Abstract
A method for producing a formed coil winding includes providing a main body having a plurality of slots distributed across the circumference for arranging layered coils; providing at least one layered coil having a first coil side and a second coil side; arranging the first coil side in a slot in the main body, wherein the layered coil forms a projection at each of the two ends of the main body; form-fittingly and/or frictionally holding the first coil side in an exit region from the slot for holding the first coil side in the slot in a rotationally fixed manner; twisting the coil sides relative to one another in a circumferential direction until the second coil side is aligned with another slot in the main body; and radially shifting the second coil side for arrangement in the other slot.
Claims
1-14. (canceled)
15. A method for producing a formed coil winding, comprising: providing a main body comprising a plurality of slots arranged so as to be distributed on a circumference for arranging layered coils, wherein the main body extends along a longitudinal axis; providing at least one layered coil, wherein the at least one layered coil has at least one first coil side and at least one second coil side; arranging the at least one first coil side in a slot of the plurality of slots of the main body, wherein the at least one layered coil forms in each case one protrusion on both ends of the main body; holding the at least one first coil side in a form-fitting and/or force-fitting manner in a region of an exit from the slot, so as to hold the at least one first coil side in a rotationally fixed manner in the slot; twisting the at least one first coil side and the at least one second coil side along a circumferential direction relative to one another until the at least one second coil side is co-aligned with another slot of the plurality of slots of the main body; and radially displacing the at least one second coil side for arrangement in the other slot.
16. The method according to claim 15, comprising: providing an auxiliary tool comprising at least one auxiliary slot; arranging the at least one second coil side in the at least one auxiliary slot; and holding the at least one second coil side in a form-fitting and/or force-fitting manner in a region of the exit from the at least one auxiliary slot, so as to hold the at least one second coil side in a rotationally fixed manner in the at least one auxiliary slot.
17. The method according to claim 15, comprising: holding the at least one first coil side in the form-fitting and/or force-fitting hold using interlock plates that are in each case arranged or configured to be arranged on the exit from the slot, further comprising: arranging a first interlock plate and a second interlock plate on an end side on the respective exit from the slot, wherein the interlock plates have contact faces oriented toward one another; and twisting the interlock plates relative to one another in the circumferential direction, wherein the at least one first coil side is held in the form-fitting and/or force-fitting manner by way of the contact faces.
18. The method according to claim 15, comprising: bending the at least the one first coil side and the at least one second coil side by bending portions.
19. The method according to claim 15, comprising: arranging coil starts and/or coil ends in a guide element in which the coil ends are entrained during twisting.
20. The method according to claim 15, comprising: radially supporting the at least one first coil side and the at least one second coil side during twisting by arranging a support element which has a radially outward oriented support face.
21. The method according to claim 15, comprising: simultaneously arranging a slot wedge when radially displacing the at least one second coil side into the slot, wherein the slot wedge is configured to latch in a form-fitting and/or force-fitting manner into the slot.
22. A stator, produced according to the method according to claim 15.
23. The stator according to claim 22, comprising: a plurality of slots, wherein the plurality of slots have in each case at least one engagement portion which is configured to provide the form-fitting and/or force-fitting arrangement of a slot wedge.
24. A tool for producing formed coil windings, comprising: two interlock plates arranged along a rotation axis, wherein the interlock plates are configured to form at least one opening which is configured for arrangement of at least one coil side of a layered coil, wherein the at least one opening has contact faces which are oriented toward one another in a circumferential direction; and wherein the contact faces are configured to be mutually moved in the circumferential direction in such a manner that the at least one coil side is held in a form-fitting and/or force-fitting manner.
25. The tool according to claim 24, wherein the interlock plates have in each case one base plate and a plurality of webs extending radially away from the base plate, and wherein the contact faces are formed on the base plate and on the webs.
26. The tool according to claim 25, wherein the webs are L-shaped.
27. The tool according to claim 25, wherein the webs, conjointly with the base plate, are configured to completely or almost completely enclose the at least one coil side.
28. The tool according to claim 25, wherein at least one web has a bending portion.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0056] FIG. 1 shows schematic views of a stator body for visualization of the method;
[0057] FIG. 2 shows a schematic view of a stator body when viewed along the longitudinal axis thereof, wherein an auxiliary tool is arranged in the stator body;
[0058] FIG. 3 shows a plurality of schematic views of a layered coil;
[0059] FIG. 4 shows a schematic detailed view in which the twisting of the layered coils is schematically shown in a diagram;
[0060] FIG. 5 shows two perspective views of embodiments of interlock plates;
[0061] FIG. 6 shows a diagram for visualization of the form-fit and/or force-fit by way of the interlock plates;
[0062] FIG. 7 shows two schematic views for illustration of the method sequence when expanding a coil side of a layered coil into a slot;
[0063] FIG. 8 shows a schematic partial view of a slot of a main body, in which a slot wedge is arranged;
[0064] FIG. 9 shows two schematic views which show an embodiment of a support element and of a guide element; and
[0065] FIG. 10 shows a schematic view of a main body for visualization of the position of a tool, of two guide elements and of a support element.
