Method for Producing a Single- Or Multi-Layer Coil, Layer Coil, Electric Machine, and Device

Abstract

A method for producing a single- or multi-layer coil, includes the steps of: providing a flat wire; deforming the flat wire along a deforming direction in order to produce one or more winding sections which are designed to be offset relative to a starting section of the flat wire, wherein the one or more winding sections are designed to form coil layers which run on winding planes arranged in an offset manner relative to the deforming direction; and winding the one or more winding sections on the respective winding plane in order to form one or more coil layers.

Claims

1.-15. (canceled)

16. A method for producing a single or multiple layer coil, the method comprising the steps of: providing a flat wire; deforming the flat wire along a deforming direction in order to produce one or more winding sections configured to be offset in relation to a starting section of the flat wire, wherein the winding section or sections are designed to form coil layers which run in winding planes arranged in an offset manner relative to the deforming direction; and winding the winding section or sections within the respective winding plane to form one or more coil layers.

17. The method according to claim 16, further comprising the step of: arranging the flat wire in a deforming tool in order to produce an S-shaped deforming region.

18. The method according to claim 16, wherein the flat wire has a rectangular cross section, and the deforming direction is perpendicular to a short side of the rectangular cross section.

19. The method according to claim 16, further comprising the step of: producing the winding sections before the winding of the one or more coil layers.

20. The method according to claim 16, further comprising the step of: forming an end section of the coil layer in a last of, or a single one of, the winding plane.

21. The method according to claim 16, wherein successive coil layers are wound one after the other.

22. The method according to claim 16, further comprising the step of: winding the one or more one coil layers from inside to outside.

23. The method according to claim 16, further comprising the step of: arresting at least the starting section in an interlocking and/or frictionally engaging manner during the winding.

24. The method according to claim 16, further comprising the step of: introducing an angle, which is adapted to a slot angle, of a stator, between the winding planes.

25. A layer coil, comprising: at least one coil layer formed from a flat wire, wherein the at least one coil later lies in a winding plane which is offset in relation to a coil beginning of the layer coil, and wherein the offset is produced by deforming the flat wire along a deforming direction which is oriented perpendicularly or substantially perpendicularly to the winding plane.

26. The layer coil according to claim 25, further comprising: a multiplicity of coil layers, wherein the coil layers are respectively kept at a distance from one another by an offset, and wherein each offset is produced by deforming the flat wire along a deforming direction which is oriented perpendicularly or substantially perpendicularly to the winding planes of the coil layers.

27. The layer coil according to claim 26, wherein a number of the coil layers are oriented at an angle in relation to one another, which angle is adapted to a slot angle.

28. An electric machine comprising at least one layer coil according to claim 25.

29. A device for producing a single or multilayer coil, comprising: two guiding sections by way of which a flat wire can be wound to form one or more coil layers, wherein the guiding sections have guiding elements which are designed for guiding the flat wire.

30. The device according to claim 29, further comprising: means for arresting the flat wire and/or the already formed layer coil in an interlocking and/or frictionally engaging manner.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] FIG. 1 is a schematic view of a flat wire and of a forming tool;

[0041] FIG. 2 shows a number of views of a schematically represented layer coil;

[0042] FIG. 3 shows a schematically represented multi-layer coil in a side view;

[0043] FIG. 4 shows a view (seen along a longitudinal axis) of a multi-layer coil in a schematic representation.

DETAILED DESCRIPTION OF THE DRAWINGS

[0044] FIG. 1 schematically shows a flat wire 1, it having a starting section 12, which is offset with respect to a winding section 2 by an offset x. The aforementioned offset x is achieved by way of a deforming region 3, which may also be referred to as a twisted S shape. The deforming region 3 is introduced by deforming the flat wire 1 along a deforming direction U, as indicated by the arrow. The winding section 2 subsequently lies in a plane E, which is offset with respect to the starting section 12 by the offset x. Schematically indicated in the right-hand half of FIG. 1 is a forming tool 20, which has an upper die and a lower die and which is intended to deform a flat wire 1 arranged in between in such a way that a deforming region 3 is created. Depending on whether a single- or multi-layer coil is to be created, a number of such deforming regions 3 may be created.

[0045] FIG. 2 shows in a number of schematic views an embodiment of a single-layer coil. In the middle view it can be seen how a layer coil 10, which has a coil layer 16 in a winding plane E, is formed from a flat wire 1, such as that indicated in FIG. 1. The layer coil 10 comprises a starting section or coil beginning 12 and also an end section or a coil end 14, which respectively project beyond the coil layer 16, cf. in this respect also the view represented on the left. The coil layer 16 and the coil end 14 are offset or kept at a distance in relation to the coil beginning 12 by an offset x, this being created by way of a deforming region 3. In the view on the left, the form or shape of the coil layer 16 can be seen. In particular, it can be seen that the coil layer 16 is wound from the inside to the outside. Shown on the right is the section A-A, as it is indicated on the left. The windings of the flat wire 1 can be seen in the section, with the rectangular cross section evident in particular. The deforming direction U is perpendicular or substantially perpendicular to the short side of the flat wire 1. Correspondingly, considerable force is required during the deforming along the deforming direction U. A forming tool 20, such as that indicated in FIG. 1, is correspondingly advantageously used for this. The winding itself for forming the at least one coil layer 16 takes place around the long side, with less expenditure of force being required to do so.

[0046] FIG. 3 shows a multi-layer coil 10, the basic construction being the same as in the case of the single-layer coil, cf. FIG. 2. However, in the present case a number of winding planes E are formed, in which coil layers 16 are respectively formed. Correspondingly, a number of deforming regions 3 are likewise formed. The reference signs 30 denote guiding sections of a device or a tool which is used for forming the layer coil. The guiding sections 30 comprise guiding elements 32, which are intended to guide, arrest or position, etc., regions or sections of the layer coil 20. In particular, guiding elements 32 by way of which the deforming regions are guided and positioned are provided for example. Expediently, all of the deforming regions 3 are created by tools such as those indicated in FIG. 1. However, not all of the deforming regions must in this case have exactly the same form. In particular, the deforming region between the starting section 12 and the first winding plane E expediently has a different form than the deforming regions 3 between the winding planes E. Reference sign 34 indicates two clamping elements which are designed to arrest the starting section or coil beginning 12 of the layer coil 10 during the winding. Alternatively, a number of such clamping elements 34 may also be provided or arranged to hold the layer coil 10 in some sections during the winding.

[0047] FIG. 4 shows a view seen along a longitudinal axis of the multi-layer coil 10, comprising in the present case three coil layers 16. It is indicated that the winding planes E, in which the coil layers 16 run, are not oriented parallel to one another but are at an angle ? in relation to one another which is expediently adapted to a slot angle, for example of a stator, at which the layer coil 10 is intended to be arranged.

LIST OF REFERENCE SIGNS

[0048] 1 Flat wire [0049] 2 Winding section [0050] 3 Deforming region, twisted S shape [0051] 10 Layer coil [0052] 12 Starting section, coil beginning [0053] 14 End section, coil end [0054] 16 Coil layer [0055] 20 Forming tool [0056] 30 Guiding sections [0057] 32 Guiding element [0058] 34 Clamping elements [0059] x Offset [0060] ? Angle [0061] W Winding plane