阅读说明：本技术 用于制造电的机器的转子的绕组的方法 (Method for producing a winding of a rotor of an electrical machine ) 是由 拉尔斯·胡斯梅耶 于 2021-06-09 设计创作，主要内容包括：用于制造电机器的转子的绕组的方法及电机器,转子由多个U形弯曲的导体部件构成,每一个导体部件都有封闭端部和开口端部,开口端部有第一边腿和第二边腿,该方法包括：把多个导体部件的开口端部插入到成型模具的多个凹槽中；多个导体部件交错,从而U形弯曲的导体部件的封闭端部从成型模具的凹槽中伸出并形成卷绕头；卷绕头在多个导体部件交错期间形成变细的形状,在含有成型模具的中轴线的剖切面中,在延伸经过第一点和第二点的直线与成型模具的中轴线之间的角度至少为10°,第一点在绕组的外直径上位于导体部件从成型模具伸出的平面高度上,第二点在绕组的外直径上位于等于卷绕头的总高度的至少10％、至多90％的高度上。(A method of manufacturing a winding for a rotor of an electric machine and an electric machine, the rotor being formed of a plurality of U-shaped bent conductor members, each conductor member having a closed end and an open end, the open end having a first leg and a second leg, the method comprising: inserting the open ends of the plurality of conductor members into the plurality of recesses of the molding die; the plurality of conductor members are staggered so that the closed ends of the U-shaped bent conductor members protrude from the grooves of the forming die and form a winding head; the winding head is formed in a tapering shape during the interleaving of the plurality of conductor parts, the angle between a straight line extending through a first point on the outer diameter of the winding at the height of the plane of the conductor parts projecting from the forming die and a second point on the outer diameter of the winding at a height equal to at least 10% and at most 90% of the total height of the winding head being at least 10 DEG in a cross-sectional plane containing the central axis of the forming die.)

1. Method for producing a winding, in particular a plug winding, of a rotor (100) of an electrical machine, in particular a starter motor, wherein the rotor (100) is formed from a plurality of U-shaped bent conductor parts (120), wherein each of the conductor parts (120) has a closed end and an open end, wherein the open end has a first leg and a second leg, wherein the method comprises:

inserting the open ends of a plurality of conductor parts (120) into a plurality of recesses (13, 14) of a forming tool (10), wherein the closed ends of the U-shaped bent conductor parts (120) project out of the recesses (13, 14) of the forming tool (10);

-the plurality of conductor parts (120) are staggered such that the closed ends of the U-shaped bent conductor parts (120) form a winding head (105);

wherein the winding head (105) is formed in a tapered shape, wherein, in a cross-section containing the central axis (140) of the forming die (10), an angle between a line (107) extending through a first point (108) and a second point (109) and the central axis (140) of the forming die (10) is at least 10 °, wherein the first point (108) is located on the outer diameter of the winding at a height (H) of a plane at which the conductor part (120) protrudes from the forming die (10), wherein the second point (109) is located on the outer diameter of the winding at a height (H) which is equal to at least 10%, at most 90%, of the total height (H) of the winding head (105).

2. The method of claim 1, wherein forming the winding head (105) into a tapered shape comprises: at least the radially outermost leg of the conductor part (120) projecting from the moulding tool (10) is bent tangentially and radially inwards with respect to the moulding tool (10).

3. A method according to claim 2, wherein the radial angle (α) is at least 0.25 times the tangential angle (β).

4. The method according to any one of the preceding claims, wherein "shaping the winding head (105) into a tapered shape" is carried out as follows: such that the outer diameter of the winding head (105) at the tip is smaller than at the first point (108).

5. The method of any of the preceding claims, wherein "forming the winding head (105) into a tapered shape" further comprises:

lowering a compression mold (20) onto the winding head (105), wherein the compression mold (20) is designed to apply an axial force in the direction of the conductor parts (120) and a radial force in the direction of the center axis (140) of the forming mold (10) to the winding head (105) during or after the staggering of the conductor parts (120).

