US008698370B2

(12) United States Patent

(10) Patent N0.:

(45) Date of Patent:

Roos
(54)

METHOD FOR PRODUCING THE ROTOR

WINDING OF AN ELECTRICAL MACHINE,
AND AN ELECTRICAL MACHINE WITH A
ROTOR WINDING WHICH IS PRODUCED IN
ACCORDANCE WITH THIS METHOD

(75) Inventor:

Gerald Roos, Sasbachried (DE)

(58)

Notice:

H02K 23/62; H02K 57/00

IPC ............................................ .. H02K 3/28, 15/02

(56)

(87)

Nov. 19, 2008

PCT/EP2008/065857

371 (0X1)
(2), (4) Date:

Nov. 23, 2010

4,876,472 A *
6,822,365 B2 *

10/1989
11/2004

Shirakiet al. ............... .. 310/198

Mori ........................... .. 310/234

(Continued)
FOREIGN PATENT DOCUMENTS
DE
DE
JP

10 2004 062 813

10 2006 036 835
2007-282500

7/2006
2/2008
10/2007

Primary Examiner * John K Kim

PCT Pub. No.: WO2009/103368

(74) Attorney, Agent, or Firm * Merchant & Gould PC.

PCT Pub. Date: Aug. 27, 2009

(57)

(65)

Jun. 2, 2011

Foreign Application Priority Data

Feb. 22, 2008

Int. Cl.
H02K 3/28
H02K 15/02
H02K 3/04
H02K 21/22
H02K 23/62
H02K 57/00
(52) US. Cl.

ABSTRACT

The invention relates to a method for producing the rotor

winding of an electrical machine having at least four exciter

Prior Publication Data

US 2011/0127871 A1

(30)

See application ?le for complete search history.

References Cited
U.S. PATENT DOCUMENTS

Subject to any disclaimer, the term of this

patent is extended or adjusted under 35

PCT Filed:
PCT No.:

Field of Classi?cation Search

USPC .............. .. 310/154.45, 177, 198, 234; 29/596

U.S.C. 154(b) by 471 days.

(21) Appl. No.:
12/918,494
(22)
(86)

Apr. 15, 2014

CPC ......... .. H02K 3/04; H02K 3/28; H02K21/22;

(73) Assignee: Robert Bosch GmbH, Stuttgart (DE)

(*)

US 8,698,370 B2

(DE) ....................... .. 10 2008 000 377

poles in the stator (11) and having a commutator rotor (13)

with a number of slots (N) and pole teeth (Z) which deviates
from the number of exciter poles, and having a number of
individual tooth coils (S) and laminations (L) which is at least
twice as high as the number of pole teeth, wherein the indi
vidual tooth coils are wound, starting from the ?rst coil (S1)
onto in each case that pole tooth with the lowest angular error

(51)

(Wi) in relation to a pole division (Pt). In order to permit

(2006.01)
(2006.01)
(2006.01)
(2006.01)
(2006.01)
(2006.01)

non-critical guidance of the winding wire (17) in the region of

the lamination connections, provision is made, at least in the
case of a last-wound section (B) of the coils (S), preferably in
the case of all of the coils, for the winding wire (17), with
which contact is made by a lamination (L) in each case
between two coils (S), to be fed from one side of the lamina

CPC .. H02K3/04 (2013.01); H02K3/28 (2013.01);

H02K21/22 (2013.01); H02K 23/62 (2013.01);

H02K57/00 (2013.01)
USPC .... .. 310/177; 310/154.45; 310/198; 310/234;

29/596

tion (L) and guided away from the other side, and for at least
one pole tooth (Z), but at most two pole teeth (Z) to be situated
between the slot (N) from which the winding wire (17) of the
lamination (L) is fed and the slot (N) at which said winding
wire is guided away from the lamination (L).
2 Claims, 11 Drawing Sheets

US 8,698,370 B2
Page 2
(56)

References Cited

2006/0220489 A1 *

2007/0152532 A1*
US PATENT DOCUMENTS
2003/0014858 A1 >1<

1/2003

2005/0184612 A1*

8/2005 (3103 et al. ................... .. 310/158

2005/0269894 A1 *

2006/0208605 A1 *

12/2005

Yamazaki et a1,

2007/0257572 A1*
H 29/596

7/2007 R003 et a1.

