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EP-4010967-B1 - MANUFACTURING SYSTEM AND METHOD FOR MANUFACTURING A STATOR WITH BAR CONDUCTORS

EP4010967B1EP 4010967 B1EP4010967 B1EP 4010967B1EP-4010967-B1

Inventors

  • Peschina, Jürgen
  • FROMMER, Stefan

Dates

Publication Date
20260513
Application Date
20200723

Claims (16)

  1. A holding device (9) for a stator (2) having a main body (3) and a multiplicity of bent and/or straight bar conductors (4), wherein the holding device (9) has at least one first set of fingers (10) for engaging between the bar conductors (4) at a first end side (11) of the main body (3), wherein the holding device (9) has a first rotatable cam disk (32) for displacing the fingers (10) of the first set, characterized in that the cam disk (32) is driven via a slide gate (38) and that the slide gate (38) has a securing means (39) which prevents displacement of the slide gate (38) in an inactivated state.
  2. A manufacturing system (1) for manufacturing a stator (2) for an electric machine, in particular an electric motor, wherein the stator (2) has a main body (3) and a multiplicity of bent and/or straight bar conductors (4), wherein the manufacturing system (1) has the following: - a bending machine (5) for bending free ends (6) of the bar conductors (4), - a spreading machine (7) for spreading apart the free ends (6) of the bar conductors (4) in the radial direction, - a welding machine (8) for welding the free ends (6) of in each case at least two bar conductors (4), - a holding device (9) according to claim 1 for the stator (2), wherein the holding device (9) is able to be affixed on the bending machine (5), the spreading machine (7) and the welding machine (8), wherein the manufacturing system (1) furthermore has a loading and unloading station (17) for the holding device (9), and wherein an activation element (40) for the securing means (39) is configured on the loading and unloading station (17).
  3. The manufacturing system (1) as claimed in claim 2, characterized in that the holding device (9) has a uniform interface (18) for affixing the holding device (9) on the bending machine (5), the spreading machine (7) and the welding machine (8).
  4. The manufacturing system (1) as claimed in one of the preceding claims 2 or 3, furthermore having a handling apparatus (20) for moving the holding device (9) to the bending machine (5), the spreading machine (7) and the welding machine (8), in particular wherein the holding device (9) has a coupling portion (21), preferably a quick-change coupling portion, for the handling apparatus (20).
  5. The manufacturing system (1) as claimed in one of the preceding claims 2 to 4, characterized in that the holding device (9) has a first component of a centering clamping system, in particular of a zero-point clamping system, and in that the bending machine (5), the spreading machine (7) and the welding machine (8) have in each case a complementary component of the centering clamping system.
  6. The manufacturing system (1) as claimed in one of the preceding claims 2 to 5, characterized in that the holding device (9) has a centering element (26) for radially bearing of the fingers (10) of the first set.
  7. The manufacturing system (1) as claimed in one of the preceding claims 2 to 6, characterized in that the fingers (10), between an engagement portion (30) and a drive portion (31) of the respective finger (10), have in each case an elastic element (29).
  8. The manufacturing system (1) as claimed in one of the preceding claims 2 to 7, characterized in that the holding device (9) has a second set of fingers (35) for engaging between the bar conductors (4) at a second end side (36) of the main body (3).
  9. The manufacturing system (1) as claimed in claim 8, characterized in that the holding device (9) has a second rotatable cam disk (37) for displacing the fingers (35) of the second set.
  10. The manufacturing system (1) as claimed in claim 9, characterized in that the two cam disks (32, 37) are able to be driven in common by the slide gate (38).
  11. The manufacturing system (1) as claimed in one of the preceding claims 2 to 10, characterized in that the bending machine (5), the spreading machine (7) and the welding machine (8) form a first manufacturing circuit (42) for circulating the holding device (9), in that the manufacturing system (1) has a further spreading machine (43), a further welding machine (44) and a further holding device (45) for a stator (2), and in that the bending machine (5), the further spreading machine (43) and the further welding machine (44) form a second manufacturing circuit (46) for circulating the further holding device (45).
  12. The manufacturing system (1) as claimed in one of the preceding claims 2 to 11, characterized in that the manufacturing system (1) has a common platform (49) on which the components of the manufacturing system (1) are arranged.
  13. A holding device (9) as claimed in claim 1, characterized in that the holding device (9) has a second set of fingers (35) for engaging between the bar conductors (4) at a second end side (36) of the main body (3), that the holding device (9) has a second rotatable cam disk (37) for moving the fingers (35) of the second set, and that the two cam disks (32, 37) are able to be driven in common by the slide gate (38).
  14. A method for manufacturing a stator (2) for an electric machine, in particular an electric motor, with a manufacturing system as claimed in one of the claims 2 to 12, comprising the steps: a) affixing (100), in particular clamping, the main body (3) and the bar conductors (4) in the holding device (9, 45), wherein the fingers (10, 35) of the holding device (9, 45) engage between the bar conductors (4), b1) moving (102) the holding device (9, 45) to the bending machine (5), and bending (104) the free ends (6) of the bar conductors (4), b2) moving (106) the holding device (9, 45) to a spreading machine (7, 43), and spreading apart (108) the free ends (6) in the radial direction, c) moving (110) the holding device (9, 45) to the welding machine (8, 44), and welding (112) the free ends (6) of at least two of the bar conductors (4), d) releasing (116) the stator (2) in the holding device (9, 45), wherein the fingers (10, 35) are disengaged from between the bar conductors (4), and retrieving (118) the stator (2) from the holding device (9, 45).
  15. The method as claimed in claim 14, characterized in that steps a) and d) are carried out in the loading and unloading station (17, 48), and in that the holding device (9, 45) between steps c) and d) is moved (114) to the loading and unloading station (17, 48).
  16. The method as claimed in one of claims 14 or 15, characterized in that initially at least one method cycle takes place using a first holding device (9, 45), and in that subsequently at least one method cycle takes place using a second holding device for a stator of another type.