6. The method according to claim 5, wherein the compression mould (20) has a female die of tapered shape, which receives the winding head (105).

7. The method of claim 5 or 6, wherein "forming the winding head (105) into a tapered shape" comprises: the inner mould part (11) of the moulding tool (10) is rotated relative to the outer mould part (12) of the moulding tool (10).

8. The method according to claim 7, wherein the compression mould (20) is rotatable or stationary together with the inner mould part (11) or the outer mould part (12).

9. A method according to any one of claims 5 to 8, wherein the height of the winding head (105) is set by adjusting the lowering height of the compaction die (20).

10. The method of any of the preceding claims, wherein "forming the winding head (105) into a tapered shape" comprises: the winding head (105) is rotationally symmetrical.

11. The method of any one of the preceding claims, wherein the winding head forms the tapered shape which is conical, stepped, convex or concave.

12. An electrical machine with a winding head (105) made according to any one of claims 1 to 11.

Technical Field

The invention relates to a method for producing a winding of a rotor of an electrical machine and to an electrical machine.

Background

The rotor of an electrical machine, in particular a starter motor, can be formed from a metallic rotor core with inserted U-shaped conductor parts as windings or so-called plug windings. The arc-shaped portion protruding from the core forms a so-called winding head which may have a specific shape, as described in DE 102014226224 a 1. In this case, the arcuate sections rotate relative to one another, for example in a compound manner, when a force is applied axially by means of a so-called compression die, in the forming die, so that a winding head having an approximately cylindrical shape is formed. The composite body thus produced from the interleaved conductor parts can then be removed from the forming die by means of a conveying device and inserted into a plurality of recesses on the rotor core.

Although the conductor parts are limited in their axial width by the application of force in the axial direction, they may be widened at will in the radial direction. The winding head thus formed may have an imbalance, for example, as a result of which different forces act on the winding head, for example at high rotational speeds, and the winding head is deformed unevenly. Furthermore, the winding head can have a low radial strength (resistance to centrifugal forces).

Disclosure of Invention

According to the invention, a method for producing a winding of a rotor of an electrical machine and an electrical machine are proposed, having the features of the independent claims. Advantageous embodiments are the subject matter of the dependent claims and the subsequent description.

The invention relates to a method for producing a winding, in particular a plug winding, for a rotor, which makes it possible to produce winding heads having the same radial width, while maintaining the radial strength and reducing the unbalance.

The method according to the invention is used in particular for producing a rotor of an electrical machine, in particular a starter motor. The winding is formed from a plurality of U-shaped bent conductor parts, each of which has a closed end and an open end, wherein the open end has a first leg and a second leg.

In the method according to the invention, the open ends of the plurality of conductor parts are inserted into the plurality of recesses of the forming die. The first leg is inserted, for example, into an inner mold part of the molding tool, and the second leg is inserted into an outer mold part of the molding tool. The closed ends of the U-shaped bent conductor parts project from the forming tool and are staggered, i.e. the tool parts are rotated relative to one another, in order to form the winding head.

The winding head forms a tapering shape during or after the interleaving of the plurality of conductor parts, wherein, in a cross-section containing the center axis of the forming die, the angle between a straight line extending through the first point and the second point and the center axis of the forming die is at least 10 °, preferably at least 20 °, preferably at least 25 °, in particular at least 30 °. The first point is located on the outer diameter of the winding at the level of the plane of projection of the conductor part from the forming die, and the second point is located on the outer diameter of the winding at a level equal to at least 10% and at most 90% of the total height of the winding head. The second point is for example located at a height equal to at least 20%, preferably at least 30%, preferably at least 40% and preferably at most 80%, preferably at most 70%, preferably at most 60% of the total height of the winding head. The lower limit and the upper limit of the height of the second point may be combined with each other freely in particular.