4/2008 R003

2009/0058213 A1 *

3/2009

Sugishima et {11. ......... .. 310/198

38%833331 21* 1358?? 522:

310/177
"""""""""""""" "

* cited by examiner

310/234

11/2007 Nakano et a1. ............ .. 310/68 D

2008/0093943 A1

Yamamoto et a1. ......... .. 310/216

9/2006 Aoyama et a1. ............. .. 310/264

10/2006 Osawa et a1. ............... .. 310/198

US. Patent

Apr. 15, 2014

Sheet 1 0f 11

US 8,698,370 B2

US. Patent

Apr. 15, 2014

16

Sheet 2 0f 11

US 8,698,370 B2

16

US. Patent

Apr. 15, 2014

Sheet 3 0f 11

US 8,698,370 B2

FIG. 4
Spule

La

Polzahn

de-

relli

Le

1
2
3
4

1
a
15
2

10
7
'

3
5
10
2

14
15
14
15

Ii
re
Ii
re

5
1
2
4

'
a
'
5

B
15
2
9

>a

5
6
7
8

9
16
3
10

4
1
'

7
9
4
6

14
15
14
15

Ii
re
Ii
re

9
1
6
8

'
2
'
9

16
3
10
17

>b

9
10
11
12

17
4
11
18

B
'
5
'

1
3
8
10

14
15
14
15

ll
re
Ii

3
5
10
2

'
6
'
3

4
11
18
5

>6

13
14
15
16

5
12
19
6

2
'
9
'

5
7
2
4

14
15
14
15

Ii
re
Ii
re

7
9
4
6

'
10
'
7

12
19
6
13

>d

17
18
19
20

13
20
7
14

6
'
3
'

9
1
6
8

14
15
14
15

Ii
re
Ii
re

1
3
8
10

'
4
'
1

20
7
14
1

>9

FIG. 5A
S4 S1

82

S3
2

N1

N1-N10
F1

Z1

: :Z1 Z10
LJ S1-S4

16

US. Patent

Apr. 15, 2014

2.5m.2255FE2E3zgEo-nm

2
w
N
a
m
2
.

w
_.
_
m
2
=
.

m
2
=
N
.

N_.
Q
w
2
N
2
-

N
m
w
2
2
.

m
w
N
.2

2
m
=
w
N
.

m
2
=
w
N
.

US 8,698,370 B2

Sheet 5 0f 11

2
m
w
N
2
.

w
m
N_.
n
2
=
.

2
N
N_
2
.

m
2
N
N_.
.2

w
2
=
m
.

2
N_
=
N
m
.

2
w
N
2
.

Q
N
2
=
w
.

w
2
N
N
2
.

_.
N_
w
o
2
=
.

_
_.
w
N
2
N
2
.

N
o
2
=
w
.

US. Patent

Apr. 15, 2014

Sheet 6 0f 11

US 8,698,370 B2

FIG. 7
51 82a

84b

82b

$3

84a
2

17

,1
17aL'

N1-N1 0

[121-210
"U' 'S1-S4

FIG.8
><q):0

Spule

La

de-

relli

de-

relli

Le

'

10

re

'

'

'

'

li

'

Ii

15

15

10

10

re

'

'

'

li

'

Ii

FIG.9
10

81 82a

84b

82b
6

83
8

84a
10

N1-N10

FMHHHH M11211

I J

1181-84

_E920T2 3 4 5 6 7 s 910|11|12|13|14|1516|17|18|19|20|1 2|3| : L1-L20

US. Patent

Apr. 15, 2014

Sheet 9 0f 11

US 8,698,370 B2

FIG. 12
Spule

La

Polzahn

de.

relli

Le

1a
2a
3a
4a

1
8
15
2

'
'
'
'

8
10
5
7

14
13
14
13

Ii
re
Ii
re

8
15
2
9

5a
6a
7a
8a

9
16
3
10

'
'
'
'