DETAILED DESCRIPTION OF THE DRAWINGS
[0066] FIG. 1 in a schematic illustration shows on the left a main body 10, wherein this is a stator body, for example. The latter extends along a longitudinal axis L, or a rotation axis R, respectively. By way of example, a layered coil 20 is arranged in a slot of the stator body 10. The layered coil 20 exits the slot in each case at the end side of the stator body 10, cf. reference signs 14, which denote the respective slot exit. The layered coil 20 forms in each case a protrusion on the end side of the stator body 10. The main body is illustrated in the center, when viewed along the longitudinal axis L, or along the rotation axis R, respectively. The slots 12 are schematically illustrated as radially extending lines, cf. reference sign 12 (for reasons of clarity, only one slot is provided with a reference sign). The layered coil 20 is arranged in the upper slot 12, at the 12 o'clock position, but only by way of one coil side. (In order to form a formed coil) the other coil side must be arranged in a slot that is spaced apart therefrom, as is schematically shown on the right. Intense forces act on the layered coil 20 in the process. Layered coils are in each case preferably arranged in all slots, whereby these layered coils are expediently deformed in an automated and simultaneous manner. An auxiliary tool as is schematically shown in FIG. 2 is expediently used herein.
[0067] FIG. 2 shows the stator body 10, substantially known from FIG. 1, when viewed along the longitudinal axis L, wherein an auxiliary tool 30 is formed/arranged in the interior, and in turn has a multiplicity of slots 32 of a congruent design. An auxiliary tool 30 of this type allows a multiplicity of layered coils to be simultaneously deformed.
[0068] FIG. 3 shows in a schematic view an embodiment of a layered coil 20, wherein the layered coil 20 has a coil start 24 and a coil end 26. The layered coil 20 has a first coil side 21 and a second coil side 22. The layered coil 20 schematically illustrated here is a simple layered coil. Additionally, there are also multiple layered coils, for example double, triple, quadruple layered coils, etc. The cross section, schematically illustrated with A-A, is on the extreme right. The layered coil 20 is expediently formed from a flat wire which preferably has an angular, presently in particular a rectangular, cross-sectional shape. The arrangement of the layered coil when producing the formed coil winding expediently takes place in such a manner that, for example, the first coil side 21 is arranged in the stator body, and the second coil side 22 is arranged in an auxiliary tool (cf. reference sign 30 in FIG. 2), or in a correspondingly designed and positioned slot. The coil sides 21 and 22 are mutually twisted by twisting the auxiliary tool relative to the main body or stator body. In particular in the region of its protrusions, the layered coil 20 is shaped into a more or less complicated three-dimensional structure. Once the second coil side(s) has/have been moved to a desired position, it or they is or are displaced or expanded by being displaced radially into the corresponding slot of the stator body. Accordingly, a triple layered coil would have three first coil sides 21 and accordingly three second coil sides 22.
[0069] FIG. 4 shows in a schematic view three layered coils 20 during twisting. Illustrated in particular is a slot exit 14 from a main body 10, wherein the latter extends along a longitudinal axis L. Reference sign U schematically indicates a circumferential direction. An intermediate plate 43 is arranged on the end side of the stator body or main body 10. Arranged adjoining thereto is a tool 40 which has a first interlock plate 41 and a second interlock plate 42. The interlock plates 41 and 42 form in each case openings 44 along the longitudinal axis L, through which the layered coils or coil sides protrude; cf. reference sign 20. For reasons of clarity, only one opening is presently provided with a reference sign (cf. reference sign 44). The arrows, which are provided with the reference sign S, identify a potential displacement direction of the respective interlock plates 41, 42. By converging the interlock plates 41, 42, the layered coils 20 arranged therebetween can be held in a form-fitting and/or force-fitting manner. As a result, the layered coils 20, or in particular the coil sides thereof, are securely positionally fixed in relation to the main body 10 and in particular also held in a rotationally fixed manner in the slots of the main body 10. The layered coils 20 are deformed or twisted, respectively, as is schematically indicated by the arrow with the reference sign V. However, the tool 40 holds the layered coils 20 reliably within the respective slot in the region of the slot exit 14, and prevents tilting or twisting of the layered coils 20, or of the corresponding coil sides, in the respective slot.