In contrast to the prior art, the clear width of the winding head or conductor part is thus limited radially at least along a straight line from the first point to the second point. Preferably, the angle is the same for each section containing the central axis, i.e. the angle between the straight line and the central axis remains constant along the entire circumference, resulting in a rotationally symmetrical shape. The winding head is thus thinned and, due to the smaller radial position, is subjected to less centrifugal force during rotation. Furthermore, the winding head has a smaller unbalance than a generally cylindrical winding head, as a result of which the winding head is subjected to less deformation, for example at high rotational speeds. The winding head thus has a greater radial strength (resistance to centrifugal forces).

Advantageously, the "shaping the winding head into a tapered shape" comprises: at least the radially outermost leg of the conductor part projecting from the forming tool is bent tangentially and radially inwards (i.e. towards the centre axis of the forming tool) with respect to the forming tool.

Although the radial bending results in the winding head being given a tapering shape, the tangential bending of the conductor parts also results in the conductor parts being staggered relative to one another according to the winding scheme and the axial extension of the winding head being reduced.

Advantageously, the radial angle (i.e. the angle between the central axis of the forming tool and the straight line) is at least 0.25, preferably at least 0.3, preferably at least 0.4, in particular at least 0.5 times the tangential angle, i.e. the angle between the conductor part and the end face of the forming tool running perpendicular to the central axis of the forming tool. In other words, the smaller the extent to which the conductor parts are radially bent, the greater the extent to which they can be bent preferably radially inwards. In particular, damage to the material of the conductor can thus be avoided, while nevertheless a short overall height of the winding head is achieved.

Advantageously, the "shaping of the winding head into a tapered shape" is carried out as follows: so that the outer diameter of the winding head at the tip is smaller than at the first point. This results in the winding head having a greater resistance to centrifugal forces and no or less deformation even at high rotational speeds.

Advantageously, the "shaping the winding head into a tapered shape" further comprises: the pressing tool is lowered onto the winding head or onto the closed end of the conductor part, wherein the pressing tool is designed to apply an axial force in the direction of the conductor part and a radial force in the direction of the center axis of the forming tool to the winding head during the staggering of the conductor parts or during the rotation of the two tool parts relative to one another about the axis of rotation of the forming tool or of the subsequent winding head.

The axial widening of the conductor part is limited by the axial force in the direction of the conductor part, that is to say the height of the winding head is adjusted. Furthermore, the radial forces in the direction of the central axis of the forming die result in a tapering shape of the winding head.

As a result of the insertion of the conductor part into the shaping tool and the subsequent fixing, the winding head can be formed in a tapered shape, wherein in particular a previously set radial angle and/or tangential angle is obtained. This results in the winding heads thus produced having almost the same shape and being almost indistinguishable from each other. The winding heads can thus be formed exactly to the respectively desired shape.

Advantageously, the compression mould has a female die of tapered shape, which receives the winding head. The conductor component is thus defined in the axial direction and in the radial direction by the pressing die, wherein the shape of the matrix is transferred to the winding head. This improves the shape quality of the winding head and ensures that the shape of the winding head does not differ.

Advantageously, the "shaping the winding head into a tapered shape" comprises: so that the inner mould part of the forming mould is rotated in relation to the outer mould part of the forming mould. The inner leg layer (e.g., first leg) is inserted into the inner mold section and the outer leg layer (e.g., second leg) is inserted into the outer mold section. The rotation thus results in at least one of the inner and outer leg layers rotating with the inner or outer mold section, respectively. Here, the conductor members are staggered with respect to each other. Here, the greater the rotation of the inner or outer mould part, the greater the degree of staggering of the conductor parts.

Advantageously, the compression mold can be rotated or fixed together with the inner mold part or the outer mold part. This also results in the conductor part being pressed on the one hand against the matrix of the pressing tool in order to form the tapering shape and on the other hand being stabilized in the tapering shape.

Advantageously, the height of the winding head is set by adjusting the lowering height of the compaction die. In summary, it is thereby possible to produce precisely the winding head with the desired height and the desired tapering shape, so that the different requirements imposed on the winding head by the respective electrical machine, into which the rotor is to be installed, can be met.

