EP-4740231-A1 - METHOD AND SYSTEM FOR WINDING A COIL MEMBER

Abstract

The invention relates to a method and a system for winding a flat wire (3) edgewise onto a coil member (2).

Inventors

• RODLER, Markus
• MOSER, STEFAN

Assignees

• InTiCa Systems SE

Dates

Publication Date

20260513

Application Date

20240722

Claims (1)

1. patent claims 1 ) Method for winding a coil body (2) with a flat wire (3) in a standing arrangement, the method comprising the following steps: - Providing a coil body (2) with a winding area (2.1 ); - Providing a flat wire (3) which can be fed to the winding area (2.1) of the coil body (2) via a wire guide (4), wherein the wire guide (4) has an elongated, rail-like guide area (4.1) which is guided directly to the winding area (2.1) for winding the coil body (2) and which guides the flat wire (3) at least on a narrow side (3.1) facing away from the coil body (2) and a broad side (3.2) of the flat wire (3); - Rotating the coil body (2) while simultaneously feeding the flat wire (3) by means of the wire guide (4) so that the flat wire (3) is placed in an upright position on the winding area (2.1 ) of the coil body (2), wherein a guiding force directed radially to the coil body longitudinal axis (SLA) is exerted on the flat wire (3) by a first section (4.1.1 ) of the guide region (4.1 ) of the wire guide (4) and a contact pressure directed parallel or substantially parallel to the coil body longitudinal axis (SLA) is exerted on the flat wire (3) at least temporarily by a second section (4.1.2) of the guide region (4.1 ) of the wire guide (4); - Winding the winding area (2.1) several times with the flat wire (3) so that a directly wound coil body (2) with a coil comprising several turns is produced. 2) Method according to claim 1, characterized in that the winding region (2.1) of the coil body (2) has a cross-section with a non-circular outer peripheral contour. 3) Method according to claim 2, characterized in that the winding region (2.1) of the coil body (2) has a plurality of winding region surfaces (2.1.1, 2.1.2, 2.1.3), and wherein the flat wire (3) is guided by means of the wire guide (4) over a length (I) which is equal to or greater than the greatest width of the winding region surfaces (2.1.1, 2.1.2, 2.1.3), which is measured perpendicular to the coil body longitudinal axis (SLA). 4) Method according to one of the preceding claims, characterized in that the flat wire (3) is at least temporarily attached to a preceding coil winding by the wire guide (4), so that the coil windings adjoin one another without gaps. 5) Method according to one of the preceding claims, characterized in that the flat wire (3) rests in a form-fitting manner in the guide region (4.1) of the wire guide (4). 6) Method according to one of the preceding claims, characterized in that the wire guide (4) is moved in the radial direction relative to the coil body longitudinal axis (SLA), in such a way that the flat wire (3) guided through the wire guide (4) has a predetermined position relative to the winding area surfaces (2.1.1, 2.1.2, 2.1.3) of the winding area (2.1) of the coil body (2) when the coil body (2) rotates in the radial direction. 7) Method according to claim 6, characterized in that the flat wire (3) is guided by the wire guide (4) at a distance of less than 1 mm in the radial direction to the winding area (2.1) and/or that the flat wire (3) is pressed radially by the wire guide (4) at least partially onto the winding area (2.1) of the coil body (2). 8) Method according to one of the preceding claims, characterized in that the wire guide (4) is translationally movable at least in an axial direction running radially to the coil body longitudinal axis (SLA). 9) Method according to one of the preceding claims, characterized in that the wire guide (4) is moved by a cam gear or by a motor drive. 10) Method according to one of the preceding claims, characterized in that the wire guide (4) is designed in several parts and that the second section (4.1 .2) of the guide region (4.1) of the wire guide (4) is changed in its position for applying at least the last coil turn, so that the flat wire (3) is guided only in the region of its narrow side (3.1) which faces away from the coil body (2) when applying at least the last coil turn. 11) Method according to one of the preceding claims, characterized in that the wire guide (4) is movable in a controlled manner in the direction of the coil body longitudinal axis (SLA), in each case stepwise after the application of a coil turn by the shorter cross-sectional dimension of the flat wire (3). 12) System for winding a coil body (2) with a flat wire (3) in a standing arrangement, comprising a rotationally drivable holder (5) for the coil body (2) and a wire guide (4) by means of which the flat wire (3) can be positioned on a winding area (2.1) of the coil body (2), wherein the wire guide (4) has an elongated, rail-like guide area (4.1) which is positioned directly on the winding area (2.1) for winding the coil body (2) and which guides the flat wire (3) at least on a narrow side (3.1) facing away from the coil body (2) and a broad side (3.2) of the flat wire, wherein the wire guide (4) is designed in such a way and is positioned relative to the coil body (2) when the coil body (2) rotates about its coil body longitudinal axis (SLA) in such a way that a first section (4.1.1) of the A guiding force directed radially to the coil body longitudinal axis (SLA) is exerted on the flat wire (3) by the guide region (4.1) of the wire guide (4) and a contact pressure directed parallel or substantially parallel to the coil body longitudinal axis (SLA) is exerted on the flat wire (3) at least temporarily by a second section (4.1.2) of the guide region (4.1) of the wire guide (4). 13) System according to claim 12, characterized in that the first and second sections (4.1.1, 4.1.2) of the guide region (4.1) of the wire guide (4) enclose the flat wire (3) at an angle. 14) System according to claim 12 or 13, characterized in that the guide region (4.1) of the wire guide (4) is adapted to the outer contour of the flat wire region which rests against the guide region (4.1). 15) System according to one of claims 12 to 14, characterized in that the winding area (2.1) of the coil body (2) has a cross-section with a non-circular outer circumferential contour and that the wire guide (4) can be adjusted in the radial direction relative to the coil body (2) by a cam gear or by a motor drive such that the wire guide (4) maintains a defined distance from the winding area (2.1) of the coil body (2) when the coil body (2) rotates. 16) System according to one of the preceding claims 12 to 15, characterized in that the wire guide (4) is designed in several parts, in such a way that when winding the coil body (2) the second section (4.1.2) of the guide area (4.1 ) of the wire guide (4) can be temporarily moved away so that the guide of the flat wire (3) is only through the first section (4.1.1 ) of the guide area (4.1 ) of the wire guide (4).