2
4
9
1

14
13
14
13

Ii
re
Ii
re

16
3
10
17

9a
10a
11a
12a

17
4
11
18

'
'
'
'

6
8
3
5

14
13
14
13

Ii
re
Ii
re

4
11
18
5

13a
14a
15a
16a

5
12
19
6

'
'
'
'

10
2
7
9

14
13
14
13

Ii
re
Ii
re

12
19
6
13

17a
18a
19a
20a

13
20
7
14

'
'
'
'

4
6
1
3

14
13
14
13

Ii
re
Ii
re

20
7
14
1

1b

'

14

re

'

2b

12

Ii

15

3b

15

'

10

14

re

'

4b

12

Ii

9
16

5b

'

14

re

'

6b

16

12

Ii

7b

'

14

re

'

10

8b

10

12

Ii

17

9b

17

'

14

re

10b

12

Ii

11

11b

11

'

14

re

'

18

12b

18

10

10

12

Ii

13b

'

14

re

'

12

14b

12

12

Ii

19

15b

19

'

14

re

'

16b

12

Ii

13
20

17b

13

'

14

re

'

18b

20

12

Ii

19b

'

14

re

'

14

20b

14

12

Ii

10

US. Patent

Apr. 15, 2014

Sheet 10 0f 11

US 8,698,370 B2

FIG. 13A
83a
10

MM
______ __

__|_

\ I

84a 51a
5

82a
s

HH

1o

N1-N10

Mm

'11'S1a-S4a

V'i_

551 2 3 4 s 6 1 a 9|1o|11|12|1a|14|15|1e|17|1a|19|20|1|2|3| _ L1-L20

FIG. 13B

US. Patent

Apr. 15, 2014

Sheet 11 0f 11

Spule

La

de-

re/li

1a
28
3a
4a

1
8
15
2

10
3
7
10

12
'
12
'

F6

5
2
2
9

5a

5
2

1 2|3|4|5|6|7

12

re
re

10|11|12|13|14|15

US 8,698,370 B2

de-

10

'
12
'
12

'

relll

Le

ll

8
15
2
9

ll

16

US 8,698,370 B2
1

METHOD FOR PRODUCING THE ROTOR

WINDING OF AN ELECTRICAL MACHINE,
AND AN ELECTRICAL MACHINE WITH A
ROTOR WINDING WHICH IS PRODUCED IN
ACCORDANCE WITH THIS METHOD

ing wire on the connection lugs of the laminations being

greatly reduced by at least one pole tooth being disposed
between the winding wire being fed to and guided away from
a connection lug and thereby ensuring a suf?cient wrap of
said connection lug. A further advantage is that in the case of
these coils the winding wire cannot slide down between the

This application is a National Stage Application of PCT/

EP2008/065857, ?led 19 Nov. 2008, which claims bene?t of
Ser. No. 10 2008 000 377.8, ?led 22 Feb. 2008 in Germany
and which applications are incorporated herein by reference.
To the extent appropriate, a claim of priority is made to each
of the above disclosed applications.

coil and the connection lug to the commutator when the coils
continue to be continuously wound. This results from the fact
that at most two pole teeth are situated between the winding

wire being fed and guided away from said connection lug, and
consequently the winding wire does not extend over a large
circumference.

The invention relates to a method for producing the rotor

An improved and uniform guidance of the winding wire on

winding of an electrical machine as well as to an electrical

the commutator side of the rotor thus occurs as a result of the

winding wire being led from the coil to the lamination,

machine having a rotor winding produced in accordance with

this method.
BACKGROUND

It is known from the German patent publication DE 10

20

2004 062 813 A1 how to select the number of the slots and
pole teeth, which alternate on the circumference of a commu
tator rotor, such that it deviates from the number of exciter
poles in the stator. The number of the so-called individual
tooth coils is equal to the number of commutator laminations
but twice as high as the number of pole teeth and slots. The
coils, which are wound on the pole teeth in an evenly distrib
uted manner, are thereby contacted on the connection lugs of
the laminations with a prede?ned lamination interstice

25

length. Starting from the ?rst coil, all further coils, which are

30

ments, wherein su?icient room is available between the com

mutator and the pole teeth of the armature, if for preferably a

?rst portion of the coils, which are continuously wound in
succession, the winding wire is led from the coil to the lami
nation as well as from the lamination to the next coil across a

supporting ring disposed on the rotor shaft. In so doing, the

coils are offset to the lamination in each case by at least 90 .

continuously wound in succession, are wound onto in each

case that pole tooth with the lowest angular error in relation to
a pole division.

