CA3027318A1

CA3027318A1 - Method for winding the winding teeth, winding support device and needle winding device

Info

Publication number: CA3027318A1
Application number: CA3027318A
Authority: CA
Inventors: Jan-Peter Jastrzembski; Matthias Wenzel; Florian SELL-LE BLANC
Original assignee: Aumann Espelkamp GmbH
Current assignee: Aumann Espelkamp GmbH
Priority date: 2016-10-11
Filing date: 2017-10-10
Publication date: 2018-04-19
Also published as: JP2019531683A; WO2018069298A1; BR112018075885A2; EP3309938B1; CN109478835A; PL3309938T3; EP3309938A1; HUE052726T2; ES2856299T3; HRP20210279T1; SI3309938T1

Abstract

In a method for winding the winding teeth (2) of the rotor or stator (1) of an electric machine, a winding support device (3) is attached to at least one end side of the rotor or stator (1) lying in the axial direction (X), and is detachably connected to the rotor or stator (1), wherein the winding teeth (2) and the winding support device (3) are subsequently wound with a winding wire, preferably using a needle winding technique. The winding wire is deflected in the region of the winding support device (3), and the winding support device (3) is removed again after the winding of the rotor or stator (1). The winding support device (3) comprises a plurality of wire guide elements (30), wherein each winding tooth (2) to be wound is assigned a wire guide element (30). The wire guide element (30) has a winding tooth extension section (34), which is designed in such a way that same extends the winding tooth (2) in the axial direction (X).

Description

METHOD FOR WINDING THE WINDING TEETH, WINDING SUPPORT
DEVICE AND NEEDLE WINDING DEVICE
TECHNICAL FIELD
The invention relates to a method for winding the winding teeth of a rotor or stator of an electric machine, a winding support device, in particular for use in such a method, and a needle winding device.
PRIOR ART
When winding internally grooved laminated stacks, as used for rotors or stators, the needle winding technique is preferably used. The needle carrier moves through the laminated stack and moves, with its movement, the wire in the respective groove. On the end faces of the laminated stack, plastic end caps are usually used, which are used for laying the wire in the winding head and isolate the coil body from the laminated stack. The plastic end caps must absorb the forces of the wire and are therefore provided with the necessary wall thicknesses so that electrical machines wound in such a way require a large amount of space. In addition, such plastic end caps are also wound around during the lamination of the laminated stacks. They thus remain on the rotor or stator and thus require additional space. Furthermore, the use of end disks results in disadvantages due to different wire lengths of different phases, which have a negative effect on the power density of different phases of an electric machine.

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2 . , , , DE 10 2014 009 799 Al describes a method with a winding support device which is arranged reversibly. In this case, the winding support device is fixed for winding by means of a clamping mechanism enclosed by the laminated stack and, after winding, is removed from the electric machine by loosening the clamping mechanism.
This winding support device is designed for a plurality of grooves, so that the winding support device may be used in each case only for one groove spacing and one fixed coil width. In addition, after winding a plurality of teeth, this system must be removed from these teeth and moved to another position of the laminated stack, so that the winding process may continue there. This procedure is time-consuming, since several refitting processes are necessary.
SUMMARY OF THE INVENTION
The object of the invention is to provide a winding support device and an associated winding method, which have no limitation with respect to the design of the winding system and make costly refitting unnecessary.
This object is achieved by a method for winding the winding teeth of the rotor or stator of an electric machine according to the characteristics of claim 1 and a winding support device according to the characteristics of claim 5.
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3 . . , .
, Advantageous embodiments may be found in the respective dependent claims.
The invention proposes a method for winding the winding teeth of the rotor or stator of an electric machine, in which a winding support device is placed on the axial end side of the rotor or stator and detachably connected to the rotor or stator. The winding teeth and the support winding device are then wound with a winding wire, preferably using a needle winding technology, whereby the winding wire is deflected in the region of the winding support device, and the winding support device is removed again after the rotor or stator has been completely wound. The winding support device comprises a plurality of wire guide elements, each winding tooth to be wound being assigned a wire guide element and the wire guide element having a winding tooth extension section which is designed such that same extends the winding tooth in the axial direction. Preferably, the winding support device is designed so that it may be taken out after winding to the interior of the rotor or stator by removing the wire guide elements. The method according to the invention is preferably a needle winding method with distributed windings.
Because a winding support device is mounted on each winding tooth, the grooves between the winding teeth remain open and any desired winding scheme may be implemented without restriction by the winding support device. The process thus obtained makes it possible to form rotors or stators which have a different winding head geometry in comparison with I

