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 for producing a winding bar for a stator winding of a stator of a rotating electric machine, comprising: two processing units which are arranged at a variable distance from one another, wherein each processing unit has processing means for processing an end portion of the winding bar, wherein each processing means is arranged on the respective processing unit so as to be pivotable about a pivot axis via at least one respective pivot arm, wherein the pivot axis is identical to a longitudinal center axis of the rotating electric machine, and wherein a radial distance between each processing means is variable relative to the pivot axis.

2. The system as claimed in claim 1, wherein a first processing means 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 and then to deform the resulting, angled-off portion of the winding bar about a bending axis extending transversely to the pivot axis in order to form a winding head portion of the winding bar.

3. The system as claimed in claim 2, wherein at least one processing unit has at least one lifting crane 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.

4. The system as claimed in claim 2, wherein at least one processing unit has a plurality of processing means 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, and wherein each gripper is functionally connected to a respective actuator by means of which the respective gripper is moved back and forth on the respective pivot arm radially and/or parallel to the pivot axis.

5. The system as claimed in claim 2, wherein a second processing means 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.

6. The system as claimed in claim 2, wherein at least one processing unit has at least one processing means 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 is severed from the angled-off portion.

7. The system as claimed in claim 1, further comprising: at least one system electronics which is designed to arrange the processing units with respect to one another and to arrange the individual processing means relative to the pivot axis and also to control the processing means in dependence on predetermined structural parameters of the rotating electric machine.

8. A method for producing a winding bar for a stator winding of a stator of a rotating electric machine, comprising: providing a winding bar blank; determining structural parameters of the rotating electric machine with respect to a longitudinal center axis of the rotating electric machine; arranging processing means with consideration to the determined structural parameters of the rotating electric machine; and carrying out temporally sequential processing steps on the winding bar blank by means of the processing means.

9. The method as claimed in claim 8, wherein at least one position of an opening cone of a winding head of the stator relative to the longitudinal center axis and a cone angle () of the opening cone of the winding head are determined as structural parameters of the rotating electric machine.

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

11. The system as claimed in claim 4, wherein each gripper is functionally connected to a respective actuator by means of which the respective gripper is moved back and forth on the respective pivot arm radially and/or parallel to the cone angle ().

12. The system as claimed in claim 1, wherein the processing means comprise: an angle deformer adapted to produce an angled-off portion of the winding bar, grippers adapted to clamp the angled-off portion of the winding bar, a deformer adapted to deform a free end portion of the angled-off portion of the winding bar about a bending axis, and a separating unit adapted to sever an end portion of the free end portion of the angled-off portion of the winding bar.

13. The method as claimed in claim 8, wherein the processing means comprise: an angle deformer adapted to produce an angled-off portion of the winding bar, grippers adapted to clamp the angled-off portion of the winding bar, a deformer adapted to deform a free end portion of the angled-off portion of the winding bar about a bending axis, and a separating unit adapted to sever an end portion of the free end portion of the angled-off portion of the winding bar.

14. The method as claimed in claim 13, wherein the sequential processing steps comprise: producing the angled-off portion of the winding bar with the angle deformer, clamping the angled-off portion of the winding bar with the grippers, deforming the free end portion of the angled-off portion of the winding bar about the bending axis with the deformer, and severing the end portion of the free end portion of the angled-off portion of the winding bar with the separating unit.

15. The method as claimed in claim 8, wherein the rotating electric machine is a turbogenerator.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] An embodiment of a system according to the invention is explained below with reference to the appended schematic drawings, in which:

[0021] FIG. 1 shows a schematic illustration of an exemplary embodiment of a system according to the invention;

[0022] FIG. 2 shows a schematic illustration of a processing unit of the system shown in FIG. 1;

[0023] FIG. 3 shows a further schematic illustration of the processing unit shown in FIG. 2; and

[0024] FIG. 4 shows a schematic and perspective illustration of the processing unit shown in FIGS. 2 and 3.

DETAILED DESCRIPTION OF INVENTION

[0025] 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.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] 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.

[0030] 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 .

[0031] 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.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.