Description

Method and system for winding a coil body The invention relates to a method and a system for directly winding a coil body with a flat wire in a vertical arrangement. It is known to wind coil bodies directly with a round wire. When using a flat wire, it is known from the document EP 2 854 263 B1 to first wind an air coil (i.e. to produce the coil alone without directly winding a coil body) and then to place this air coil on a coil body, in particular a core made of a ferromagnetic material. The known manufacturing process cannot be used for coil bodies with projecting pole faces that improve the magnetic flux or other projecting side faces connected to the coil body, since the coil must have a larger internal opening than the cross-section of the winding area onto which the flat wire winding is to be plugged due to the side faces projecting beyond the cross-section of the winding area. Based on this, it is the object of the invention to provide a method which enables a direct winding of a coil body with a flat wire in a standing arrangement. The object is achieved by a method having the features of independent patent claim 1. A system for winding of a coil body is the subject of the independent patent claim 11. Preferred embodiments are the subject of the dependent claims. According to a first aspect, a method for winding a coil body with a flat wire in a standing arrangement is disclosed. The method comprises the following steps: First, a coil body with a winding area is provided. In a first embodiment, the winding area can have a non-circular outer circumferential contour in cross section. In an alternative embodiment, the winding area can be rotationally symmetrical with respect to a coil body longitudinal axis, i.e. have a circular outer circumferential contour in cross section. The coil body has an upper and a lower side surface, which preferably protrude, i.e. the side surfaces protrude laterally at least in sections relative to the cross-sectional area of the winding area. The coil body forms, for example, a magnetic core and is made of a magnetically conductive material, for example a package of several core sheets or a ferrite material. An electrically insulating material can be provided on the outside of the magnetic core at least in sections, for example an insulating paper, a plastic overmold or a plastic shell. The opposite side surfaces preferably form the pole faces of the magnetic core. In addition, a flat wire is provided which can be fed to the winding area of the coil body via a wire guide. The wire guide has an elongated, rail-like guide area which is brought directly to the winding area for winding the coil body and which guides the flat wire at least on one side of the The wire is preferably fed in a horizontal or vertical direction towards the coil body. In principle, it is also possible to feed the wire at an angle. The coil body is then rotated around a coil body longitudinal axis while the flat wire is fed in at the same time, so that the flat wire is wound up in an upright position on the outside of the winding area of the coil body. Depending on the feed direction of the wire, the coil body longitudinal axis is aligned horizontally (with vertical wire feed), vertically (with horizontal wire feed) or diagonally. During winding, a first section of the guide area of the wire guide exerts a guiding force directed radially to the coil body longitudinal axis and, at least temporarily, a second section of the guide area of the wire guide exerts a contact pressure directed parallel or essentially parallel to the coil body longitudinal axis on the flat wire. The winding area is wrapped several times with the flat wire so that a directly wound coil body with a coil comprising several turns is produced. The technical advantage of the method is that the wire guide enables a coil body to be wound directly with a flat wire in an upright arrangement, in such a way that the flat wire can be wound very precisely and does not tend to become slanted or fall over. According to one embodiment, the winding area of the coil body has several winding area surfaces. Two Winding area surfaces preferably connect to one another by means of a curve. The winding area surfaces are flat or essentially flat. The flat wire is guided by the wire guide over a length that is equal to or greater than the greatest width of the winding area surfaces, which is measured perpendicular to the coil body's longitudinal axis. This ensures that the flat wire is guided over the entire width of the winding area surfaces. This guidance of the flat wire enables very precise alignment and positioning of the flat wire during the winding process. According to one embodiment, the flat wire is at least temporarily attached to a preceding coil winding by the wire guide, so that the coil windings adjoin one another without gaps. This applies in particular from the second coil winding onwards. The first coil winding is preferably attache