4 manually wound rotors or stators. The machine-wound rotors or stators according to the invention are characterized in that the winding wire has more edges or edges in the region of the winding head than is the case with manually wound rotors or stators, in which the winding wire in turn has elliptical or circular contours in the region of the winding head. Thus, rotors or stators wound according to the method of the invention may be recognized by the angular geometry of the wire loops of the winding head that deviates significantly from the ellipse or circular shape.
In a preferred embodiment of the method, a wire guide element is used, the width of which transverse to the axial direction is less than or equal to the width of the associated winding tooth in the region of its radially free end. On the one hand, the width of the groove between the winding teeth is not restricted by the support winding device, and the eyelets of the winding projecting beyond the winding teeth in the axial direction are slimmer.
The proposed structure may preferably be further extended by an extension of the winding support device into the interior of the rotor or stator. As a result, the edges of the grooves contained in the laminated stack may be covered, so that the winding wire may be protected from damage in the winding process.
In a further preferred embodiment of the method, the winding support device, in particular each wire guide element, is fastened to the rotor or stator, before the winding, by means of at least one pin or bolt or in general by means of a fastening element, such as a fastening plate, which may be screwed to the rotor or stator, for example.
Each wire guide element, the sum of which forms the winding

5 support device, is fixed to the rotor or stator by a pin or bolt or fastening element, so that the transverse forces occurring during winding do not lead to a displacement of individual wire guide elements in the circumferential direction, which would possibly cause a disruption of the winding process.
In a particularly preferred embodiment of the method, the winding support device, in particular each wire guide element, is detached, after winding, from the rotor or stator by removing the pin or bolt or fastening element, and then removed. The protruding eyelets of the windings are exposed and are subsequently arranged in such a way that the product becomes more compact.
The invention also relates to a winding support device used in the method, which has at least one wire guide element with at least one winding tooth extension section extending in an axial direction for abutment against the winding tooth of a rotor or stator and for the axial extension of the winding tooth, wherein the winding tooth extension section is disposed on a first side of the wire guide element. Furthermore, the winding support device comprises at least one wire deflecting section arranged on a second side opposite the first side of the wire guide element with a wire receiving recess arranged between webs, whose depth I

6 , , direction extends in a radial direction (R) perpendicular to the axial direction (X), wherein the wire receiving recess is opened radially outward. In this case, an abutment groove is preferably introduced in the lower web of the wire guide element, with which the wire guide element may be fixed to a pin or bolt and the winding support device may then be removed again after winding.
In a preferred embodiment, the winding tooth extension section has at its end remote from the abutment section an outwardly inclined section rising in the radial direction (R) away from the abutment section. In this way, there is more play for wire guidance through a wire outlet nozzle and the winding may be made more precise.
In a particularly preferred embodiment, a plurality of wire deflection sections are arranged between the abutment section and the end of the wire guide element opposite the abutment section.
In a very particularly preferred embodiment, the wire deflecting sections are arranged offset from each other in the radial direction (R).
In a further very particularly preferred embodiment, the section of the wire deflection sections which is nearest to the abutment section is arranged farthest outward in the radial direction (R) and the radial offset of the wire deflection sections gradually decreases towards the free end in the axial direction (X).
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7 The winding support device according to the invention, which is in particular part of a needle winding device, and thus does not remain on the body to be wound, is preferably made of metal, in particular steel, or consists thereof. In this way, the winding support device may be used repeatedly as part of the needle winder. The invention also relates to a needle winder according to claim 11. Advantageous embodiments may be found in claims 12 and 13.
The needle winding device according to the invention, which is particularly suitable for carrying out the method described above, has at least one needle winder which has a feed device, which in turn feeds at least one winding wire to at least one wire discharge nozzle. In this case, the needle winding device further has a workpiece holder, which receives or may receive a body to be wound with the winding wire, in particular a rotor or stator of an electric machine. The needle winding device comprises at least one winding support device as described above. Thus, the winding support device according to the invention is not merely a support device which subsequently remains on the wound body, but is rather a machine part.
Advantageously, it is provided that the inventive needle winding device comprises a plurality of winding support devices described above.

8 Alternatively or additionally, it may also be provided that the workpiece holder has a body to be wound, on which one or more support winding devices are releasably attached.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail below with reference to the figures of some exemplary embodiments.
Fig. 1 shows a perspective view of a rotor or stator with attached support winding devices;
Fig. 2 shows a sectional view of the arrangement in Fig. 1, Fig. 3 shows the cut-out enlargement A from Fig. 1, Fig. 4 shows a possible attachment of the winding support device to the rotor or stator, Fig. 5 shows a perspective view of a wire guide element, Fig. 6 shows a sectional view of a wire guide element which is placed on a winding tooth, Fig. 7 shows a partial sectional view according to Fig. 2 of a component which has been completely wound by the method according to the invention, after removal of the winding tool, Fig. 8 shows a partial sectional view corresponding to Fig.
2 of a component which has been wound according to a conventional manual process, after removal of the winding tool.
BEST MODE FOR CARRYING OUT THE INVENTION
Fig. 1 shows a perspective view of a rotor or stator 1, which is shown open to a quarter view for illustration. The

