DE102015004574B4 - Method for producing an electric motor - Google Patents

Abstract

Method for producing an electric motor for high motor currents,
wherein a ring winding made of bundled wire (1) is produced using a manufacturing device in a first process step with a first tool,
characterized in that
in a second method step, the winding is inserted between a lower molding tool (25, 26) of a second tool and an upper molding tool (25, 26) which is movable relative thereto,
wherein guide bolts (20) are connected to the lower and upper molding tools (25, 26) to guide the relative movement,
the lower and upper molding tools (25, 26) each have a recess extending transversely to the guide direction, into which the winding can be at least partially inserted,
wherein pins (31) subjected to spring force by a respective spring element (23) transversely to the guide direction are pressed against the inside of the winding, so that when the winding is deformed by the relative movement, the minimum bending radius is limited by means of the pins (31) and /or is complied with.

Description

The invention relates to a method for producing an electric motor.

From the US 2012/0293034 The welding of shaped wires of a wave winding is known.

From the DE 10 2008 021 779 A1 and the DE 10 2004 035 084 A1 Wave windings are known.

From the DE 10 2004 035 084 A1 Such a winding is known, which is made from one rotating wire per rotating shaft.

From the publication TZSCHEUTSCHLER, Rolf: Technology of electrical engineering. Berlin Verlag Technik GmbH, 1990. Chapter 4 “Basic technological processes for the production of windings” pages 272 - 372 - ISBN 3-341-00851-9, the closest state of the art is the production of a winding.

From the US 2010 / 0 180 977 A1 a winding apparatus is known.

From the WO 2013/129 029 A1 a coil manufacturing method is known.

From the WO 2014 / 050 409 A1 the production of windings of an electric motor is known.

From the DE 42 36 312 A1 a method for producing an excitation system for main-current motors is known.

From the US 2007 / 0 180 682 A1 an electrically rotating machine is known.

From the US 2012 / 0 293 034 A1 a stator of an electric motor is known.

From the DE 10 2008 021 779 A1 a method for producing a coil winding for a stator is known.

From the DE 10 2004 035 084 A1 a method for producing a coil winding for stators and rotors of electrical machines is known.

The invention is therefore based on the object of designing an electric motor for high motor currents that can be easily manufactured.

According to the invention, the object is achieved in the method according to the features specified in claim 1.

The advantage here is that a bundle wire winding with complex geometry can be produced in a simple manner by a pressing process, with the minimum bending radius being easily ensured.

In an advantageous embodiment, the depth of the depressions in the respective end region arranged transversely to the guide direction is deeper than between these end regions,
in particular, the depressions each run in a straight line between the assigned end regions,
in particular so that by means of the relative movement a loop region can be formed at the respective end region arranged transversely to the guide direction. The advantage here is that the loop areas can be produced in a simple manner.

In an advantageous embodiment, the pins are guided by means of an elongated hole in a guide plate, on which the spring elements are supported. The advantage is that the tour can be reached without any effort.

In an advantageous embodiment, the first tool has a bobbin, in particular a cylindrical bobbin, which is connected to a connecting plate on which a clamping means for clamping the bundle wire is provided,
in particular, the ring winding can be produced by wrapping the bobbin with bundle wire. The advantage here is that a very cost-effective, simple tool can be used to produce the ring winding.

In an advantageous embodiment, the manufacturing device has a third tool with which the winding formed by the second tool can be further shaped,
wherein the third tool, in particular stamp tool, has a base part on which two pressure plates are supported via spring elements, the pressure plates being connected to the base plate via respective linear guides, in particular guide bolts with corresponding recesses in the respective pressure plate,
wherein the third tool has a molding tool with contour sections, a first pressure plate pressing a winding section against a first contour section and a second pressure plate pressing another winding section against a second contour section,
in particular, the third tool having a groove in which the loop region formed by the second tool can be at least partially received. The advantage here is that there is a widening in the respective loop area adjacent area can be produced in a simple manner.

In an advantageous embodiment, the manufacturing device has a fourth tool, with which end regions of the winding formed by the third tool can be further shaped,
wherein the fourth tool has a pressure plate which presses the end region against the contour of a receiving plate.

