EP3096335A1 - Bobbin winding method and bobbin winding device - Google Patents

Abstract

Coil winding process in which an electrically conductive and already electrically insulated wire (1) is fed to a coil carrier (20) by means of a coil winding device (100) and wound onto it, with a thermally conductive material (3) being applied to the wire (3) during the winding process. 1) or coil carrier (20) is applied.

Description

The present invention relates to a coil winding method in which in a winding process, an electrically conductive and ready electrically insulated wire is fed by means of a coil winding device to a bobbin and wound on this. The present invention also relates to a coil winding device for supplying an electrically conductive and ready electrically insulated wire to a bobbin and for winding the wire on the bobbin.

Such coil winding methods and coil winding devices are basically known from the prior art and are used for producing coils for electrical machines such as hand tool machines. The bobbin on which the wire is wound or wound, may be a pole tooth of an electrical machine or have such. In operation, a current is applied to the electrically conductive wire in order to convert electrical energy into mechanical energy, in particular rotational energy, by means of the electromotive principle.

It is an object of the present invention to provide a coil winding method and a coil winding apparatus, which enable the production of coils with more compact dimensions.

With respect to the coil winding method, the object is achieved in that during the winding process, a thermally conductive material is applied directly to the wire and / or the bobbin.

The invention includes the realization that current-charged coils have energy losses that lead to heating of the coil. This heat can typically be dissipated only radially outward poorly, since the windings of the coil often have no area contact with each other and remain between the wires air gaps. In the case of coils of the prior art, this disadvantageously leads to the fact that high-quality wire qualities have to be used or larger construction volumes of the coil are required.

Characterized in that in the coil winding method according to the invention during the winding process, a thermally conductive material directly on the wire and / or the Coil carrier is applied, air gaps or inclusions between the wire layers or turns can be avoided and a flat, good heat conducting contact of the turns or wire layers are made to each other. Advantageously, a winding operation downstream of the application of a thermally conductive material on the then already finished wound coil account.

A coil produced in accordance with the invention has the advantage that the heat generated during a current flow through the wire can now be dissipated to the outside in an improved manner. This is the one hand, the production of coils with more compact dimensions, that is higher power densities possible. Furthermore, the fact that now cheaper wire qualities are used for the production of the coil, a significant cost reduction in the production of coils achieved.

Furthermore, with the use of a corresponding material, the fixation of the wire on the coil or the wires can be improved with each other.

In a preferred embodiment of the coil winding method, the thermally conductive material is applied to the wire, if this is already located as an at least partially coil on the bobbin. The method may provide that before or while the wire comes into contact with or wound onto the bobbin, thermally conductive material is also applied to the bobbin itself. This may be the case, for example, in the production of the first winding layer of the wire on the coil carrier.

It has proven to be advantageous if the thermally conductive material by a material application unit, based on a direction of rotation of the bobbin, leading and / or trailing applied to the wire and / or the bobbin.

In a leading order of the thermally conductive material on the bobbin, for example, each newly wound winding of the wire is embedded in the then already on the bobbin heat-conductive material. With regard to further layers, a leading order may mean that initially a gap of a respectively underlying wire layer is first filled with the thermally conductive material and then the wire still to be wound is embedded at this point. As part of a trailing order, a wire section can first be wound onto the bobbin and then the thermally conductive material can be applied to this.

In a particularly preferred embodiment, the thermally conductive material is applied to the wire or the coil carrier via a material application unit. The During the winding process, the material application unit can be moved relative, preferably in parallel, to a reel carrier longitudinal axis of the reel carrier. During the winding process, the material application unit can be moved relative to the winding tool, preferably in the same direction as the winding tool, and / or carried along. If necessary, it is also possible to realize an opposite movement of the material application unit to the winding tool.

The method may provide that the thermally conductive material is a paste, an adhesive or a wax. The thermally conductive material may be provided as a fluid, as a pad, or as a filamentary / unrollable material. In a preferred embodiment, the thermally conductive material is sprayed onto the wire and / or the coil carrier.