Advantageously, the "shaping the winding head into a tapered shape" comprises: the winding head is rotationally symmetrical. A rotationally symmetrical winding head has a small unbalance. This results in a more smooth operation of the starter motor when rotating, thus reducing or preventing noise generation, particularly at high rotational speeds.

The winding head is formed with a tapering shape which is advantageously conical, stepped, convex or concave. If the tapering shape is, for example, conical, the case of the winding head extends from the first point along a straight line through the second point.

If the tapering shape is, for example, stepped, the steps lie, for example, on a straight line such that the rear edge of each step contacts the straight line and thus also the second point, or below the straight line such that the front edge of each step contacts the straight line and thus also the second point. Instead, the convex or concave shapes extend along a straight line such that the shapes intersect the straight line at a second point.

These shapes thus serve to taper the winding head along a straight line from the first point towards the second point, and furthermore alternative or hybrid shapes suitable for achieving such tapering are possible.

Other advantages and designs of the invention will become apparent from the description and drawings.

Drawings

The invention is illustrated schematically in the drawings by means of embodiments and will be described below with reference to the drawings.

Fig. 1 schematically shows a preferred embodiment of a forming die for manufacturing a winding according to the invention of a rotor;

FIG. 2 schematically illustrates a preferred embodiment of a compaction mold;

fig. 3 schematically shows a forming die and a compacting die with inserted conductor parts;

figure 4 schematically shows a preferred embodiment of a rotor with a conical winding head.

Detailed Description

A preferred embodiment of a forming die for manufacturing a winding according to the invention for a rotor is schematically shown in fig. 1 and is generally designated 10.

The forming tool 10 has an inner tool part 11 and an outer tool part 12, wherein the inner tool part 11 and the outer tool part 12 are rotatable relative to one another.

The inner mould part 11 has an outer groove 13 on its outer circumference and the outer mould part 12 has an inner groove 14 on its inner circumference. Both the inner recesses 14 and the outer recesses 13 are designed to receive a plurality of U-shaped conductor parts 120 (see fig. 3) or respectively straight legs thereof.

Each U-shaped conductor member 120 has a closed end and an open end, wherein the open end has a first leg and a second leg.

The first leg can be inserted, for example, into one of the outer recesses 13 of the inner mould part 11 and the second leg can be inserted into one of the inner recesses 14 of the outer mould part 12. The closed ends of the plurality of conductor members 120 protrude from the molding die 10 after being inserted into the molding die 10, and form the winding head 105 (see fig. 3).

By rotating the two mold portions relative to each other, the conductor members 120 may be interleaved with each other according to a winding scheme.

However, the conductor member 120 is arbitrarily stretched in the radial direction when the winding head 105 is formed, and is formed into a random shape. The winding head thus formed has an imbalance, as a result of which, for example, different forces act on the winding head at high rotational speeds and the winding head is deformed unevenly. Furthermore, the winding head can have a low radial strength (resistance to centrifugal forces). To prevent this radial expansion, a compression die 20 (see fig. 2) is used to form the winding head 105 into a tapered shape, such as a cone, a step, a convex or a concave shape.

A preferred embodiment of the compaction die 20 is schematically shown in fig. 2 to form the winding head 105 into a tapered shape, here a cone shape. Fig. 3 schematically shows a forming die 10 and a pressing die 20 with an inserted conductor part 120.

The pressing mold 20 includes a holding member 21 and a tapered member 22. The conical member 22 has a cylindrical watchcase 221 on the outside and a female die in the form of an inner cone 222 on the inside.

Furthermore, the holding member 21 may be constituted by a fixed holding member and a rotatable holding member which is rotatably disposed with respect to the fixed holding member and which can accept the rotational movement of the inner mold portion 11 and the outer mold portion 12 of the molding die 10 so as to protect the conductor part 120 from relative movement and damage.

The conical member 22 has a first opening 223. The inner cone 222 conically extends from the first opening 223 towards the holding member 21 such that the inner diameter of the conical member 22 tapers towards the holding member 21. The inner diameter of the first opening 223 is preferably larger than the inner diameter of the winding head 105 so that the winding head 105 may be received and tapered by the tapering member 22 without damage.

