WAVE WINDING DEVICE AND METHOD FOR PRODUCING A WAVE WINDING

Abstract

A wave winding device includes a wire outlet nozzle arrangement through which a winding wire or a plurality of winding wires is fed. It further includes a shaping core at least rotatably displaceable relative to the wire outlet nozzle arrangement, on which the winding wire or the winding wires is or are windable. The wave winding device further includes a bending aid deliverable to the winding wire, which is designed to bend a section of a winding wire fed from the wire outlet nozzle arrangement before the section is placed on the shaping core.

Claims

1. A wave winding device, including a wire outlet nozzle arrangement (1) through which a winding wire (2) or a plurality of winding wires (2) is fed, and including a shaping core (4) at least rotatably displaceable relative to the wire outlet nozzle arrangement (1), on which the winding wire (2) or the winding wires (2) is or are windable, wherein the wave winding device further comprises a bending aid (3, 3a) deliverable to the winding wire (2), the bending aid (3, 3a) being designed to bend a section (2a) of a winding wire (2) fed from the wire outlet nozzle arrangement (1) before the section (2a) is placed on the shaping core (4).

2. The wave winding device according to claim 1, wherein the bending aid (3) has a comb-like shape.

3. The wave winding device according to claim 2, wherein the winding wire (2) is a flat wire and the comb-like shape of the bending aid (3) includes intermediate spaces, the width of which is dimensioned such that it is greater than the narrow side of the flat wire (2) but smaller than the wide side of the flat wire (2).

4. The wave winding device according to claim 1, wherein the bending aid (3, 3a) is deliverable in a direction parallel to the feed direction of the winding wire (2).

5. A method for producing a wave winding, in which a winding wire (2) or a plurality of winding wires (2) is fed from a wire outlet nozzle arrangement (1) to a shaping core (4) and wound on the shaping core by rotating the shaping core (4), wherein i) the fed winding wire (2) is placed on and held fast to the shaping core (4); ii) the shaping core (4) is then rotated by 180; comprising: between step i) and step ii), delivering a bending aid (3) to the fed winding wire (2) in a step ia), so that the winding wire (2) is held by the bending aid (3).

6. The method according to claim 5, wherein the winding wire (2) used is a flat wire, which is held in an upright position by the bending aid (3).

7. The method according to claim 5, wherein during step ii), in particular, for example, after a 90 rotation of the shaping core (4), the bending aid (3) is withdrawn from engagement with the winding wire (2) in a step iia).

8. The method according to claim 7, wherein steps i) and ii), in particular, i), ia), ii), iia) are carried out repeatedly.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The invention is explained in greater detail below with reference to the FIGS. 1 through 13.

[0020] FIG. 1 shows a detail, in which a shaping core is wound with winding wire,

[0021] FIG. 2 shows a wire outlet nozzle arrangement having winding wires and a deliverable bending aid,

[0022] FIG. 3 schematically shows a part of a stator core or a rotor core, in which a winding is inserted into the grooves,

[0023] FIGS. 4 through 10 show a sequence of winding steps,

[0024] FIG. 11 shows the production of a winding head based on the prior art,

[0025] FIG. 12 shows the production of a winding head based on the hairpin technology, and

[0026] FIG. 13 shows the production of a winding head based on the method according to the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0027] FIG. 1 shows a shaping core 4, which is in the process of being wound. The winding wires 2 are guided through the comb-like ends 3a of the bending aid 3 and have been placed on the flat side of the shaping core 4. The winding wires 2 are held on the shaping core 4 by means of wire holder elements 6. The wire holder elements 6 are preferably gripper jaws, which grasp the winding wire 2 and press it against the shaping core 4.

[0028] The bent sections 2a of the winding wire are shown at the lower end of the shaping core 4. The situation shown is chronologically shortly before the shaping core 4 starts to rotate about the center axis, which is situated in the drawing plane. As the rotation starts, the winding wires 2 are guided through the comb-like ends 3a of the bending aid 3 in order to prevent the winding wire 2 from twisting during bending. The wire holder elements 6 are subsequently moved on the shaping core 4 in a direction transverse to the orientation of the winding wire, in order to achieve a predefined offset of the winding wire 2, a setting, during bending. In the process, the winding wire 2 drops onto the blade due to the radial shortening in the projection and the installation space used by the bending aid 3 is no longer present. The winding process is explained in greater detail below with reference to the FIGS. 4 through 10.

