Patent ID: 8667666

Claim:
A method for producing a wave wound electrical element of an electrical machine, the produced electrical element having a distributed wave winding of intertwined wire groups which wire groups have interlaced wires, the wires of which wave winding are i) shaped continuously in wavelike fashion into a) straight segments which are introduced into slots of the electrical element and b) head portions with each head portion joining two adjacent straight segments of one wire and protruding past an associated first or second end face of the electrical element, and ii) associated in pairs whose straight segments occupy the same slots but whose head portions protrude from opposite ends of the slots receiving two successive straight segments of the associated wires, said method comprising the steps of: forming two interlaced wire groups separately, said forming step for each wire group including the steps of winding up n parallel wires with intermediate spacing onto a striplike former that is rotatable about a longitudinal axis thereof, said winding up step, for an electrical element having a number of slots divisible by 2 n that are to be occupied by the wave winding, including the steps of (i) spacing each of the parallel wires on the former with a predetermined intermediate spacing corresponding to a spacing of the slots of the electrical element, (ii) bending over so as to be doubled over one straight segment and forming a first end turn for one head portion of each of the parallel wires; and (iii) pausing of the rotational winding movement and axially displacing the straight segments of each wire group formed in said spacing and bending steps while maintaining the intermediate spacing thereof, together with the adjoining first end of the respective associated end turn relative to a second end of the respective associated end turn, along the axis of rotation of the former by n times the predetermined intermediate spacing in a predetermined direction so that the end turns form head portions; and (iv) repeating steps (i), (ii) and (iii) for the straight segments for any intermediate slots and finally for last n slots on the former to form each of the two individually interlaced wire groups; winding the two individually interlaced wire groups onto one another in an axial relative position in which the straight segments, created from associated wires on opposite sides of the striplike former, are made to coincide in a relative position in which the straight segments of the wires associated in pairs, in successive slots to be occupied thereby, alternatingly assume a radially outer position and a radially inner position so that the two interlaced wire groups form an intertwined wave winding; and introducing the intertwined wave winding into the slots of the electrical element in a direction transversely to a longitudinal extent of the slots to form the wave wound electrical element.