As an alternative to the fact that the thermally conductive material is applied to the wire when it is already at least partially coil on the bobbin, the thermally conductive material can be applied to the still-to-be-wound wire. In other words, a wire section already to be wound up may already have a thermally conductive material to be applied in the course of the method before this wire section comes into contact with the coil carrier.

In a preferred embodiment, the thermally conductive material is only applied to the wire after the wire has passed a winding tool of the coil winding device, which plastically deforms the wire. Alternatively, the method may provide that the thermally conductive material is already applied to the wire before the wire passes a winding tool of the coil winding apparatus that plastically deforms the wire. As another alternative, it is possible for the thermally conductive material to be applied to the wire while the wire passes through a winding tool of the coil winding apparatus that plastically deforms the wire.

It has proven to be advantageous if the thermally conductive material is applied in strips along a longitudinal axis of the wire. The thermally conductive material may be applied to the wire such that a respective cross section of the wire in the circumferential direction is only partially covered by thermally conductive material. The thermally conductive material may be in the form of four strips equally spaced along the circumference of the wire. However, it is also possible that the thermally conductive material extends in more than four stripes. The coil winding method may be a linear, needle or flyer winding method, and carried out on a linear, needle or bobbin winder, respectively. The linear winding device may also be referred to as a layer winder or Bobinwickler.

The invention is also achieved by a coil device of the aforementioned type, wherein the coil winding device has a material application unit, by means of which during the winding process, a thermally conductive material can be applied directly to the wire and / or the bobbin.

In a preferred embodiment of the coil winding device, the material application unit is arranged and arranged such that the thermally conductive material is applied to the wire when it is already located as an at least partially coil on the bobbin.

In an alternative embodiment, the material application unit may be arranged and arranged such that the thermally conductive material is first applied to the wire after the wire has passed a winding tool of the coil winding device, which plastically deforms the wire. Alternatively, the material application unit may be arranged and arranged such that the thermally conductive material is already applied to the wire before the wire passes through the winding tool of the coil winding device, which plastically deforms the wire. Alternatively, the material application unit may be arranged and arranged such that the thermally conductive material is applied to the wire while the wire passes through the winding tool of the coil winding apparatus, which plastically deforms the wire.

In a further preferred embodiment, the material application unit is arranged and arranged such that the thermally conductive material is applied in strips along a longitudinal axis of the wire, preferably applied to the wire such that a respective cross section of the wire is only partially covered in the circumferential direction of thermally conductive material.

Further preferably, the coil winding device can be designed and set up such that the material application unit applies the heat-conductive material to the wire or the coil carrier in advance and / or trailing relative to a direction of rotation of the coil carrier.

Preferably, the coil winding device is designed and set up so that the material application unit is moved during the winding process relative to the winding tool, preferably in the same direction as the winding tool. In a further embodiment, this coil winding device is designed and set up so that the material application unit is moved relatively, preferably in parallel, to a coil carrier longitudinal axis of the coil carrier during the winding process and / or the material application unit is carried along with the winding tool.

It should be understood that the features described with reference to the coil winding method should also be deemed to be disclosed with respect to the coil winding assembly and vice versa. For example, when it is disclosed with respect to the coil winding method that the thermally conductive material is applied to the still-to-be-wound wire, it should be disclosed that the coil winding device is designed to apply the thermally conductive material to the wire still to be wound.

Further advantages will become apparent from the following description of the figures. In the figures, various embodiments of the present invention are shown. The figures, the description and the claims contain numerous features in combination. The person skilled in the art will expediently also consider the features individually and combine them into meaningful further combinations. In the figures, identical and similar components are numbered with the same reference numerals.