Description

The invention relates to a manufacturing system for producing a stator for an electric machine, in particular an electric motor, wherein the stator comprises a base body and a plurality of bent or straight conductors. The invention further relates to a method for producing a stator for an electric machine, in particular an electric motor, wherein the stator comprises a base body and a plurality of straight or bent conductors. Electrical machines, such as electric motors, commonly feature a stator with a coil winding. Traditionally, the coil winding is produced by winding a wire. However, such winding methods are technically complex and subject to limitations. Furthermore, the fill factor (the area covered by the wire in a wound cross-section) is limited in wound coils. The coils of stators in electrical machines can alternatively be formed by interconnected rod conductors inserted into a stator body. Particularly in the field of electrically driven (or powered) motor vehicles, electric motors with stators featuring rod conductors are increasingly used. To connect two rod conductors, their free ends are typically welded together. Before welding, the rod conductors are usually bent so that the free ends of the two conductors to be welded are brought close together. Furthermore, the free ends of the rod conductors are usually spread out radially before welding so that rod conductors not being welded together do not touch each other. According to the current state of the art, handling and fixing the stator with the rod conductors is very complex. From the WO 2019/040958 A1 A manufacturing system with a holding device for manufacturing a stator of an electric machine with rod conductors is known. Object of the invention The invention is based on the objective of providing a manufacturing system and a manufacturing process for the accelerated and cost-effective production of stators with rod conductors. Brief description of the invention This problem is solved by a manufacturing system for producing a stator for an electric machine according to claim 2. According to the invention, the holding device serves to handle the stator and fix it to the individual machines of the production system. During the machining of a stator with the machines of the production system, the stator is generally not removed from the holding device but remains held in it. The production system allows the stator to be manufactured without providing special fixtures for the type of stator being produced on each individual machine. The holding device thus forms an intermediate element for connecting the stator to the individual machines. Mounting and holding devices on the machines can therefore be designed more simply and cost-effectively, as they only need to be adapted to the holding device. The holding device also speeds up the process of attaching the stator to the individual machines. In particular, it is not necessary to laboriously fix the base body and the rod ladder on each of the machines. The holding device can be used for The machines are equipped with a set of coupling elements. Each machine typically has a set of corresponding feedback elements. For different types of stators, particularly those with different dimensions (e.g., length and diameter), the feedback elements on the machines within the production system remain identical; only the holding devices (specifically adapted to the respective stator type, e.g., in terms of length and diameter) are used. The bending, spreading, and welding machines can therefore be used to manufacture different types of stators without modification. The holding device can also be used universally outside the production system for handling the stator. The holding device has at least one set of fingers. These fingers are used to engage between the pole sections at a first end face of the base body. When the fingers engage between the pole sections, they typically overlap the base body, at least partially. The fingers of the first set can therefore fix the base body in at least one direction. By engaging between the pole sections, the fingers can fix and align them. Typically, the fingers rest against the pole sections when they engage between them. The fingers of the holding device are generally movable in the radial direction between an open (radially outward extended) and a closed (radially inward extended) position. In the open position, the stator can be inserted into and removed from the holding device. The fingers typically have at least one shoulder, preferably two, for radially clamping the ladder. This allows for particularly precise alignment of the ladder. The bending machine is used to bend the free ends of the pole ladders so that the free ends of at least two pole ladders to be welded together are brought close together. The spreading machine is used to spread the free ends of the pole ladders radially. Spreading prevents the ends of pole ladders that are not to be welded toge