Device and method for producing wave winding wires for a coil winding

A wave winding device for producing wave winding wires for a coil winding of an electric machine via flat winding, the wave winding device comprising:

• a linear guide mechanism;
• and
• a row of shaping elements each having a holder for holding a straight wire section of a wire to be bent and a bending mold for shaping a wave winding head region between the straight wire sections, the shaping elements being linearly movable relative to each other on the linear guide mechanism and rotatably mounted about a respective axis of rotation in such a way that, from an initial position in which the holders of the shaping elements are aligned with respect to one another, respectively neighboring shaping elements rotate in mutually opposite directions and the shaping elements thereby approach one another with their axes of rotation in order to form a meandering wave winding wire with straight wire sections and chevron-shaped wave winding heads in between from the wire held in the holders,
• wherein the linear guide mechanism comprises a first linear guide and a second linear guide, a spacing between which is variable,
• wherein a conversion mechanism is further provided for converting a change in the spacing of the first linear guide and the second linear guide into a rotational movement of the shaping elements.

A wave winding device for producing wave winding wires for a coil winding of an electric machine via flat winding, the wave winding device comprising:

• a linear guide mechanism;
• and
• a row of shaping elements each having a holder for holding a straight wire section of a wire to be bent and a bending mold for shaping a wave winding head region between the straight wire sections, the shaping elements being linearly movable relative to each other on the linear guide mechanism and rotatably mounted about a respective axis of rotation in such a manner that, from an initial position in which the holders of the shaping elements are aligned with respect to one another, respectively neighboring shaping elements rotate in mutually opposite directions and the shaping elements thereby approach one another with respective axes of rotation, in order to form a meandering wave winding wire with straight wire sections and chevron-shaped wave winding heads in between from the wire held in the holders,
• and a wire-end bending and fixing device configured to bend wire ends of the wire to be bent inserted into the linearly aligned holders prior to a rotational movement of the shaping elements and to positively fix the wire ends to the associated outer shaping element.

A method for producing wave winding wires for a coil winding of an electric machine via flat winding, the method comprising:

• a) providing a row of shaping elements each having a holder for holding a straight wire section of a wire to be bent and a bending mold shaping a wave winding head region between the straight wire sections, the shaping elements being linearly movable relative to each other and rotatably supported about a respective rotation axis;
• b) inserting a wire into the mutually aligned holders of the shaping elements;
• c) driving opposite rotational movements of respectively adjacent shaping elements by changing a spacing of linear guides of a linear guide mechanism for guiding the linear movement of the shaping elements and converting a change in spacing into rotational movements of the shaping elements, and
• d) bending a meandering wave winding wire having straight wire sections and chevron-shaped wave winding heads therebetween by the opposite rotational movements.