9 unwound blank is composed of a ring of winding teeth 2, between each of which lie the winding grooves. Winding support devices 3 are mounted on the ends of the rotor or stator 1 in the axial direction (X), wherein the individual wire guide elements 30 abut with the abutment section 33 against the respective winding tooth 2. In this exemplary embodiment, the winding support device 3 is fixed, inter alia by a fastening element embodied here as a securing ring 11, which in the example shown is screwed tight to a receiving ring 10 (not shown in the left-hand part of the figure). The respective receiving rings 10 are attached to a support frame 12 and secure the seat of the winding support device 3.
The sectional view in Fig. 2 shows some details of the arrangement from Fig. 1 more clearly. At the axial ends of the rotor or stator 1, the winding support devices 3 are provided which comprise at least one wire guide element 30.
The wire guide element 30 has a winding tooth extension section 34 with an abutment section 33, with which the wire guide element 30 rests against the winding tooth 2, and a obliquely rising section 35, which is arranged on the part lying in the axial direction X. Furthermore, a number of wire deflecting sections 31, 32 are arranged on the outside on wire guide elements 30 in the radial direction R. These wire deflecting sections 31, 32 comprise wire receiving recesses 31 and delimiting webs 32. The wire deflecting sections 31, 32 are arranged offset to one another in the radial direction R, wherein the radial offset relative to the winding tooth 2 gradually decreases in the axial direction away from the rotor or stator 1.
The winding support device 3 is preferably fastened by a 5 circumferential securing ring 11 to a receiving ring 10 and thus secured against displacement. It is not necessary that the securing ring 11 is made in one piece. It is quite conceivable that the securing ring 11 is composed of several circular segments, which may facilitate the

10 assembly and disassembly of the securing ring 12.
The detail marked A in Fig. 1 is shown enlarged in Fig. 3.
A number of wire guide elements 30, of which only a few wire deflection sections 31, 32 are shown with the wire receiving recesses 31 and the webs 32 arranged therebetween, are arranged on a receiving ring 10 on the rotor or stator 1. In order to fix the position of the wire guide elements 30, pins or bolts 4 are inserted in the receiving ring 10, against which the wire guide elements 30 abut.
For this purpose, an abutment groove 36 (not shown in the figure) may be introduced at the axially innermost web 32.
This arrangement may be secured with a securing ring 11 (not shown here), which is fixed with screws which are screwed into the threaded holes 14 of the receiving ring 10.
Fig. 4 shows a winding support device 3 which is applied to the rotor or stator 1 and which comprises a plurality of

11 wire guide elements 3. On the web 32 of the wire guide elements 30 lying closest to the rotor or stator 1, the securing ring 11 rests on the receiving ring 10 with a row of bores 13 which receive the pins or bolts 4 and have threaded holes 14. By means of screws, which are screwed through the bores 13 in the threaded holes 14 aligned hereby, the retaining ring 11 and thus the support winding device 3 is fixed.
The previously described type of fixation of the winding support device 3 on the rotor or stator 1 to be wound is one of several possibilities. There are certainly other fixation possibilities conceivable; as an example, an extension of the wire guide elements 30 inwardly beyond the winding tooth 2, wherein the axially opposite wire guide elements 30 are connected to a web running in front of the winding tooth 2. This web could also at least partially cover the edges of the winding teeth, thus protecting the wire against damage during the wire guidance during the winding process.
The winding support device 3 is designed so that it may be extracted, after winding, towards the interior of the rotor or stator 1 out by removing the wire guide elements 30.
Fig. 5 shows an embodiment of a wire guide element with a series of wire deflecting sections 31, 32, in which the radial offset of the wire receiving recesses 31 gradually decreases from the bottom to the top (in the X
30 direction). The reduction is chosen so that the wire length

12 of the windings always remains the same. In the lower web 32 of the wire guide elements 30 an abutment groove 36 is introduced, with which the wire guide element 30 is fixed to the pin or bolt 4. The bottom 37 of the wire receiving recesses 31 may be flat. However, in a preferred embodiment, this bottom 37 may also be curved or arched. As a result, the wire may better conform to the bottom shape of the wire receiving recess 31 during winding and the tensile force during winding may be reduced.
Fig. 6 shows a sectional view of a wire guide element 30, which rests with the abutment section 33 on a rotor or stator 1. In the receiving ring 10, a pin or bolt 4 is inserted, which engages in the abutment groove 36 of the wire guide element 30. The securing ring with the screw is not shown here for reasons of clarity.
With the winding support device 3, a rotor or stator 1 may be wound more compactly, since the winding support device 3 may be removed again after winding and thus reduces the necessary volume at the axial ends of the rotor or stator 1 in the region of the winding heads. The modular design of the winding support device 3 makes it possible to use these in different circumstances and not just for a type of rotor or stator.
This makes the winding processes more cost-effective and storage simpler.
In Figs. 7 and 8, the winding heads are compared in the case according to the method of the invention (Fig. 7) and in the case of the conventional manual method (Fig. 8), [

