Apparatus for forming wave windings for rotor and stator lamination packets of electrical machines

• US 7,185,414 B2
• Filed: 08/07/2003
• Issued: 03/06/2007
• Est. Priority Date: 06/27/2003
• Status: Expired due to Fees

• Current Assignee: Elmotec Statomat Vertriebs GmbH (Elmotec Statomat Incorporated)
• Original Assignee: Elmotec Statomat Vertriebs GmbH (Elmotec Statomat Incorporated)
• Inventors: Sadiku, Sadik
• Primary Examiner(s): Tugbang; A. Dexter
• Assistant Examiner(s): PHAN, THIEM D
• Application Number:
  US10/635,903
• Publication Number:
  US 20040261885A1
• Time in Patent Office: 1,307 Days
• Field of Search: 295/98, 295/96, 296/05, 296/06, 721/91, 140/92.1, 140/92.2, 140/105
• US Class Current: 29/598
• CPC Class Codes: H02K 15/0478 Wave windings, undulated windings when on diagonally wound hollow coils H02K15/0492
• CPC Class Codes: H02K 15/06 Embedding prefabricated windings in machines
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

An apparatus in which wave windings with a defined number of waves are cut from a continuously formed wave winding band. In forming with a wire guide, the wave winding band is laid in alternation around the outer side faces of forming protrusions, offset from one another on the circumference of two disks. The two disks can be driven to rotate. In the angular range in which the wave winding band is driven on the circumference of the disks or roller, the spacing between one forming protrusion of one row and the next forming protrusion in the other row is increased by such an amount that the outer side faces of the forming protrusions form the winding heads of the wave windings. The wave windings cut from the wave winding band are introduced into radially outwardly open slots of a lamination packet or a rotorlike transfer tool.

Claims

1. An apparatus having

a forming device for forming a wave winding band and

a device for introducing wave windings cut from this band into radially outwardly open slots of a cylinder member which is one of a rotor or stator lamination packet or a similar transfer tool,

characterized in that the forming device for the wave winding band has

a rotatable device which is one of two rotatable disks or one rotatable roller and

two rows of forming protrusions distributed uniformly over the circumference of the rotatable device and offset from one another relative to the respectively other row and protruding past the circumference of the rotatable device, and

a wire guide guided in such a way that a winding wire can be placed in undulating fashion in alternation about outer side faces of the successive forming protrusions on the circumference, the outer side faces having a shape which corresponds to a shape to be generated of winding heads of the wave windings.

2. The apparatus of claim 1, characterized in that a free spacing measured at the circumference between one forming protrusion of one row and the next forming protrusion in the other row is equivalent to the thickness of the winding wire.

3. The apparatus of claim 1, characterized in that in plan view on the circumference of the rotatable device, the outer side faces, pointing away from one another, of the forming protrusions each have the shape of a gable.

4. The apparatus of claim 1, characterized in that, along the circumferential length traversed by a wave winding on the rotatable device, the axial spacing between one forming protrusion of one row and the next forming protrusion of the other row can initially be increased and then reduced.

5. The apparatus of claim 4, characterized in that each row of forming protrusions is mounted on a disk that is supported individually in tumbling or oblique fashion such that the spacing between the two rows along the circumferential length traversed by the wave winding is initially increased and then reduced, and as a result of the increase in spacing, the winding wire, drawn tautly against gable-shaped outer side faces of the forming protrusions, is formable with corresponding gable-shaped winding heads.

6. The apparatus of claim 1, characterized in that

the wire guide is a carrier driven to rotate about an axis of rotation located essentially transversely to the axis of rotation of the rotatable device and has at least one eccentric looping peg and one tappet that can be axially advanced in controlled fashion and is disposed essentially on the axis of rotation,

the carrier having the at least one looping peg immediately next to the rotatable device revolves in chronological adaptation to the rotary motion thereof,

in a first intermediate phase of a work cycle, the tappet can be advanced to the winding wire, delivered into the space between the carrier and the rotatable device, and to a forming protrusion of one row, so that the winding wire is retained on this forming protrusion to form a first loop, and

in a second intermediate phase, in which a forming protrusion of the other row is located axially in front of the at least one looping peg, a stripper can be actuated by which a second loop formed from the winding wire on the at least one looping peg can be stripped from the at least one looping peg onto the forming protrusion located in front of the at least one looping peg.