Fig. 1

ein erstes Ausführungsbeispiel einer erfindungsgemäßen Spulenwickelvorrichtung, auf der ein erfindungsgemäßes Spulenwickelverfahren ausgeführt wird;

Fig. 2

ein zweites Ausführungsbeispiel einer erfindungsgemäßen Spulenwickelvorrichtung, auf der ein erfindungsgemäßes Spulenwickelverfahren ausgeführt wird;

Fig. 3

ein drittes Ausführungsbeispiel einer erfindungsgemäßen Spulenwickelvorrichtung, auf der ein erfindungsgemäßes Spulenwickelverfahren ausgeführt wird;

Fig. 4

ein viertes Ausführungsbeispiel einer erfindungsgemäßen Spulenwickelvorrichtung, auf der ein erfindungsgemäßes Spulenwickelverfahren ausgeführt wird;

Fig. 5

ein fünftes Ausführungsbeispiel einer erfindungsgemäßen Spulenwickelvorrichtung, auf der ein erfindungsgemäßes Spulenwickelverfahren ausgeführt wird;

Fig. 6

ein sechstes Ausführungsbeispiel einer erfindungsgemäßen Spulenwickelvorrichtung, auf der ein erfindungsgemäßes Spulenwickelverfahren ausgeführt wird;

Fig. 7

ein siebtes Ausführungsbeispiel einer erfindungsgemäßen Spulenwickelvorrichtung, auf der ein erfindungsgemäßes Spulenwickelverfahren ausgeführt wird;

Fig. 8

ein achtes Ausführungsbeispiel einer erfindungsgemäßen Spulenwickelvorrichtung, auf der ein erfindungsgemäßes Spulenwickelverfahren ausgeführt wird;

Fig. 9

ein neuntes Ausführungsbeispiel einer erfindungsgemäßen Spulenwickelvorrichtung, auf der ein erfindungsgemäßes Spulenwickelverfahren ausgeführt wird.

Show it:

Fig. 1

a first embodiment of a coil winding device according to the invention, on which a coil winding method according to the invention is carried out;

Fig. 2

A second embodiment of a coil winding device according to the invention, on which a coil winding method according to the invention is carried out;

Fig. 3

a third embodiment of a coil winding device according to the invention, on which a coil winding method according to the invention is carried out;

Fig. 4

A fourth embodiment of a coil winding device according to the invention, on which a coil winding method according to the invention is carried out;

Fig. 5

A fifth embodiment of a coil winding device according to the invention, on which a coil winding method according to the invention is carried out;

Fig. 6

a sixth embodiment of a coil winding device according to the invention, on which a coil winding method according to the invention is carried out;

Fig. 7

A seventh embodiment of a coil winding device according to the invention, on which a coil winding method according to the invention is carried out;

Fig. 8

an eighth embodiment of a coil winding device according to the invention, on which a coil winding method according to the invention is carried out;

Fig. 9

A ninth embodiment of a coil winding device according to the invention, on which a coil winding method according to the invention is carried out.

Exemplary embodiments :

Fig. 1 shows a coil winding device 100 according to the invention for supplying an electrically conductive and already electrically insulated wire 1 on a to a coil carrier 20 and for winding the wire 1 on the bobbin 20. The coil winding device 100 has a material application unit 30, by means of which during the winding process, a thermally conductive material 3 can be applied to the wire 1 and the bobbin 20.

The wire 1 is plastically deformed by a winding tool 10 and fed to the bobbin 20, wherein the bobbin is rotatably mounted about its Spulenträgerlängsachse 21, so that the wire 1 can be wound on the bobbin 20 by rotation of the bobbin 20. The thermally conductive material 3 is in in Fig. 1 illustrated embodiment applied to a material application unit 30, wherein the material application unit 30 is formed along the movement axis 31 movable.

On the in Fig. 1 A coil winding method according to the invention is carried out, in which in a winding process the electrically conductive and already electrically insulated wire 1 is fed by means of the coil winding device 100 or by its winding tool 10 to a coil carrier 20 and wound onto it, wherein the thermally conductive material 3 on the coil carrier 20 is applied.

In Fig. 1 the state is shown in which an incomplete first layer of the wire 1 is located on the bobbin 20 and the thermally conductive material 3 is applied to the bobbin 20 when the wire is already at least partially located as a spool on the bobbin 20. Im in Fig. 1 illustrated embodiment, the thermally conductive material 3 is provided as a thread-like and unrollable material. The thermally conductive material 3 may be, for example, medium viscosity to solid.