Fixing means such as screws 23 are used to connect the conical member 22 with the holding member 21. To this end, the screw 23 passes through the second opening 224 of the conical member 22 and connects the conical member 22 with the retaining member 21 from the inside. Alternatively, other fixing means such as bolts or other fixing means such as brazing, bonding, welding, etc. may be used to connect the cone member 22 with the holding member 21. It is furthermore possible for the retaining member 21 to be formed integrally with the conical member 22.

In order to restrain and form the winding head 105, as can be seen in fig. 3, the conductor member 120 is inserted into the molding die 10. The compaction die 20 is lowered from above onto the winding head 105. The compression mold 20 is designed to apply an axial force to the conductor part 120 during the tangential staggering and a radial force to the central axis 140 of the forming mold 10 or of the winding head 105. By adjusting the descending height of the pressing mold 20, the height of the winding head 105 can be accurately adjusted.

The compression mould 20 is also designed for stabilizing the conductor component 120 during rotation of the inner mould part 11 and/or the outer mould part 12. For this purpose, the compression mold 20 is designed in a stationary manner, i.e., does not rotate with one of the mold parts during rotation. However, the compression mold 20 can also be designed such that it rotates with the inner mold part 11 or the outer mold part 12.

The closed end or winding head 105 of the conductor member 120 is thus tapered. A feature of such a conical winding head 105 is that the radial clear width of the conductor part 120 is limited compared to a cylindrical winding head. The winding head 105 is thus substantially conical and has a smaller imbalance than a cylindrical winding head, as a result of which it is subjected to less deformation, for example at high rotational speeds, or has a higher rotational speed stability. The winding head 105 thus has a greater radial strength (resistance to centrifugal forces).

Moreover, each tapered winding head produced using such a compaction die 20 has substantially the same tapered shape and is nearly identical to the other winding heads so produced. This results in winding heads made with the same construction of the compaction die having the same conical shape even in different factories. The use of the pressing tool 20 thus results in a certain shape of the winding head being ensured.

Furthermore, if different winding heads are to be manufactured, for example with different inclination angles or winding head heights, other pressing dies can easily be used. The production can then be made flexible to meet the respective requirements without great delay.

In addition, the winding head may be formed in a certain shape according to the selection of the female die of the pressing die 20, and thus the winding head may also be formed in a stepped shape, a convex shape, or a concave shape. The form may be selected according to the application of the winding head, preferably and then according to the requirements on the winding head.

A preferred embodiment of a rotor 100 with a conical winding head 105 is schematically illustrated in fig. 4.

The rotor 100 includes a rotor core 104 and a rotor shaft 130 for supporting the rotor 100 and for transmitting torque. The rotor core 104 has a plurality of grooves 110 into which windings formed of a plurality of U-shaped bent conductor members 120 are inserted.

In a sectional plane containing the central axis 140 of the rotor core 104, the radial angle α between a line 107 extending through the first point 108 and the second point 109 and the central axis 140 of the rotor core 104 is here approximately 20 °. The first point 108 is located at the level of the plane where the conductor members 120 protrude from the rotor core 104 on the outer diameter of the winding, and the second point 109 is located at the level h on the outer diameter of the winding. The height H is approximately equal to 45% of the total height H of the winding head 105. The tangential angle β between the conductor parts 120 and the end face of the rotor core 104 running perpendicularly to the central axis 140 of the rotor core 104 is here approximately 40 °. The angle α is thus here approximately 0.5 times the tangential angle β. However, the ratio of the angle α to the tangential angle β can be adjusted by a person skilled in the art to meet the respective requirements depending on the application of the rotor 100.

Due to the conical shape, the outer diameter of the winding head 105 at the tip, i.e. at the side facing away from the rotor core 104, is smaller than when protruding from the rotor core 104. This results in the winding head 105 having a greater resistance to centrifugal forces and undergoing no deformation, or less deformation, even at greater rotational speeds. The winding head 105 is thus more durable than a cylindrical winding head.