In the exemplary embodiments depicted and described in

this publication, a problem arises by the winding wire, which

respectively from the lamination to the coil, in each case

between two additional pole teeth situated closer to the lami
nation for at least a portion of coils, which are continuously
wound in succession. Care should thereby be taken to ensure
that two pole teeth lie between the respective lamination and
the point where the winding wire is fed through. As an alter
native thereto, it can be advantageous in armature embodi

In order to reduce the torque ripple and improve the com

mutation, the inductance in the pole teeth is reduced in an
ef?cient manner as a result of at least the coils, which are

provided with an angular error in relation to the pole division,

35

being wound so as to be distributed onto two pole teeth

situated across from each other. In addition, the force com

ponents at the pole teeth situated opposite to each other,

often in alternating succession contacts the coils to the com

mutator laminations, being on the one hand directly guided

which are caused by supplying current to the coils, are

out of a slot to the connection lug of a lamination and on the

thereby equally large and consequently in an advantageous

other hand having to be guided out of the slot over a large

circumferential area to the connection lug. As the coils con

40

tinue to be continuously wound, said winding wire being

situated opposite to each other. The rotor winding can thereby

be particularly easily produced if the divided coils are in each

guided across a circumferential area then slips in the direction

of the laminations onto the winding wires being directly

guided to the slots and thereby impedes further contacts onto
the connection lugs of the laminations.
In the exemplary embodiments according to FIGS. 8 and
10 of this publication, the connecting wires on the connection

case continuously wound in succession as coil halves con

nected in series. Provision is made alternatively thereto for

45

the divided coils if necessary to be connected in each case as

coil halves in parallel to their common initial and end lami

nation. It is advantageous in achieving a symmetric coil con
?guration for the coils with angular error and the coils without
angular error to be continuously wound in succession in uni

lugs of the laminations are partially hooked in such a manner

that only an acute angle is formed between the wire leading to

the lamination and the one leading away from said lamina
tion. This has the disadvantage of enabling the thus formed

manner cancel each other out. All coils are thereby expedi
ently divided and are wound in each case onto two pole teeth

50

form sequence. In a modi?cation to the invention, it can be

advantageous for achieving a favorable torque ripple or a

uniform distribution of weight across the rotor circumference

wire eyelet on the connection lug to resiliently expand.

Because when contacting the winding wire on the connection

if the coil halves are in each case wound with different num

lug the insulating varnish of said winding wire is melted in the

bers of windings at least for a portion of the coils divided up

on pole teeth situated opposite each other

region of the eyelet by so-called hot staking, the danger exists

55

of short circuits occurring to the winding wire eyelets of

adjacent connection lugs.

BRIEF DESCRIPTION OF THE DRAWINGS

The present inventive solution strives to improve the wire

guiding on the connection lugs of the laminations in order to
avoid contacting problems as well as to prevent a critical,

60

The invention is by way of example explained below in

detail using the Figures. The following are shown:
FIG. 1 a schematic depiction of the electrical machine
according to the invention in a front view,
FIG. 2 the developed view of the machine from FIG. 1 in

resilient expansion of the eyelets.

SUMMARY

schematic depiction having a ?rst individual tooth coil;

The method for producing the rotor winding of an electri
cal machine with the distinguishing features of claim 1 has the
advantage of a resilient expansion of the eyelets of the wind

65

FIGS. 3a to 3f show schematically different forms of con

nection of the winding wire to a plurality of adjacent com
mutator laminations.

