Wireworking – Article making or forming – Forms and frames
Reexamination Certificate
1999-08-06
2001-05-01
Larson, Lowell A. (Department: 3725)
Wireworking
Article making or forming
Forms and frames
Reexamination Certificate
active
06223784
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and device for producing wave windings for electrical machines, especially for a stator of a three-phase generator.
2. Prior Art
The invention is based on a method and a device for producing wave windings for electric machines according to U.S. Pat. No. 4,857,787. In that instance, the winding for each phase of a three-phase generator is first wound onto a drum or a polygon with the necessary number of windings and is then deformed into a star shape. After this, the winding is folded into two halves so that the two halves are disposed next to one another. Then the two halves are pivoted in such a way that the gaps of the star-shaped loops or waves of one winding half have a loop of the other winding half disposed in them. The wave winding of the one phase that is prepared in this manner is then inserted axially in a known manner into the slots of a stator lamination packet. In the same manner, the winding of the second and third phase of the three-phase generator are then successively preformed, divided, pivoted in relation to each other so that they are offset from one another, and inserted into the stator lamination packet.
The division of each phase winding into two parts and the pivoting in relation to one another is relatively costly in this method and can be produced by means of commercially available robots for a large-scale mass production only with a multitude of malfunction-prone manufacturing steps.
The automatic large-scale mass production of two-part wave windings with waves of that are offset from one another should be simplified and improved with the current embodiment.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved method for producing wave windings for electrical machines, especially for a stator of a three-phase generator, which is simpler than the current method.
It is another object of the present invention to provide an improved device for producing wave windings for electrical machines, especially for a stator of a three-phase generator.
According to the invention the method provides a wave winding for a stator of a three-phase generator, which is divided into two winding halves, each consisting of at least one continuous winding wire. Each winding half is in a circular or polygonal shape or deformed into a star shape. They are offset from each other by one pole pitch (p). The wave winding is arranged in grooves provided in a stator lamination packet so that alternating winding heads of the two winding halves are formed on both sides of the stator lamination packet around a circumference of the stator lamination packet. The method comprises the steps of:
a) winding the at least one continuous winding wire in a first winding direction to form a first winding half in the circular or polygonal shape;
b) switching over the at least one continuous winding wire into an opposite winding direction in a winding loop;
c) after the switching over of the at least one continuous winding wire, winding the at least one continuous winding wire in the opposite winding direction to form a second winding half in the circular or polygonal shape;
d) simultaneously deforming both the first winding half and the second winding half into a star shape; and
e) after the deforming of step d) rotating the first winding half and the second winding half with respect to each other by one pole pitch, so that the winding loop between the first winding half and second winding half transitions into the star shape.
The device according to the invention comprises means for winding the at least one continuous winding wire in a first winding direction to form a first winding half in the circular or polygonal shape; means for switching over the at least one continuous winding wire into an opposite winding direction in a winding loop after the formation of the first winding half; means for winding the at least one continuous winding wire in the opposite winding direction to form a second winding half in the circular or polygonal shape after the switching over; means for simultaneously deforming both first winding half and the second winding half into a star shape and means for rotating the first winding half and second winding half with respect to each other by one pole pitch after the deforming so that the winding loop between the first winding half and second winding half transitions into the star shape.
The means for winding the at least one continuous winding wire to form the first winding half and the second winding half in the device according to the invention comprises a winding bell rotatable in either of two rotation directions, a plurality of radially movable forming clamps connected to the winding bell and arranged around its circumference, so that the at least one continuous winding wire is wound around the forming clamps.
The means for switching over comprises a loop puller for forming the winding loop and the means for deforming both first winding half and second winding half comprises forming levers and means for moving the forming levers radially inward to engage with the first winding half and the second winding half wound around the forming clamps.
The method according to the invention and the provided device for producing wave winding halves that are offset from one another, according to the characterizing features of the invention has the advantage that on a winding bell, the two continuous winding halves that are wound one after the other are already wound in an opposite winding direction to one another and deformed into a star shape. By way of a winding loop that is formed between the two winding halves, the two winding halves can then be rotated to the left or right in relation to each other by one pole pitch so that the waves of the two winding halves, which are embodied as star-shaped, are then offset in relation to each other by one pole pitch. Subsequently, the wave winding that is preformed in this fashion is inserted in a known manner into a stator lamination packet of a generator. In the same manner, all three-phase windings of the three-phase generators are produced separately as wave windings and are inserted one after the other into the stator lamination packet. In this manner, the wave windings, with winding halves that are offset from one another, can be produced in a simple and reliable manner in a few work steps in one winding station, and can be transferred to an insertion station.
REFERENCES:
patent: 5881778 (1999-03-01), Barrera
Larson Lowell A.
Robert & Bosch GmbH
Striker Michael J.
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