METHOD AND LINEAR DEVICE FOR LINEAR WINDING OF A RECTANGULAR WIRE

Abstract

A method for winding a rectangular wire in a winding space of a coil former or of a winding tool to form a linearly wound coil, wherein the rectangular wire in the winding space is wound in at least one layer in an axial laying direction. Before the coil is wound, a guide device is introduced at least partially into the winding space, and the guide device has, in the laying direction, a stop which delimits the rectangular wire in the laying direction; the guide device is entrained, during the winding process, as the winding of the coil in the laying direction increases; and the guide device is withdrawn from the winding space before the last winding is wound in front of a second lateral stop. A linear winding device for performing the method is disclosed.

Claims

1. A method for winding a rectangular wire in a winding space of a coil former to form a linearly wound coil, wherein the rectangular wire in the winding space is wound in at least one layer in an axial laying direction, having the method steps of: feeding the rectangular wire to a lateral contact of the winding space and holding the wire in relation to the coil former; linear winding of the coil by rotating the coil former while forming windings and continuously feeding the rectangular wire from a feed tracked in the laying direction until the last winding of the layer is wound in the laying direction; wherein a) before winding the coil, a guide device is at least partially inserted into the winding space, wherein the guide device has a stop in the laying direction which limits the rectangular wire in the laying direction; b) the guide device is entrained during winding as the winding of the coil in the laying direction increases; and c) the guide device is moved out of the winding space before the last winding is wound in front of a second lateral contact.

2. The method according to claim 1, wherein the guide device has a guide roller which rolls on the rectangular wire and the guide roller of the guide device has a stepped diameter and between a small diameter and a large diameter the stop is provided for the rectangular wire, and wherein the guide roller with the small diameter rolls on the rectangular wire and with the large diameter limits the rectangular wire in the laying direction.

3. The method according to claim 1, wherein at least one of the windings is pressed against a winding base by means of at least one pressure roller.

4. The method according to claim 1, wherein fixing rollers are provided in a feed of the wire in front of the guide device, which can be displaced in the laying direction, wherein during winding the guide device follows the fixing rollers in the laying direction.

5. The method according to claim 1, wherein the guide device is turned after step c) in relation to the laying direction, so that the stop is reversed with respect to the lateral contacts and the rectangular wire and another layer of the coil is wound according to the method.

6. The method according to claim 1, wherein the guide device is at least one of resiliently mounted in relation to the coil former or tracked in a force or path controlled manner.

7. The method according to claim 2, wherein the guide roller has a reshaping effect on the rectangular wire at least temporarily during unwinding.

8. A linear winding device for winding a rectangular wire in at least one layer in an axial laying direction in a winding space of a coil former to form a linearly wound coil, the device having a rotatably driven carrier for receiving a coil former, wherein the device is provided for winding the rectangular wire fed to the device in a feed direction from a feed in a linear winding method of a laying direction in the winding space of the coil former, wherein the device has a guide device movable in the laying direction for guiding the rectangular wire in the winding space, wherein the guide device guiding the rectangular wire in the laying direction has a limiting stop, and the guide device is resiliently mounted in relation to the coil former or is movable in a force or path controlled manner.

9. The linear winding device according to claim 8, wherein the guide device can be turned with respect to the laying direction so that the stop of the guide device is in the laying direction when the laying direction is reversed rests on the supplied rectangular wire.

10. The linear winding device according to claim 8, wherein the device has at least one pressure roller for pressing the supplied rectangular wire.

11. The linear winding device according to claim 8, wherein the guide device has a guide roller which rolls on the rectangular wire and the guide roller of the guide device has a stepped diameter and between a small diameter and a large diameter the stop is provided for the rectangular wire, and wherein the guide roller with the small diameter rolls on the rectangular wire and with the large diameter limits the rectangular wire in the laying direction.

12. The linear winding device according to claim 8, the guide device can turn in relation to the laying direction, so that the stop can be reversed with respect to the lateral contacts and the rectangular wire and another layer of the coil can be wound.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Further features, details and advantages of the disclosure result from the wording of the claims and from the following description of exemplary embodiments with reference to the drawings. In the figures:

[0027] FIG. 1: shows a schematic method sequence for linear winding of a coil winding according to an embodiment of the method with four-sided delimitation of the rectangular wire;

[0028] FIG. 2: shows a schematic method sequence for linear winding of a coil winding according to an embodiment of the method with three-sided delimitation of the rectangular wire;

[0029] FIG. 3: shows a schematic representation of a linear winding device for carrying out the method.

[0030] Unless otherwise stated, the reference signs will be used consistently below. Unless otherwise stated, the reference signs in the text always refer to all figures. Likewise, unless otherwise stated, all reference signs in the figures always refer to the entire description of the exemplary embodiments below.

DETAILED DESCRIPTION

[0031] FIGS. 1 and 2 show a schematic method sequence for linear winding of a coil winding according to an embodiment of the method with a four-sided delimitation of the rectangular wire 20 (FIG. 1) and with a three-sided delimitation of the rectangular wire 20 (FIG. 2). A rectangular wire 20 held on a lateral contact 16, 18 of a winding space 12 of a coil former 10 or a winding tool 10 is wound around the coil former 10 or the winding tool 10 according to the linear winding method, in that it is rotatably driven. The rectangular wire 20 is offset in the laying direction V so that a layer 24 of windings 21 of the rectangular wire 20 results in the winding space 12. For the method, it is provided in both embodiments that before winding the coil, a guide device 30 is at least partially inserted into the winding space 12, wherein the guide device 30 has a stop 34 in the laying direction V which limits the rectangular wire 20 in the laying direction V.