The coil winding device 100 is set up so that the thermally conductive material 3 is applied in advance to the coil carrier 20 by the material application unit 30. For this purpose, the material application unit 30 is movably arranged along the movement axis 31 with respect to the coil carrier 20, the movement axis 31 extending parallel to the coil carrier longitudinal axis 21. During the winding process, the material application unit 30 is carried along in the same direction to the winding tool 10, wherein first the thermally conductive material 3 is applied to the bobbin 20 and then a aufzuwickelnder portion of the wire 1 is embedded in the thermally conductive material 3. Again Fig. 1 can be removed, the thermally conductive material 3 in the course of the winding process uniformly in the respective air gap 1 'between the respective turns of the Wire 1 distributed so that the air gap 1 'is substantially completely filled by thermally conductive material 3. In this way, according to the invention, the thermal conductivity of the coil is improved, so that a loss of heat can be dissipated to the outside in an improved manner.

In the embodiment of the Fig. 1 For example, the winding tool 10 and the material application unit 30 are arranged on opposite sides of the coil carrier 20. In the coil winding device 100 of Fig. 1 the thermally conductive material 3 is first applied to the coil carrier 20 or in further layers only on the wire 1, after the wire 1, the winding tool 10 of the coil winding device 100, which has the wire 1 plastically deformed, passed.

This in Fig. 2 illustrated embodiment 100 corresponds substantially to the reference to Fig. 1 described embodiment, wherein in Fig. 2 the winding of a second layer of the wire 1 on the bobbin 20 is shown. As well as in Fig. 1 the material application unit 30 is carried forward to the winding tool 10, so that a still wound portion of the wire 1 is embedded in the thermally conductive material 3, as can be seen on the upper side of the bobbin. In the coil winding method described on the coil winding apparatus 100 of the Fig. 2 is carried out, comes a thermally conductive material 3 having a higher viscosity than in Fig. 1 used, which is recognizable by the fact that the thermally conductive material 3 emerges from the material application unit 30 in the form of a slightly widening jet.

Fig. 3 shows a coil winding device 100, for example, the Fig. 1 , in side view. Again Fig. 3 can be removed, the winding tool 10 and the material application unit 30 are arranged on opposite sides of the coil carrier 20 to be wound. A winding of the wire 1 on the bobbin 20, which is rotatably mounted about the bobbin longitudinal axis 21, takes place in the direction of rotation R. Fig. 3 be well taken that the order of the thermally conductive material 3 by the material application unit 30 in advance with respect to the direction of rotation R of the bobbin 20 takes place. The thermally conductive material 3 may be, for example, medium viscosity to solid.

In Fig. 4 now an embodiment of a coil winding device 100 is shown, are arranged in the material application unit 30 and winding tool 10 on the same side of the bobbin. Again Fig. 4 can be removed, an order of the thermally conductive material 3 is carried by the material application unit 30 trailing on the bobbin 20, based on the direction of rotation R. The thermally conductive material 3 may be, for example, medium viscosity to solid.

At the in Fig. 5 illustrated embodiment takes place in the coil winding method according to the invention, an order of the thermally conductive material 30 on the wire 1, if this is already located as a coil on the bobbin 20, wherein in the embodiment of Fig. 5 an order of the thermally conductive material 3 by way of example by means of spraying. Accordingly, a jet of the exiting sprayable material 3 is significantly widened at an exit point 30 of the material application unit. As already with reference to the embodiment of the Fig. 1 is also described in the embodiment of the Fig. 5 the material application unit 30 is movably mounted along the movement axis 31, whereby the movement axis 31 runs parallel to the coil carrier longitudinal axis 21.

As the embodiment of Fig. 5 can be removed, a spraying takes place after a wire is already on the bobbin 20 is located. Like the same Fig. 5 can be removed, it is covered as a coil on the bobbin 20 befindlicher wire 1 with the sprayed thermally conductive material 3, so that in a higher position on the bobbin 20 unwound portion of the wire 1 in the thermally conductive material 3, on the respectively below lying position of the wire 1 is embedded.