13 after removal of the winding tool. In both cases, a wire loop 5 is shown, which covers part of the end side of the wound body. In the method according to the invention, after removal of the winding tool, a wire loop 5 remains, which has clearly recognizable edges or corners 5a. In contrast, the conventional method according to Fig. 8 provides a round winding head of the respective wire loop 5 without corners or edges. Because of this, a product which has been wound by the method according to the invention may be clearly recognized by the geometry of the angled head.

Claims

14

1. A method for winding the winding teeth (2) of the rotor or stator (1) of an electric machine, a winding support device (3) is attached to at least one end side of the rotor or stator (1) lying in the axial direction (X), and is removably connected to the rotor or stator (1), wherein the winding teeth (2) and the winding support device (3) are subsequently wound with a winding wire, preferably using a needle winding technique. The winding wire is deflected in the region of the winding support device (3), and the winding support device (3) is removed again after the winding of the rotor or stator (1), characterized in that the winding support device (3) comprises a plurality of wire guide elements (30), wherein each winding tooth (2) to be wound is assigned a wire guide element (30), wherein the wire guide element (30) has a winding tooth extension section (34), which is designed in such a way that same extends the winding tooth (2) in the axial direction (X).

2. The method according to claim 1, characterized in that a wire guide element (30) is used, the width of which transversely to the axial direction (X) is less than or equal to the width of the associated winding tooth (2) in the region of its end, which is free in the radial direction (R).

3. The method according to claim 1 or 2, characterized in that the winding support device (3), in particular each wire guide element (30), is attached, before winding by means of at least one pin or bolt (4) or a fastening element, in particular a clamping element, on the rotor or stator (1).

4. The method according to claim 3, characterized in that the winding support device (3), in particular each wire guide element (30), is removed, after winding, by removing the pin or bolt (4) or fastening element from the rotor or stator (1).

5. A winding support device (3), in particular for use in a method according to any one of the preceding claims, comprising at least one wire guide element (30) with at least one winding tooth extension section (34) extending in an axial direction (X) for abutment against the winding tooth (2) of a rotor or stator (1) and for the axial extension of the winding tooth (2), wherein the winding tooth extension section (34) is arranged on a first side of the wire guide element (30), and at least one wire deflection section (31, 32), which is disposed on a second side opposite the first side of the wire guide element (30), with a wire receiving recess (31), the depth direction of which extends in a radial direction (R) perpendicular to the axial direction (X), wherein the wire receiving recess (31) is open outwardly in the radial direction, and with an abutment section (33) for abutment against the end side of a rotor or stator (1).

6. The winding support device (3) according to claim 5, characterized in that the winding tooth extension section (34) has at its end remote from the abutment section (33) a section (35), which rises outwardly and obliquely in the radial direction (R) away from the abutment section.

7. The winding support device (3) according to claim 5 or 6, characterized in that a plurality of wire deflecting sections (31, 32) is arranged between the abutment section (33) and the end of the wire guide element (30) opposite the abutment section.

8. The winding support device (3) according to claim 7, characterized in that the wire deflecting sections (31, 32) are offset from each other in the radial direction (R).

9. The winding support device (3) according to claim 7, characterized in that the section of the wire deflecting sections (31, 32), which is next to the abutment section (33) is arranged farthest outward in the radial direction (R) and the radial offset gradually decreases towards the free end of the wire guide element in the axial direction (X).

10. The winding support device (3) according to any one of claims 5 to 9, characterized in that it consists of metal, in particular steel.

11. A needle winding device, in particular for carrying out a method according to any one of claims 1 to 4, comprising at least one needle winder, which has a feed device which feeds at least one winding wire to at least one wire outlet nozzle, wherein the needle winder further comprises a workpiece holder, which receives or may receive a body to be wound with the winding wire, in particular of the rotor or stator (1) of an electric machine, characterized in that the needle winding device comprises at least one winding support device (3) according to any one of claims 5 to 10.

12. The needle winding device according to claim 11, characterized in that it comprises a plurality of winding support devices according to any one of claims 5 to 11.

13. The needle winding device according to any one of claims 11 or 12, characterized in that the workpiece holder has a body to be wound, on which one or more winding support devices are removably attached.