[0029] FIG. 2 shows a wire outlet nozzle arrangement 1, from which multiple winding wires 2 exit. The bending aid 3, which may be moved in the X-direction relative to the wire outlet nozzle arrangement 1, is situated in the area of the outlet nozzles (below the latter in the example shown). The situation shows the bending aid 3 with the comb-like ends 3a in a partially extended state. The intermediate spaces between the teeth or projections of the comb-like end 3a are wider than the narrow side of the winding wire 2, so that the winding wire is able to drop into the intermediate spaces of the comb in the upright position. At the same time, the intermediate space is significantly narrower than the wide side of the flat winding wire 2, so that the bending aid thus designed prevents the winding wire 2 from being able to twist during bending and thus from yielding via the narrow side.

[0030] FIG. 3 shows a detail of a stator core or rotor core 5, in which a flat wire 2 consisting of a flat material is inserted into the grooves 5a. The winding wire 2 is bent in the direction of the narrow side toward a winding head 2a and is therefore not protracted in the direction of the circumference of the stator or the rotor. Such a design allows for a very compact construction of the stator or rotor.

[0031] FIG. 4 shows the initial situation of a winding. The smallest thickness of the shaping core 4 points upwardly. The winding wires are placed on the upper side and are held by the wire holder elements 6. The winding wires 2 exit from the wire outlet opening arrangement 1. The bending aid 3, which in a non-use situation is located below the wire outlet nozzle arrangement, is above (below would also be conceivable) the wire outlet nozzle arrangement 1. The two sections 2a of the winding wire 2, which exhibit a distinct curvature and originate from a preceding winding cycle, are shown at the left and right ends of the shaping core 4.

[0032] In FIG. 5, the bending aid 3 is delivered to the comb-like end 3a by having been moved in the arrow direction X from the non-use position. In FIG. 6, the shaping core 4 begins to rotate, wherein the winding wires 2 are guided into the comb-like ends 3a of the bending aid 3. In FIG. 7, the shaping core 4 has been rotated by 90, and the winding wire 2 has been bent by 90 at the section 2a, wherein the winding wire 2 at that point is guided through and held at the comb-like end 3a of the bending aid 3. In this situation, the winding wire 2 is above the tip of the shaping core 4. This corresponds to the situation depicted in FIG. 1. The bending aid 3 is subsequently returned again to the non-use position below the wire outlet nozzle arrangement 1, as shown in FIG. 8.

[0033] In the next step, the placed winding wires 2 are pulled in by means of the wire holder elements 6 in the drawing plane, as a result of which the winding wires 2 are interlocked and the winding heads 2a of the winding wires 2 produced by the bending end up on the narrow side of the shaping core 4, as is shown in FIG. 9. This produces, as when a prefabricated U-hairpin is set (compare FIG. 12), a different shape of the wire transition in the winding head optimized for the compactness of the winding head 2a.

[0034] Finally, as shown in FIG. 10, the shaping core 4 is rotated further until a 180 rotation is completed. The newly wound winding wires 2, which are supported on top of the shaping core 4, are grasped and held in place by the wire holder elements 6. The next winding cycle according to FIGS. 4 through 10 may then be repeated.

[0035] In addition, the inclusion of the bending aid 3 with its comb-like end 3a prevents the winding wire 2, especially during the bending process, from yielding to the bending movement via the narrow side by twisting during the bending. With such a bending aid 3, it is possible to reliably shape a narrow flat wire 2 via the narrow side to form a wave winding and to thus integrate it in a stator core or a rotor core 5 in a cost-effective and space-saving manner.

[0036] The reshaping process according to the invention is schematically shown once again in FIG. 13. During the creation of a wave winding, an integrated pre-bending process and a subsequent setting process are carried out by means of the bending aid 3. This involves a two-stage reshaping process: The winding wire 2 is initially bent for placement on the shaping core (P3) and after subsequent placement on the shaping core, the setting (P1, P2) is carried out, in which the two straight sections of the wire are pulled apart relative to one another in the direction of the arrows B1, respectively PII. In this way, it is also possible to produce winding heads 2a which, as in the hairpin technology (cf. FIG. 12), are more helical and may be very compactly designed in the product produced with the wave windings. In the particular case described herein in which upright wound flat wire is used (other wire geometries are also conceivable), the comb shape of the bending aid also prevents the flat wire from tipping out during bending and a stable uniform winding pattern is produced.