Search

WO-2026092805-A1 - METHOD AND MANUFACTURING APPARATUS FOR PRODUCING A WAVE WINDING, AND WAVE WINDING

WO2026092805A1WO 2026092805 A1WO2026092805 A1WO 2026092805A1WO-2026092805-A1

Abstract

The invention relates to a method for producing a wave winding (1), the method comprising winding electrical conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) around a stepped winding blade (4) with steps (71, 72, 73) in order to form a winding mat (2), the steps (71, 72, 73) being configured to reduce height deviations between radially inner and outer conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) in the rolled state of the winding mat (2), wherein at least two adjacent steps (71, 72, 73) are used for conductors (34, 56) which have different circumferential positions in the rolled state of the winding mat (2).

Inventors

  • CHAMBRION, MARTIN
  • SELL-LE BLANC, Florian
  • OEHLER, FABIAN
  • POPP, STEPHAN
  • Litt, Audrey
  • RENZ, ALBERT

Assignees

  • Schaeffler Technologies AG & Co. KG

Dates

Publication Date
20260507
Application Date
20251021
Priority Date
20241028

Claims (8)

  1. 1. Method for producing a wave winding (1) in which electrical conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) are wound around a stepped winding blade (4) with steps (71, 72, 73) to form a winding mat (2), wherein the steps (71, 72, 73) are configured to reduce height deviations between radially inner and outer conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) in the rolled state of the winding mat (2), characterized in that at least two adjacent steps (71, 72, 73) are used for conductors (34, 56) with different circumferential positions in the rolled state of the winding mat (2).
  2. 2. Method according to claim 1, characterized in that the steps (71, 72, 73) of the winding blade (4) are adapted in their length (5) and height (6) such that the ladders (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) dip asymmetrically into the winding mat (2) in the circumferential direction.
  3. 3. Method according to claim 1 or 2, characterized in that the at least two adjacent steps (71 ,72,73) have different lengths (5).
  4. 4. Method according to one of claims 1-3, characterized in that the length (7) at which a conductor (34, 56) is wound around a first stage (71, 72, 73) differs from the length (8) at which the conductor (34, 56) is wound around the adjacent stage (71, 72, 73).
  5. 5. Manufacturing device (9) for producing a shaft winding (1) , comprising • a stepped winding blade (4) around which electrical conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) are wound to form a winding mat (2), as well as • a wire feed device for winding the winding blade (4) with the electrical conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56), characterized in that the manufacturing device (9) uses at least two adjacent stages (71, 72, 73) for conductors (34, 56) with different circumferential positions in the rolled state of the winding mat (2) during winding.
  6. 6. Manufacturing device (9) according to claim 5, characterized in that the steps (71 ,72,73) of the winding blade (4) are adapted in their length (5) and height (6) so that the ladders (12,13,22,24,33,34,35,44,46,55,56) dip asymmetrically into the winding mat (2) in the circumferential direction.
  7. 7. Manufacturing device (9) according to claim 5 or 6, characterized in that the at least two adjacent steps (71 ,72,73) have different lengths (5).
  8. 8. Wave winding (1) in which a rolled mat (2) of conductors (12, 13, 22, 24, 33, 34, 35, 44, 46, 55, 56) is wound around a stepped winding blade (4) with steps (71, 72, 73), characterized in that at least two adjacent steps (71, 72, 73) are used for conductors (34, 56) with different circumferential positions in the rolled state of the mat (2).

Description

Method and manufacturing apparatus for the production of a wave winding as well as wave winding The present invention relates to a method and a manufacturing device for producing a wave winding, in which electrical conductors are wound around a stepped winding blade with steps to form a winding mat, the steps being configured to reduce height deviations between radially inner and outer conductors in the wound state of the winding mat. The invention further relates to a wave winding. Methods and manufacturing devices for producing wave windings in which electrical conductors are wound around a stepped winding blade are known. In particular, a rolled mat of conductors is used, which is wound around a winding blade with steps to precisely arrange the conductors in radial positions. The steps of the winding blade serve to reduce height deviations between radially inner and outer conductors. Typically, the conductors are arranged uniformly in a flat mat with a constant foot-to-foot distance. However, as soon as the mat is rolled around the winding blade, this foot-to-foot distance changes depending on the radial position of the conductors. Conductors located in radially outer positions sink deeper into the rolled state than conductors in inner positions, leading to significant height deviations. It is therefore known in principle to use a stepped winding blade, in which the wires are wound on different steps of the winding blade according to their radial positions. This arrangement helps to compensate for the geometric differences between the radial positions of the conductors and to make the winding more uniform. Nevertheless, there are significant problems and disadvantages with the known methods and devices. In particular, contact marks can form between the wires during the rolling and expanding process if they are at the same or a similar height in the rolled state. This occurs especially when the radially inner and outer wires are... Wrapping around the steps of the sword, these contact marks reach a similar height. They occur primarily at the overlapping points of the mat and can penetrate so deeply into the conductors that the insulating material of the wires is damaged, exposing the underlying copper. This poses a significant risk for high-voltage applications, as exposed copper can lead to safety problems, particularly short circuits or breakdowns. Another disadvantage of known methods lies in the difficulty of designing a compact winding head without causing mechanical damage during the winding process. The uniform winding head height achieved by the stepped winding blades often results in suboptimal winding compactness. This leads to increased space requirements for the wave winding, which inefficiently utilizes machine space and thus increases the overall size and material costs. Furthermore, the uneven arrangement of the wires, particularly in the overlap areas, contributes to mechanical stress and material fatigue, which can negatively impact the winding's service life. Furthermore, the problems described lead to increased material usage, particularly for conductive materials like copper, as additional installation space is required to compensate for the geometric and mechanical deficiencies. This not only increases material costs but also results in inefficient electrical performance, since larger winding heads can lead to higher resistance losses and thus reduced energy efficiency. The object of the invention is therefore to avoid or at least reduce the problems known from the prior art and to provide an improved method and an improved manufacturing device for producing a shaft winding. It is also an object of the invention to realize an optimized shaft winding. This problem is solved by a method for producing a wave winding in which electrical conductors are wound around a stepped winding blade with steps to form a winding mat, wherein the steps are configured to reduce height deviations between radially inner and outer conductors in the rolled state of the winding mat, wherein at least two adjacent steps are used for conductors with different circumferential positions in the rolled state of the winding mat. This combination of features offers the advantage that, by using adjacent steps for conductors with different circumferential positions in the rolled state of the mat, the formation of additional local contact indentations between the wires is minimized, especially at the points where the mat overlaps. The adapted step configuration prevents the conductors from pressing against each other in different circumferential and/or radial positions, which can lead to deep contact indentations in conventional winding processes. These indentations are problematic because they can be so deep that the copper is exposed, leading to significant high-voltage safety risks. With the solution described here, the winding head remains compact while simultaneously ensuring that no damage occurs to the conducto