region 54 is formed on a rim of the second recess 50 pointing in the direction of movement.
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[0160] This may be advantageous in situations where the wire ends 12a, 12b, for example, have become twisted due to the grasp of the oblique guide and therefore cannot be positioned quite exactly between the first and second elements 36, 40, or at least not with a relative force that is acceptable with regard to the construction effort.
[0161] For example, the fixing and clamping member 60 may include a plunger 64.
[0162] In a modification shown in
[0163] In the exemplary embodiment of the capturing device 32 shown in
[0164] Preferably, the narrower region 54 extends over a smaller distance in the circumferential direction (=tangential direction) than the wider region 56.
[0165] As can be seen particularly in
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[0167] As is apparent particularly from
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[0169] Then, a relative movement of the elements 36, 40 from the receiving position into a clamping position takes place. If the elements 36, 40, which are configured as clamping disks, for instance, are located in an intermediate position (half closed) during the course of this movement, the wire ends are radially orientated via the oblique guides 44, 66, so that the wire ends are already radially positioned in this position but still may deviate in the circumferential direction (tangential direction).
[0170] In
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[0172] The insertion aiding means 68 also has an oblique guide, e.g., a third oblique guide 70, which may also be configured as a funnel-shaped oblique inserting portion. This oblique guide 70 is inclined in an axial direction and in a circumferential direction or in a radial direction.
[0173] For example, the insertion aiding means 68 is provided with a third recess 72, which is aligned with the first and second recesses 48, 50 in a receiving position of the positioning and clamping device 10. At least one rim of the third recess is beveled and thus forms an insertion bevel 74. Preferably, opposing rims of the third recess 72 are each provided with an insertion bevel with an opposite inclination, so that a funnel-shaped insertion aid is created.
[0174] If several first and second recesses 48, 50 are provided, a corresponding arrangement of third recesses 72 is preferably provided.
[0175] In one exemplary embodiment, the insertion bevels 74 are formed on a stationary plate serving, for example, as a base plate 76 on which the disk-shaped elements 36, 40 are rotatably mounted.
[0176] During the above-mentioned placement of the positioning and clamping device 10, the machine part 14 and the positioning and clamping device 10 are axially moved relative to each other. In the process, the first and second elements are located in the receiving position with their recesses 48, 50 overlapping wider regions in such a way that these wider regions also overlap the third recess 72. The wire ends are prepositioned by the insertion bevels 74 in the first and second recesses, or the insertion bevels 74 ensure that the wire end are able to end up in the first and second recesses at all. Then the process of the rotation in opposite directions of the first and second elements 36, 40 takes place, which was already described above, so that the wire ends are first positioned in the radial direction and are then positioned in the circumferential direction and subsequently clamped.
[0177] Thus, the insertion aiding means 68 may also be considered a further exemplary embodiment of the capturing device 32, while the two elements 36, 40 together form the fixing and clamping device 34.
[0178] In all embodiments, the driving device 38 may have a spring-driven, electric, pneumatic or hydraulic configuration. Preferably, it has an energy store, such as a spring, which can be locked and abruptly released, so that the driving device applies a strong relative movement impulse to the elements 36, 40 and, if applicable, clamping member 60. The torque forces for clamping a group of wires to be produced by the driving device may be in the range of 400 Nm to 3000 Nm, e.g., at 1800 Nm.
[0179] The features described with respect to the individual exemplary embodiments may be combined with one another in any way and may also be omitted in other embodiments.
[0180] While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms comprise or comprising do not exclude other elements or steps, the terms a or one do not exclude a plural number, and the term or means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.
LIST OF REFERENCE NUMERALS
[0181] 10 Positioning and clamping device [0182] 12a-12d Wire end [0183] 14 Machine element [0184] 16 Stator [0185] 18 Coil winding [0186] 20 Groove [0187] 22 Manufacturing device [0188] 24 Bracket [0189] 26 Machining device [0190] 28 Welding device [0191] 30 Relative up-and-down movement machine elementpositioning and clamping device [0192] 32 Capturing device [0193] 34 Fixing and clamping device [0194] 36 First Element [0195] 38 Driving device [0196] 40 Second Element [0197] 44 First oblique guide [0198] 48 First recess [0199] 50 Second recess [0200] 52 At least partially oblique rim [0201] 54 Narrower region [0202] 56 Wider region [0203] 58 Oblique inserting portion [0204] 60 Fixing and clamping member [0205] 62 Counter-holder [0206] 64 Plunger [0207] 66 Second oblique guide [0208] 68 Insertion aiding means [0209] 70 Third oblique guide [0210] 72 Third recess [0211] 74 Insertion bevel [0212] 76 Base plate