US 8,698,370 B2
3

FIG. 4 shows in a ?rst exemplary embodiment the winding

table created pursuant to the FIGS. 3a to 3f and
FIGS. 5a to 5e show in schematic depiction the production

possible torque ripple of the electrical machine, the number of

pole teeth deviates from the number of exciter poles P.
FIG. 2 shows in schematic depiction a developed view of
the direct current motor 10 from FIG. 1, with which the

of the rotor winding according to the winding table pursuant

to FIG. 3 in ?ve sections.

winding method for producing and disposing the coils S on

the pole teeth Z of the rotor 13 is explained below in detail.
The six-pole stator 11, the ten pole teeth Z1 to Z10, the ?rst

FIG. 6 shows the winding table for a second exemplary

embodiment having 10 divided coils,

FIG. 7 shows in schematic depiction the production of 4

two individual tooth coils S1 and S2 as well as the twenty

laminations L1 to L20 of the commutator 16 can be recog

coils of the rotor winding according to a ?rst section of the

winding table pursuant to FIG. 6.
FIG. 8 shows as a further exemplary embodiment the ?rst
section of a winding table having a changed direction of the
windings with respect to the table pursuant to FIG. 6.

FIG. 9 shows in schematic depiction the production of 4

coils of the rotor winding according to the section of the
winding table pursuant to FIG. 8.
FIG. 10 shows the winding table for a fourth exemplary
embodiment having 20 divided coils and
FIG. 11 shows in schematic depiction the production of the
rotor winding according to a ?rst section of the winding table
pursuant to FIG. 10.
FIG. 12 shows the winding table for a ?fth exemplary
embodiment of twenty divided coils,
FIG. 1311 shows in schematic depiction the production of
the ?rst four partial coils according to the ?rst section of the
winding table pursuant to FIG. 12 and
FIG. 13b shows in schematic depiction the production of
the four partial coils connected in parallel with said ?rst four
partial coils according to a second section of the winding table
pursuant to FIG. 12.

20

more, established that all of the coils S are contacted in each

25

30

FIG. 14 shows the ?rst section of a winding table for a sixth

exemplary embodiment having a changed connection con

?guration with respect to the winding table pursuant to FIG.
35

table pursuant to FIG. 14.

DETAILED DESCRIPTION
40

A permanent-magnetically excited six-pole direct current

motor is schematically depicted in a front view in FIG. 1 as a

?rst exemplary embodiment and is denoted with the numeral

10. Machines of this type are preferably used for actuating
drives, radiator fans and the like in motor vehicles and have to

45

reliably operate under heavy loads if possible for the entire

service life of the motor vehicle. Their construction must
therefore be as robust as possible. The electrical machine 10
has a six-pole stator 11, which interacts with a commutator
rotor 13, subsequently referred to as rotor, via a working air
gap 12. The rotor 13 consists of a lamination stack 14, which
is attached to a rotor shaft 15 that is supported on both sides.

Ten uniformly spaced pole teeth Z are disposed on the cir

cumference of the lamination stack 14. Slots N for receiving
in total twenty coils S of a rotor winding 18 are con?gured
between said pole teeth Z. The coils S are thereby produced
by automatic coiling machines as individual tooth coils in
pairs around a respective pole tooth Z. The coils S are thereby

In order to be able to continuously wind the individual

tooth coils S in the manner of a spiral winding onto the pole
teeth Z, a lamination interstice lengthY is de?ned for all of the
coils S, which ensures that the end of each coil is contacted to
a free lamination L. A lamination interstice lengthY of seven
laminations is provided in FIG. 2, i.e. Y:7.

As already depicted and described in detail in the afore

mentioned German patent publication DE 10 2004 062 813
Al, the initial lamination La and the end lamination Le can
initially be consecutively ascertained for all of the coils. Sub
sequently the angular error Wf in relation to the pole division
of the stator 11 is ascertained for each additional coil of the
rotor, which succeeds coil S1, in a ?rst round for each pole

50

From the angular error of the second coil S2 ascertained in

this manner for each pole tooth Z, that pole tooth, on which
the coil S2 has the smallest angular error Wf, is now ascer
tained in an additional step. The smallest angular error Wf:
55

18, respectively the largest angular error-maximum cosine

value:0.951, is ascertained in this manner for the coil S2 on
the pole tooth Z5. The same angular error also occurs on the

pole teeth Z8, Z10, and Z3, which can be utilized for an

optimal coil connection.