[0032] In the embodiment according to FIG. 1, the rectangular wire 20 is limited in all spatial directions. In the laying direction V laterally through the first lateral contact 16 of the winding space 12 or through the previous winding 22 as well as through the stop 34 of the guide device 30 and, viewed radially with respect to the axis of rotation D of the coil former 10 or the winding tool 10, through the winding base 14 or the previous layer 25 of the winding and through the guide device 30. For this purpose, the guide device 30 has a guide roller 32 with an offset forming the stop 34, resulting in two diameters 36, 38. With the first, larger diameter 36, the guide roller 32 runs in the winding space 12 next to the retracted winding 21 and limits this in the laying direction V by the stop 34 formed. With the second, smaller diameter 38, the guide roller 32 rolls on the winding 21 of the rectangular wire 20.

[0033] The guide device 30 and/or the guide roller 32 is passively mounted with respect to the coil former 10 or the winding tool 10, wherein the guide roller 32 has a bias towards the coil former 10 or the winding tool 10. Alternatively, the guide device 30 and/or the guide roller 32 is actively guided. This can be done, for example, in a force or path controlled or regulated manner. In the case of active guidance, the flange-shaped stop 34 has a radial extent relative to the axis of rotation D of the coil former 10 or the winding tool 10, which is smaller than the height of the rectangular wire 20 or corresponds to the height of the rectangular wire 20. In the case of a passive bias of the rectangular wire 20, the radial extent of the flange-shaped stop 34 is also equal to or less than the height of the rectangular wire.

[0034] In the embodiment according to FIG. 2, the rectangular wire 20 is limited in only three spatial directions. In the laying direction V laterally through the lateral contact 16 of the winding space 12 or through the previous winding 22 as well as through the stop 34 of the guide device 30 and, viewed radially with respect to the axis of rotation D of the coil former 10 or the winding tool 10, through the winding base 14 or the previous layer 25 of the winding. In this example, the guide device 30 has a guide roller 32, which forms the lateral stop 34 for the outermost winding 21 of the current position 24 of the coil winding in the laying direction V.

[0035] In both exemplary embodiments, the guide device 30 is offset in the laying direction V until the penultimate turn 23 of a layer 24 has been wound and the last winding is ready for to be wound. The guide device 30 is moved out of the winding space 12 and the last winding of the current layer 24 is wound into the winding space 12 between the penultimate winding 23 and the second lateral contact 18 of the winding space 12 and by means of a pressure roller 50 (not in shown in FIGS. 1 and 2).

[0036] A new layer 24 is then started on the last winding and the laying direction V is reversed. The guide device 30 is reintroduced into the winding space 12 and in turn forms a stop 34 in the now reversed laying direction V for the rectangular wire 20 lying between the guide device 30 and the second contact 18 of the winding space 12. In the embodiment according to FIG. 1, the special feature is that the guide device 30 must be turned with the offset in the guide roller so that the stop 34 remains facing the rectangular wire.

[0037] Subsequently, in both embodiments, the further layer 24 of the coil winding is also wound according to the method described above until the penultimate winding 23 is produced. In principle, any number of layers 24, 25 can be wound. As soon as the penultimate winding of the last layer 24 has been wound, the guide device 30 is moved out of the winding space 12 and the last winding is inserted between the penultimate winding 23 and the respective lateral contact 16, 18.

[0038] In both embodiments of the disclosure it can be provided that a pressure roller 50 presses the wound windings 21, 22, 23 in the direction of the winding base 14.

[0039] FIG. 3 shows a schematic representation of a linear winding device 100 for carrying out the method. A rectangular wire 20 is fed to a guide device 30 in a feed direction Z by fixing rollers 40, 40. The guide device 30 guides the rectangular wire 20 in the winding space 12 of the coil former 10 or the winding tool 10. The rectangular wire 20 is held on a lateral contact 16, 18 of the winding space 12 and wound around the coil former 10 or the winding tool 10 by rotating the coil former 10 or the winding tool 10 about an axis of rotation D. It is understood that the present illustration is only schematic and that there are further components, such as a spindle, which drives the coil former 10 or the winding tool 10. The guide device 30 is movable in a laying direction V running in the plane of the drawing and has a stop 34 which limits the respective wound winding 21 of the rectangular wire 20 in the laying direction V. The guide device 30 is resiliently mounted in relation to the coil former 10 or the winding tool 10 or is movable in a force or path controlled or regulated manner. The linear winding device 100 also has a pressure roller 50 for pressing the supplied rectangular wire 20, which, like the guide device 30, is resiliently mounted in relation to the coil former 10 or the winding tool 10 or is movable in a force or path controlled or regulated manner.

[0040] All of the features and advantages resulting from the claims, description and drawings, including structural details, spatial arrangements and method steps, may be essential to the disclosure either alone or in various combinations.

LIST OF REFERENCE SIGNS

[0041] 10 Coil former, winding tool [0042] 12 Winding space [0043] 14 Winding base [0044] 16 First lateral contact [0045] 18 Second lateral contact [0046] 20 Rectangular wire [0047] 21 Winding [0048] 22 Preceding winding [0049] 23 Penultimate winding [0050] 24 Layer [0051] 25 Penultimate layer [0052] 30 Guide device [0053] 32 Guide roller [0054] 34 Stop [0055] 36 First diameter [0056] 38 Second diameter [0057] 40, 40 Fixing roller [0058] 50 Pressure roller [0059] 100 Linear winding device [0060] V Laying direction [0061] H Height [0062] D Axis of rotation [0063] Z Feed direction