Bolts are connected to the pressure plate and are guided in a slot in the mounting plate. The advantage here is that the end regions can be shaped separately and can therefore be easily prepared for the subsequent electrical connection.

In an advantageous embodiment, the bundle wire has two or more shaped wires, each of which is electrically surrounded by an insulating material, in particular insulating varnish, in particular baking varnish,
in particular, the shaped wires each have a rectangular or square wire cross section. The advantage here is that a high filling factor can be achieved in the groove of the laminated core of the stator, since the groove can be easily designed with a rectangular groove cross section and the shaped wire or the stack of shaped wires, i.e. the bundle wires, with only a very small free space between Wire and laminated core can be inserted into the groove.

In an advantageous embodiment, the winding is then shaped in such a way that the two molding tools are moved towards each other so that the winding has loop regions connected over a rectilinear region,
wherein the minimum bending radius of the loop areas is maintained by pins pressed onto the inside of the winding, transversely to the direction of movement, in particular the guide direction.

The advantage here is that the winding can be formed simply by pressing the molding tools together and thus loop areas can be formed, which are connected via a straight area, i.e. an area that does not have a curve.

In an advantageous embodiment, in a third method step, the winding is stretched in the winding axial direction and then the area adjacent to the respective loop area is shaped, in particular by a stamping tool. The advantage here is that the areas of the winding adjacent to the loop areas can be shaped separately.

In an advantageous embodiment, the end regions of the bundle wire are shaped in a fourth method step, in particular with a further, in particular fourth, tool. The advantage here is that the areas provided for the electrical connections can be deformed separately.

In an advantageous embodiment, in a fifth method step, the winding with further windings produced and deformed in this way, in particular with a further eleven such windings, are arranged next to one another to form a coil winding,
In a sixth process step, the coil winding is then shaped round and inserted into grooves in a laminated core to form an active part, such as the rotor or stator of the electric motor,
In a seventh process step, the electric motor is completed by adding and connecting further parts. The advantage here is that the electric motor can be manufactured in a simple manner.

Further advantages result from the subclaims. The invention is not limited to the combination of features of the claims. For the person skilled in the art, further sensible combination options of claims and/or individual claim features and/or features of the description and/or the figures arise, in particular from the task and/or the task posed by comparison with the prior art.

• In der 1 ist ein erfindungsgemäßes erstes Werkzeug der Anlage zur Herstellung einer Spulenwicklung für einen Elektromotor gezeigt.
• In der 2 ist ein erfindungsgemäßes zweites Werkzeug in Schrägansicht gezeigt, das als Formpresswerkzeug fungiert.
• In der 3 ist das zweite Werkzeug aus einer anderen Blickrichtung dargestellt.
• In der 4 ist die vom zweiten Werkzeug geformte Wicklung aus Bündeldraht 1 gezeigt.
• In der 5 ist ein erfindungsgemäßes drittes Werkzeug in Schrägansicht gezeigt, das ebenfalls als Formpresswerkzeug fungiert.
• In der 6 ist die vom dritten Werkzeug geformte Wicklung aus Bündeldraht 1 gezeigt.
• In der 7 ist ein erfindungsgemäßes viertes Werkzeug in Schrägansicht gezeigt, das ebenfalls als Formpresswerkzeug zur Formung von Endabschnitten 80 des Bündeldrahts fungiert.
• In der 8 ist die vom vierten Werkzeug geformte Wicklung aus Bündeldraht 1 gezeigt.
• In der 9 ist die aus mehreren, insbesondere aus zwölf, solcher gemäß 8 geformter Wicklungen zusammengesetzte Spulenwicklung gezeigt, welche nach Rundbiegen in Nuten des Statorblechpakets eingelegt wird.