As Fig. 5 shows, the material application unit 30 in a transverse direction 32 transversely (which includes perpendicular) to the coil longitudinal axis 21 arranged movable and is preferably carried transversely. As a result, the material application unit 30 can advantageously be moved with increasing number of layers of the wire 1 in the course of the progressive winding process such that a constant distance between the material application unit 30 is maintained for each current position of the wire. These are exemplary with reference to Fig. 5 described movement of the material application unit 30 in the transverse direction 32 can also be realized in other embodiments.

With reference to the Fig. 6 to 9 Embodiments will now be described in which the material application unit 30 is arranged and arranged such that the thermally conductive material 3 is applied to the still to be wound wire 1, that is, in particular before the wire 1 comes into contact with the bobbin 20.

At the in Fig. 6 illustrated embodiment of the coil winding device 100, the winding tool 10 is disposed immediately adjacent to the material application unit 30. In this case, the thermally conductive material 30 is first applied to the wire 1, after the wire 1, the winding tool 10, which in the present case the wire 1 also plastically deformed, has happened. At the in Fig. 6 The embodiment shown results in the advantage that the material application unit 30 and the winding tool 10 by one and the same drive unit (not shown) can be moved. The thermally conductive material 3 may, for example, be low to firm.

In the in Fig. 7 In the embodiment shown, the material application unit 30 of the coil winding device 100 is arranged and arranged such that the thermally conductive material 3 is applied to the wire 1 while the wire 1 passes through the winding tool 10 of the coil winding device 100, which plastically deforms the wire 1. This results in a particularly compact design. In the winding tool 10, a reservoir 35 may be provided for storing the thermally conductive material 3. At the in Fig. 7 As shown, the winding device 100, the material application unit 30 is arranged and arranged such that the thermally conductive material 3 is applied in strips along a longitudinal axis L of the wire 1. In this case, an order is placed on the wire 1 such that a respective cross section of the wire 1 in the circumferential direction U is only partially covered by thermally conductive material 3. This is on the right side of the Fig. 7 shown, wherein the thermally conductive material 3 in the form of four strips which are uniformly spaced along the circumference U of the wire 1 from each other.

Like the cut picture on the right side of the Fig. 7 can be removed, the thermally conductive material 3, which runs in four strips, provided as low viscous to highly viscous material, so that there is an approximately circular deposition of the thermally conductive material 3 on the bobbin 20 in the sectional view. Like the same Fig. 7 can be removed, an order of the thermally conductive material 3 takes place on the bobbin 20 at an outlet opening 13 of the winding tool 10th

In the in Fig. 8 In the embodiment shown, a coil winding device 100 is also shown in which the thermally conductive material is applied to the wire 1 while the wire 1 passes through the winding tool 10. This does not happen as at Fig. 7 at an outlet opening 13 of the winding tool 10, but within the winding tool 10 itself. This results in how the Fig. 8 can be removed on the right side, a profile of the thermally conductive material 3, in which the thermally conductive material 3 conforms better to the wire 1.

In the in Fig. 9 embodiment shown is in contrast to those with reference to FIGS. 7 and 8 described embodiments, an order of the thermally conductive material 3 on the wire 1 before it passes a winding tool 10 of the coil winding apparatus 100, which plastically deformed the wire 1. Again Fig. 9 can be removed, the material application unit 30 is arranged relative to the longitudinal axis L (in the arrow direction) of the wire 1 in front of an inlet opening 15 of the winding tool 10. The winding tool 10 has in illustrated embodiment, an inner comb 17 through which the thermally conductive material 4, which is already on entry of the wire 1 in the winding tool 10 on the wire 1, evenly distributed on the wire 1, which in Fig. 9 is indicated by the hatching of the wire 1 after its passage through the winding tool 10.

