Arranging a wire winding in a magnetizable flux conductor element of a stator of a rotary electric machine designed as a internal rotor

A winding apparatus for arranging a wire winding in a magnetizable flux conductor of a stator of a rotary electric machine embodied as an internal rotor, the winding apparatus comprising:

• a wire insertion apparatus designed for arrangement at least in part in a receiving opening of the magnetizable flux conductor for receiving a rotatably mounted rotor of the rotary electric machine, said wire insertion apparatus comprising a carriage designed for axial movement back and forth;
• a wire guiding sleeve arranged on the carriage;
• a swivel drive designed to swivel the wire guiding sleeve between two predefinable swivel positions;
• a supporting unit designed to assist insertion of a winding wire as winding of a wire winding and comprising a guide element designed to arrange the winding wire in a predetermined one of longitudinal grooves of the magnetizable flux conductor, which are open on an opening side;
• a wire guidance unit having at its opposite axial ends end areas which protrude beyond body end face sides embodied at axial body ends of the magnetizable flux conductor and form radial angled elements, respectively, which rest with one end against the body end face sides, respectively;
• a forming tool designed for arrangement in an area of a winding head to be formed, with the forming tool having a form which is adapted to the winding head to be formed;
• and
• a tool drive unit linked mechanically to the forming tool to move the forming tool axially parallel to a longitudinal axis defined by the receiving opening of the magnetizable flux conductor such that the forming tool is able to act mechanically on ends of the winding forming the winding head, thereby enabling the ends of the winding to be deformed to form the winding head, when all ends of the winding are already arranged in an area of an end face side of the magnetizable flux conductor.

A method for arranging a wire winding in a magnetizable flux conductor of a stator of a rotary electric machine embodied as an internal rotor, wherein the magnetizable flux conductor has a receiving opening for receiving a rotatably mounted rotor of the rotary electric machine and longitudinal grooves open on an opening side for arranging the wire winding, wherein the wire winding has windings made of at least one winding wire, the method comprising:

• arranging a wire insertion apparatus at least partly in the receiving opening;
• assisting insertion of the winding wire by a supporting unit which includes a guide element to arrange the winding wire in a predetermined one of the longitudinal grooves of the magnetizable flux conductor;
• arranging a wire guiding sleeve on an axially back-and-forth movable carriage of the wire insertion apparatus for swiveling by a swivel drive between two predetermined swivel positions in order to position the windings in the respective grooves,
• arranging a forming tool in an area of a winding head to be formed;
• with the forming tool having a form adapted to the winding head;
• linking mechanically a tool drive unit to the forming tool for movement of the forming tool axially parallel to a longitudinal axis defined by the receiving opening so that the forming tool is able to actuate mechanically on ends of the winding forming the winding head, thereby enabling the ends of the winding to be deformed to form the winding head, when all ends of the winding are already arranged in thane area of end face side of the magnetizable flux conductor, and
• forming end areas of a wire guidance unit at opposite ends of the wire guidance unit to protrude at axial ends of body end face sides of the magnetizable flux conductor so as to form radial angled elements, respectively, which rest with one end against the body end face sides, respectively.