The invention will now be explained in more detail using illustrations:

• In the 1 A first tool according to the invention of the system for producing a coil winding for an electric motor is shown.
• In the 2 A second tool according to the invention is shown in an oblique view, which functions as a compression molding tool.
• In the 3 the second tool is shown from a different viewing direction.
• In the 4 the winding of bundled wire 1 formed by the second tool is shown.
• In the 5 A third tool according to the invention is shown in an oblique view, which also functions as a compression molding tool.
• In the 6 the winding of bundled wire 1 formed by the third tool is shown.
• In the 7 A fourth tool according to the invention is shown in an oblique view, which also functions as a compression molding tool for shaping end sections 80 of the bundle wire.
• In the 8th the winding of bundled wire 1 formed by the fourth tool is shown.
• In the 9 is the one made up of several, especially twelve, according to such 8th Coil winding composed of shaped windings is shown, which is inserted into grooves in the stator laminated core after bending.

As shown in the figures, the manufacturing system has several tools for producing a coil winding, which is drawn or inserted into the grooves of a laminated core. An electric motor is then produced in the system from the stator produced in this way, which is preferably designed as a three-phase motor. The tools are preferably installed in a machine, so that the bundle wire 1 is fed to the machine and the coil winding or, after feeding a laminated core, the stator of the motor is produced, in particular fully automatically. The transfer, forwarding and other handling means of the machine are not shown in the figures.

As in 1 shown, a first tool is used which has a connecting plate 2, on which a bobbin 3, which is preferably cylindrical, is provided and a clamping means 4 spaced from the bobbin 3.

The bundle wire 1 is clamped to the clamping means 4 and then guided around the bobbin 3 in several turns, preferably in seven to eight turns.

The bundle wire consists of two or more, in particular four, shaped wires. Each shaped wire has a square or rectangular wire cross-section. The four shaped wires are stacked on top of each other so that this stacked bundle can be inserted into a groove with a rectangular groove cross-section, in particular without any significant free space areas in between.

The resulting ring winding is removed from the first tool after the clamping means 4 has released the bundle and is then inserted into the second tool.

As in 2 and 3 shown, the ring winding is inserted into a recess of a lower mold 25 and into a recess of an upper tool. Upper mold 26 and lower mold 25 are then moved towards each other, the movement being guided by guide bolts 20.

Thus, when moving towards each other, the ring winding initially becomes elliptical and then elongated, with loop regions 40 being formed in the end regions of the original ring winding arranged transversely to the direction of movement, the minimum radius of curvature of which is limited by the pins 31. The pins 31 are each held in a receiving bolt which is guided in an elongated hole in a guide plate. The elongated hole extends transversely to the relative direction of movement of the two forming tools (25, 26), so that the receiving bolts 22 with the pins 31 are pressed against the winding by spring elements 23 in the transverse direction or against the transverse direction. The spring elements are supported on the support element 24, which is connected to the guide plate 21 or alternatively is designed as one piece with it.

By means of the spring elements 23, the pins act as a limitation of the minimum bending radius for the bundle wire. The bundle wire consists of shaped wires, each of which is surrounded by an insulating varnish, in particular baking varnish. By maintaining the minimum bending radius of the loop areas 40, the insulating lacquer layer remains undamaged and thus the shaped wires remain electrically insulated from one another as long as no further electrical connections are made.

The loop areas 40 are spaced apart by a straight area 41, as in 4 visible.

In the 4 The deformed winding shown is pulled apart transversely to the rectilinear area 41, so that the individual turns follow one another in the pulling direction. Each loop area is then inserted into a groove in the mold 52 of a third tool. The bundle wire thus enters the groove from above, i.e. in the groove opening direction, and is then guided in the groove direction up to the exit area in the groove, with the exit then again being carried out upwards, i.e. in the groove opening direction

By pressing in a base part, the loop areas 40 and adjacent areas are provided with a contour in that the first pressure plate 51 and the second pressure plate 55 press the loop areas 40 and adjacent areas against a first contour section 53 and a second contour section 54, respectively. The areas are thus expanded in a V shape transversely to the loop direction.

The winding deformed by the third tool is in 6 shown.

As in 7 shown, the end sections of the bundle wire are formed using the fourth tool. These end sections 80 formed in this way are in 8th shown.

