Abstract: A method of stacking wave winding wires (wires) for forming a winding mat for a stator coil winding including providing a drop magazine containing a plurality of similar wires in a receiving space, wherein a receiving space contour is configured to the received wires, such that the wires are positioned at a plurality of guide devices at different receiving space boundary locations and guided through the receiving space without changing their geometry, positioning a workpiece carrier having a retaining structure for a winding mat formed of multiple stacked wires in a first transfer position below the magazine and depositing a wire from the magazine at a first position on the workpiece carrier, positioning the workpiece carrier in a second transfer position offset from the first transfer position below the magazine, and depositing a further wire from the magazine at a position offset from the first position on the workpiece carrier.

Abstract: A bending unit for bending a bend of a wave winding for a coil winding of an electric machine, having a first holding element for holding a first segment of a wire to be bent, a second holding element for holding a second segment of the wire to be bent and at least one bending mold for bending a transition region of the wire between the first segment and the second segment. The first and the second holding elements are in engagement with each other via at least one mechanical control cam to control a relative pivoting and a relative displacement of the first and the second holding element. Furthermore, a bending device having a plurality of such bending units, a wave winding production apparatus having a plurality of bending units which are synchronized via control cams, and a bending method and a wave winding production method are described.

Abstract: A bending unit for bending a bend of a wave winding for a coil winding of an electric machine, having a first holding element for holding a first segment of a wire to be bent, a second holding element for holding a second segment of the wire to be bent and at least one bending mold for bending a transition region of the wire between the first segment and the second segment. The first and the second holding elements are in engagement with each other via at least one mechanical control cam to control a relative pivoting and a relative displacement of the first and the second holding element. Furthermore, a bending device having a plurality of such bending units, a wave winding production apparatus having a plurality of bending units which are synchronized via control cams, and a bending method and a wave winding production method are described.

Abstract: To automate a sub-process during the production of a component, which is to be equipped with coils, of an electric machine, a wire end shaping device is used, which is equipped with coils, of an electric machine, for shaping wire ends which protrude from an annular housing of the component, comprising a bending device for bending wire ends in a circumferential direction, a relative movement device for moving the housing and the bending device in a relative manner in an axial direction, and a controller. The receiving and rotating units, which receive the wire ends, of the bending device are held to be axially static relative to one another, wherein differences in length compensation and/or in a turning angle of the wire ends are handled by means of different movement profiles of the rotational movements of the receiving and rotating units.

Abstract: A method for inserting electrical conductors in slots of a component, wherein, in sections, an insulating film has two legs which are connected by a V-shaped or folded tip region. The legs lie against the slot edges such that damage to the electrical conductors by edges of the slot during the insertion thereof into the slots is avoided. The invention further relates to an associated device, to an associated cutting tool, and to an associated use.

Abstract: A method and device for manufacturing winding mats for manufacturing a coil winding of an electric machine. The winding mat is composed of wave winding wires bent as a flat winding in one plane. To be able to manufacture different coil mats with improved electrical characteristics easily and reliably in large series, it is proposed not to interlace or twist the wave winding wires, but to plug them at least partially. In addition, a method and a device for manufacturing a coil mat from several winding mats designed as individual mats are proposed. The device preferably comprises an offsetting device for introducing height offsets into winding heads of the wave winding wires.

Abstract: A method and to a device for inserting a plurality of wires into a plurality of grooves of a component, such as a stator or rotor of an electric motor, in which the wires are inserted by gripping elements.

Abstract: The invention relates to a package carrier for installing a plurality of wire windings into a component such as a stator or a rotor of an electrical machine, the component having a plurality of grooves running longitudinally which are designed to receive wire sections of the wire windings.

Abstract: The invention relates to a method for the production of a component, of an electric machine, such as, for example, a stator, comprising a wire mat which is made of wire, preferably flat wire, comprising the following steps: aligning the wire, twisting the wire in at least some sections about its longitudinal axis, z-shaped angling of the wire, winding the wire, in particular winding the wire helically onto a carrier, transferring the wire mat thus obtained onto a mounting tool.

Abstract: A winding mat formed as a flat winding and to coil mat formed from it for producing a coil winding for an electric machine. To be able to manufacture different coil mats also with layer swap and conductor swap in an automated manner and in large series and with a high degree of reliability, it is proposed to join wave winding wires by plugging. To produce the coil mat, it is proposed, among other things, to join two individual mats by plugging the mats together.

Abstract: A method and device for manufacturing winding mats for manufacturing a coil winding of an electric machine. The winding mat is composed of wave winding wires bent as a flat winding in one plane. To be able to manufacture different coil mats with improved electrical characteristics easily and reliably in large series, it is proposed not to interlace or twist the wave winding wires, but to plug them at least partially. In addition, a method and a device for manufacturing a coil mat from several winding mats designed as individual mats are proposed. The device preferably comprises an offsetting device for introducing height offsets into winding heads of the wave winding wires.

Abstract: To automate a sub-process during the production of a component, which is to be equipped with coils, of an electric machine, a wire end shaping device is used, which is equipped with coils, of an electric machine, for shaping wire ends which protrude from an annular housing of the component, comprising a bending device for bending wire ends in a circumferential direction, a relative movement device for moving the housing and the bending device in a relative manner in an axial direction, and a controller. The receiving and rotating units, which receive the wire ends, of the bending device are held to be axially static relative to one another, wherein differences in length compensation and/or in a turning angle of the wire ends are handled by means of different movement profiles of the rotational movements of the receiving and rotating units.

Abstract: A method for inserting electrical conductors in slots of a component, wherein, in sections, an insulating film has two legs which are connected by a V-shaped or folded tip region. The legs lie against the slot edges such that damage to the electrical conductors by edges of the slot during the insertion thereof into the slots is avoided. The invention further relates to an associated device, to an associated cutting tool, and to an associated use.

Abstract: A method and to a device for inserting a plurality of wires into a plurality of grooves of a component, such as a stator or rotor of an electric motor, in which the wires are inserted by gripping elements.

Abstract: The invention relates to a method for the production of a component, of an electric machine, such as, for example, a stator, comprising a wire mat which is made of wire, preferably flat wire, comprising the following steps: aligning the wire, twisting the wire in at least some sections about its longitudinal axis, z-shaped angling of the wire, winding the wire, in particular winding the wire helically onto a carrier, transferring the wire mat thus obtained onto a mounting tool.

Abstract: The invention relates to methods and devices for installing a plurality of wire windings into a component such as a stator or a rotor of an electrical machine, the component having a plurality of grooves running longitudinally which are designed to receive wire sections of the wire windings.