[0070] FIG. 5 shows in two perspective views two embodiments of interlock plates 41 and 42, respectively. A base plate from which extend in each case a multiplicity of webs 45 can be seen in each case. Only three webs 45 are in each case schematically illustrated here. Likewise, the base plates are not completely illustrated. In reality, the base plates are preferably segments of a circle which have webs of this type on the entire circumference. It can be seen that contact faces 46 are expediently provided or formed in each case on the webs as well as on the base plate, which contact faces 46 are conceived for bearing on, or contacting, respectively, the layered coils. The webs 45 are presently expediently designed to be L-shaped, as a result of which the layered coils 20 can be held completely or at least almost completely in a form-fitting manner. The webs 45 of the second interlock plate 42 expediently have bending portions 48. The function of the latter will become evident in particular upon viewing FIG. 4. The layered coils can be securely guided by the bending portions 48 during twisting. It can in particular be additionally ensured by way of a corresponding basic design of the radii of the bending portion(s) 48 that the deformation of the layered coils takes place to the greatest extent possible in a gentle manner and by a reliable process.
[0071] FIG. 6 shows the holding of a layered coil 20 in a form-fitting and/or force-fitting manner in an opening 44, which is implemented by the webs 45 of two interlock plates 41 and 42, as viewed along a longitudinal axis L. It can be seen that the layered coil 20 is securely held circumferentially by way of the geometry of the webs 45, which is presently preferably L-shaped, such that twisting of the layered coil 20 within the slot of the auxiliary tool, or else of the stator body, is avoided. An insulation applied to the layered coil, and the material of the layered coil per se, are expediently not damaged.
[0072] FIG. 7 shows in a schematic view a main body 10 in the region of a slot 12, wherein a slot 32 of an auxiliary tool 30 is arranged so as to be co-aligned with the slot 12. Apart from the (dual layer) coil side 22 of a layered coil 20, a slot wedge 70 and an expansion tool 80 are arranged in the slot 32 of the auxiliary tool 30. The second coil side of the layered coil 20 is arranged in the slot 12 of the main body 10 by displacing the second coil side 22 along an expansion direction E by the expansion tool 80, as is schematically illustrated in the right-hand half of the image. The slot wedge 70 is advantageously conjointly displaced at the same time in the process. The slot 12 furthermore advantageously has engagement portions 16 which are conceived to interact in a form-fitting and/or force-fitting manner with the slot wedge 70. The slot wedge 70, once moved to the corresponding position, is thus expediently automatically fixed in the slot 12. As is illustrated by the arrow in the right-hand half of the image, the expansion tool 80 can be returned. The slot wedge 70 is securely latched in the installed position thereof.
[0073] FIG. 8 shows a slot 12 of a main body 10 in an enlarged illustration. The substantial features are already known from FIG. 7. Illustrated in particular is a slot wedge 70 which is conceived to latch, or snap, into correspondingly designed engagement portions 16 of the slot 12. To this end, the slot wedge 70 is expediently designed to be correspondingly resilient or elastic, in particular transversely to the longitudinal axis L schematically illustrated in FIG. 8.
[0074] FIG. 9, in the left-hand half of the image thereof, shows a schematic view of a support element 60 which has a support face 62 on the circumference. Two guide elements 50, which have in each case a multiplicity of openings 52 that serve for arranging, or guiding through, the corresponding coil starts or coil ends of the layered coils are illustrated in the right-hand half of the image. It is to be ensured in particular by the guide elements 60 that the coil ends or coil starts of the layered coils are not impermissibly displaced during twisting of the layered coils. In other words, the coil starts or coil ends can be reliably entrained by the guide elements 50 and in this way be positioned, this being decisive for the automation capability of the method. The support element 60 serves in particular as an inner detent during the twisting of the layered coils.
[0075] FIG. 10 shows in a schematic view an embodiment of a main body 10 which extends along a longitudinal axis L. Illustrated in particular is the arrangement of a tool 40, of a support element 60 and of two guide elements 50 for guiding the coil starts and ends, respectively. The diagram is intended to schematically highlight the arrangement of the different elements.
LIST OF REFERENCE SIGNS
[0076] 10 Main body, stator body [0077] 12 Slot [0078] 14 Slot exit (main body, stator body) [0079] 16 Engagement portion [0080] 20 Layered coil [0081] 21 First coil side [0082] 22 Second coil side [0083] 24 End portion [0084] 30 Auxiliary tool [0085] 32 Auxiliary slot [0086] 34 Slot exit (auxiliary tool) [0087] 40 Tool [0088] 41 First interlock plate [0089] 42 Second interlock plate [0090] 43 Intermediate plate [0091] 44 Opening [0092] 45 Web [0093] 46 Contact face [0094] 48 Bending portion [0095] 50 Guide element [0096] 52 Opening [0097] 60 Support element [0098] 62 Radial support face [0099] 70 Slot wedge [0100] 80 Expansion tool [0101] L Longitudinal axis [0102] R Rotation axis [0103] U Circumferential direction [0104] E Expansion direction [0105] S Displacement direction [0106] V Twisting direction