The fourth tool has a pressure plate 70, to which two bolts 72 are attached, which are inserted into a longitudinal slot in the receiving plate 71 in order to then guide the pressure plate 70 as it approaches the receiving plate 71. The receiving plate 71 has a contour that is shaped with a corresponding contour 73. In this way, the end section 80, which is arranged between the receiving plate 71 and the pressure plate 70, can be shaped.

At the end sections 80 formed in this way, the bundle wire or a respective shaped wire of the bundle wire can be electrically connected to another shaped wire.

To produce the coil winding, twelve such bundle wires shaped in this way are braided and/or threaded into one another. After bending this round 9 Even in a straight-line arrangement, the coil winding is then pushed into grooves in a stator laminated core and in this way a stator of the electric motor is produced.

Reference symbol list

1

Bundle wire

2

connection plate

3

Bobbin

4

Clamping means

20

Guide pin

21

Guide plate

22

Locating bolt

23

Spring element

24

Support element

25

lower mold

26

upper mold

30

depression

31

Pen

40

loop area

41

straight line area

50

Base part of the stamp tool

51

first printing plate

52

molding tool

53

first contour section

54

second contour section

55

second printing plate

56

Guide pin

70

printing plate

71

Mounting plate

72

bolt

73

contour

80

End section for electrical connection

Claims (10)

Method for producing an electric motor for high motor currents, wherein a ring winding made of bundled wire (1) is produced with a first tool using a manufacturing device in a first process step, characterized in that in a second process step the winding is guided between a lower and a lower one relative to it movable upper mold (25, 26) of a second tool is inserted, with guide pins (20) for guiding the relative movement being connected to the lower and upper mold (25, 26), the lower and upper mold (25, 26 ) each have a recess extending transversely to the guide direction, into which the winding can be at least partially inserted, with pins (31) loaded with spring force transversely to the guide direction being pressed against the inside of the winding by a respective spring element (23), so that in the The minimum bending radius is limited and/or maintained by means of the pins (31) due to the relative movement-induced deformation of the winding. Procedure according to Claim 1 , characterized in that the depth of the depressions in the respective end region arranged transversely to the guide direction is deeper than between these end regions. Method according to at least one of the preceding claims, characterized in that the pins (31) are guided by means of an elongated hole in a guide plate (21), on which the spring elements (23) are each supported. Method according to at least one of the preceding claims, characterized in that the first tool has a bobbin (3) which is connected to a connecting plate (2) on which a clamping means (4) for clamping the bundle wire (1) is provided. Method according to at least one of the preceding claims, characterized in that the manufacturing device has a third tool with which the winding formed by the second tool can be further shaped, the third tool having a base part (50). has, on which two pressure plates (51, 55) are supported via spring elements (23), the pressure plates (51, 55) being connected to the base plate via respective linear guides, the third tool being a molding tool (52) with contour sections (53, 54), wherein a first pressure plate (51) presses a winding section against a first contour section (53) and a second pressure plate (55) presses another winding section against a second contour section (54). Method according to at least one of the preceding claims, characterized in that the manufacturing device has a fourth tool with which end regions of the winding formed by the third tool can be further shaped, the fourth tool having a pressure plate (70) which presses the end region against the contour ( 73) presses a receiving plate (71), bolts (72) being connected to the pressure plate (70), which are guided in a slot in the receiving plate (71). Method according to at least one of the preceding claims, characterized in that the bundle wire (1) has two or more shaped wires, each of which is electrically surrounded by an insulating material. Method according to at least one of the preceding claims, characterized in that in a third method step the winding is stretched in the direction of the winding axis and the region adjacent to the respective loop region (40) is then formed. Method according to at least one of the preceding claims, characterized in that in a fourth method step the end regions of the bundle wire (1) are shaped. Method according to at least one of the preceding claims, characterized in that in a fifth method step the winding with further windings produced and deformed in this way are arranged next to one another to form a coil winding, in a sixth method step the coil winding is then shaped round and drawn or inserted into grooves of a laminated core is used to form an active part, such as the rotor or stator of the electric motor, in a seventh process step the electric motor is completed by adding and connecting further parts.

Images