| CPC H02K 15/0478 (2013.01) [H02K 3/12 (2013.01); Y10T 29/49071 (2015.01)] | 11 Claims |
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1. A winding mat for forming a coil winding of a component of an electric machine, comprising
several wave winding wires extending in a longitudinal direction and bent in a wave shape, said wave winding wires having
straight wire sections spaced apart in the longitudinal direction and extending in a transverse direction running transversely to the longitudinal direction, and
intermediate roof-shaped winding heads,
such that adjacent straight wire sections are connected to each other by a winding head bent in a roof-shaped manner to form a half-wave section, such that first half-wave sections with first winding heads bent in a first direction and second half-wave sections with second winding heads bent in an opposite second direction are alternately provided and a first half-wave section and an adjacent second half-wave section respectively form a wave section,
wherein the wave winding wires are not interlaced or twisted, but are joined together by plugging the wave winding wires together in the transverse direction to each other in such a way that in at least one insertion region of the winding mat, a first and an adjacent second sub-section of the one wave winding wire and a first and an adjacent second sub-section of the other wave winding wire are plugged into each other in such a way that the first sub-section of the one wave winding wire is plugged-in under the first sub-section of the other wave winding wire and the second sub-section of the one wave winding wire is plugged-in over the second sub-section of the other wave winding wire, wherein:
each wave winding wire has a wire thickness in the straight wire sections which, measured in a height direction running transversely to the longitudinal direction and transversely to the transverse direction, extends over a wire thickness dimension, and each winding head has a first height offset by half a height extension dimension at a first winding head section that connects to a first straight wire section, a second height offset by a full height extension dimension at a second winding head section that connects to the first winding head section, and a third height offset by half a height extension dimension at a third winding head section that extends between the second winding head section and a second straight wire section, the height extension dimension being equal to the wire thickness dimension or equal to the wire thickness dimension plus a predetermined tolerance,
wherein the winding mat optionally includes at least one of the following features:
at least one standard region is provided in which the first height offset at each winding head is directed in a first height direction, the second height offset is directed in the opposite second height direction, and the third height offset is directed in the first height direction; or
in a transition region of a winding mat wherein the winding mat is stepped in a stair-like manner with at least one transition region forming a step in the height direction, the transition region forming an insertion region, at least one winding head in which the first height offset is directed in the first height direction, the second height offset is directed in the first direction, and the third height offset is directed in the second direction, and at least one winding head in which the first height offset is directed in the second height direction, the second height offset is directed in the second height direction, and the third height offset is directed in the first height direction are respectively provided at the wave winding wires; or
in at least one of a start region or end region of the winding mat, at least one winding head is provided in each case at the wave winding wires, in which winding head
the first height offset is directed in the first height direction, the second height offset is directed in the second height direction, and the third height offset is directed in the first height direction, or
the first height offset is directed in the second height direction, the second height offset is directed in the first height direction, and the third height offset is directed in the first height direction; or
a radial extension of a winding mat wound up in n layers has a maximum value of (n+1) multiplied by the height extension dimension in a region of the winding heads.
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