LIST OF REFERENCE NUMBERS

1

wire

1'

air gap

3

thermally conductive material

10

winding tool

13

Outlet opening of the winding tool

15

Entry opening of the winding tool

17

inner crest

20

coil carrier

21

Coil carrier axis

30

Material application unit

31

Movement axis of the material application unit

35

reservoir

100

Coil winder

L

Longitudinal axis of the wire

Q

transversely

R

direction of rotation

U

Circumferential direction of the wire

Claims (17)

Coil winding method in which in a winding process, an electrically conductive and already electrically insulated wire (1) by means of a coil winding device (100) is fed to a coil carrier (20) and wound on this,
characterized in that during the winding process, a thermally conductive material (3) directly on the wire (1) and / or the bobbin (20) is applied. Coil winding method according to claim 1,
characterized in that the thermally conductive material is applied to the wire (1) when this is already at least partially coil on the bobbin (20) is located. Coil winding method according to claim 1,
characterized in that the thermally conductive material (3) is applied to the still to be wound wire (1). Coil winding method according to one of the preceding claims,
characterized in that the thermally conductive material (3) by a material application unit (30), with respect to a direction of rotation of the bobbin (20), leading and / or trailing on the wire (1) and / or the bobbin (20) is applied. Coil winding method according to one of the preceding claims,
characterized in that the thermally conductive material (3) is first applied to the wire (1) after the wire (1) has passed through a winding tool (10) of the coil winding device (100) which plastically deforms the wire (1). Coil winding method according to one of the preceding claims,
characterized in that the thermally conductive material (3) is already applied to the wire (1) before the wire (1) passes through a winding tool (10) of the coil winding device (100) which plastically deforms the wire (1). Coil winding method according to one of claims 1 to 5,
characterized in that the thermally conductive material (3) is applied to the wire (1) while the wire (1) passes a winding tool (10) of the coil winding device (100) plastically deforming the wire (1). Coil winding method according to one of the preceding claims,
characterized in that the thermally conductive material (3) is applied in strip form along a longitudinal axis (L) of the wire (3) and applied to the wire (1) such that a respective cross section of the wire (1) in the circumferential direction (U) only partially covered by thermally conductive material (3). Coil winding method according to claim 8,
characterized in that the thermally conductive material (3) is in the form of four strips equally spaced along the circumference (U) of the wire (1). Coil winding method according to one of the preceding claims,
characterized in that the thermally conductive material (3) is a paste, an adhesive, or a wax and / or is provided as a preferably sprayable fluid, as a pad or as a thread-like / unrolling material. Coil winding method according to one of the preceding claims,
characterized in that the thermally conductive material (3) on the wire (1) or the bobbin (20) via a material application unit (30) is applied, wherein the material application unit (30) during the winding process relative, preferably parallel, to a bobbin longitudinal axis (21 ) of the bobbin (20) is moved. Coil winding method according to one of the preceding claims,
characterized in that the material application unit (30) during the winding process relative to the winding tool (10), preferably in the same direction to the winding tool (10) moves and / or carried. Coil winding device (100) for feeding an electrically conductive and already electrically insulated wire (1) to a coil carrier (20) and for winding the wire (1) onto the coil carrier (20),
characterized in that the coil winding device (100) comprises a material application unit (30) by means of which during the winding process, a thermally conductive material (3) directly on the wire (1) and / or bobbin (20) can be applied. Coil winding apparatus (100) according to claim 13,
characterized in that the material application unit (30) is arranged and arranged such that the thermally conductive material (3) is applied to the wire (1) when it is already at least partially coil on the bobbin (20). Coil winding apparatus (100) according to claim 13,
characterized in that the material application unit (30) is arranged and arranged such that the thermally conductive material (3) is applied to the still to be wound wire (1). A coil winding device (100) according to any one of claims 13 to 15,
characterized in that the material application unit (30) is arranged and arranged such that the thermally conductive material (3) is first applied to the wire (1) after the wire (1) has a winding tool (10) of the coil winding device (100) forming the Wire (1) plastically deformed, has happened. A coil winding device (100) according to any one of claims 13 to 16,
characterized in that the material application unit (30) is arranged and arranged such that the thermally conductive material (3) is applied in a strip shape along a longitudinal axis (L) of the wire (1) and applied to the wire (1) such that a respective one Cross-section of the wire (1) in the circumferential direction (U) is only partially covered by thermally conductive material (3).

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