7. The apparatus of claim 6, characterized in that the carrier revolves in the direction of rotation in which the at least one looping peg, moved with a circumferential surface against the winding wire, forms the first loop around a forming protrusion of one row and simultaneously forms the second loop around the at least one looping peg.

8. The apparatus of claim 6, characterized in that the carrier of the at least one looping peg revolves discontinuously.

9. The apparatus of claim 6, characterized in that, for varying the height of the wave windings to suit different lamination packet heights, the maximum axial spacing between the two rows of forming protrusions and the eccentricity of the at least one looping peg on the carrier are variably adjustable.

10. The apparatus of claim 1, characterized in that a stamping device is disposed between the forming device and a loading station for placing the wave windings in rod-shaped receivers, which stamping device has

(a) a conveyor means adapted to convey the wave winding with drivers mounted on an outside thereof at a spacing of adjacent straight portions of the wave windings, and

(b) one or more male dies and female dies laterally beside the conveyor means, by which said dies at least part of one winding head of a wave winding to be placed in the receiver can be forced out of the plane of the adjacent straight portions.

11. The apparatus of claim 10, characterized in that the stamping device has cutting tools for cutting the wave windings to a proper length from the wave winding band.

12. The apparatus of claim 10, characterized in that, between the forming device and the stamping device, there is a loose guide for the formed wave winding band, so that by use of this band a loop of variable length serving as a buffer store can be formed.

13. The apparatus of claim 10, characterized in that the loading station for placing the wave windings in rod-shaped receivers has

movably supported guide rails extending parallel to one another and to the receiver and extending in projection at the sides of the receiver, which said rails guide the winding heads of the wave windings,

an endlessly revolvingly guided conveyor belt which can be controlled with precise positioning, said drivers provided on an outside thereof with a same spacing as the straight portions, and

a positioning drive mechanism for moving the guide rails out of a position in front of slot entrances provided in the rod-shaped receiver into a position at the sides of the slot entrances, whereby the straight portions of the wave windings are introduced into slots of the receiver.

14. The apparatus of claim 1, characterized in that the device for introducing the wave windings into the cylinder member has

a guide for the wave windings which is disposed essentially tangentially relative to the cylinder member having radially outwardly open slots and that can be driven to rotate by a rotary mechanism,

a drive for relative advancement of the wave windings having straight portions joined by the winding heads and/or of the cylinder member along the guide at a speed corresponding to the circumferential speed of the cylinder member, and

guide or thrust devices by which the straight portions, brought to the cylinder member, of the wave windings can be introduced in succession into the radially outwardly open slots.

15. The apparatus of claim 14, characterized in that the guide has a longitudinally movable rod-shaped receiver with parallel transverse slots, into which said receiver a plurality of wave windings, to be introduced jointly into the cylinder member in one work step, can be placed with the straight portions thereof in predetermined transverse slots.

16. The apparatus of claim 15, characterized by stationary guide devices engaging the outer regions of the straight portions and/or the winding heads of the wave windings, by which said guide devices the straight portions can be positively displaced into the radially outwardly open slots of the cylinder member while the cylinder member rotates about a stationary axis and in the process rolls along the rod-shaped receiver that is moved past the cylinder member at a tangent or along a line parallel to the cylinder member.

17. The apparatus of claim 16, characterized in that where the cylinder member is a rotorlike transfer tool, in the radially outwardly open slots thereof there are radially displaceably guided slides which can be moved to beyond the outer circumference and by which the wave windings received in the radially outwardly open slots can be positively displaced into aligned, radially inwardly open slots of a rotor or stator lamination packet disposed concentrically to the transfer.

18. The apparatus of claim 17, characterized in that the axially fixed slides are provided with wedge-shaped faces and are movable radially by corresponding wedge-shaped or conical faces of a common, axially movable drive member.