60

uniformly spaced across the circumference, which interact

with two ?xed carbon brushes B1 and B2. The carbon brushes
B1 and B2 are offset to each other by 180 and are supplied
with direct current for operating the electrical machine. The
ten pole teeth Z of the rotor 13 thereby interact with three
exciter pole pairs of the stator 11. In order to achieve the least

nation L1 for the ?rst coil S1 forms the freely selectable initial
lamination La1. As a result of the disposal of the position of
the lamination L1 selected here, an offset angle v0 of
63 consequently occurs between the initial lamination La1
of the coil S1 and the pole tooth Z3 provided for this coil. The
optimal position of the coil S1 is located in FIG. 2 centered
below a pole of the stator 11. This position has an angular

tooth Z using the following formula:

connected in a special manner to a commutator 16 ?tted on

the rotor shaft 15 at the front face side of the lamination stack
14. The commutator 16 has twenty laminations L disposed

case at their beginning on an initial lamination La and at their

end on an end lamination Le. According to FIG. 2, the lami

error Wf:0.

12 and

FIG. 15 shows in schematic depiction the production of the

?rst section of the rotor winding according to the winding

nized there. The disposal of the ?rst coil S1 can be freely

selected and in this instance is associated with the third pole
tooth Z3. Furthermore, the ?rst pole tooth Z1 is hereby asso
ciated with the center of a north pole N of the stator 11. This
association can also be freely selected. In addition, the like
wise freely selectable association of the commutator lamina
tions L with the pole teeth Z is selected here, such that the ?rst
pole tooth Z1 lies exactly at the height of the lamination slit
between the laminations L1 and L20 of the commutator 16. In
accordance with FIG. 2, this position is henceforth to have the
angularposition of v:0. It therefore follows that the adjacent
pole tooth Z2 lies at the position of 36 and that the next
lamination slit is located at the position of 18. It is, further

65

In this manner, the initial and end laminations La and Le as

well as the respective optimal pole tooth Z are ascertained for

all of the coils S. In the aforementioned patent publication the
winding table required for an automatic coiling machine is
created, wherein the winding wire is led in each case directly
from the initial lamination La to the coil S, respectively from
the coil S to the end lamination Le. In the case of larger

numbers of coils, problems occur, however, thereby in guid

US 8,698,370 B2
5

ing the wire between the commutator 1 6 and the coils S so that
it is required to arrange the coil connections to the laminations
16 in proper order.

coils S using a hooking around connection to the laminations

L according to FIG. 3d; thus enabling the coils to be subse
quently contacted by a hooking connection to the laminations
when the latter portion of said coils is continuously wound. In
so doing, one of the solutions according to FIG. 3a, 3b, or 30

In FIGS. 3a to 3fdifferent options for contacting are sche

matically depicted. The winding wire 17 is thereby in each

case led around a connection lug 16a of the laminations L. In

so doing, such solutions are designated below as hooking,

is used for the hooking connection. The required winding

tables for the following exemplary embodiments are conse

wherein the winding wire is led in each case directly from the

quently created such that the winding wire 17, which is con

connection lug 16a of a lamination L to a slot N. This is the

tacted to a connection lug 16a of a lamination L, is fed from

the one side of the lamination and guided away from the other
side at least in the case of a last-wound section of the coils S
and such that at least one pole tooth Z, but at most two pole
teeth Z, are situated between the slot N from which the wind
ing wire 17 of the lamination L is fed and the slot at which said

case for the embodiments according to FIGS. 3a, 3b, 3c and

10

3e. Connections referred to below as hooking around are

those, in which the winding wire 17 is led from a connection

lug 16a of the commutator 16 aron the rotor shaft to the slot
N while resting on a supporting ring 19 made of insulating
material, which is disposed between the commutator 16 and

winding wire is guided away from the lamination L. In order

to achieve this, the winding wire 17 must be led from the coil
S to the lamination L, respectively from the lamination L to

the lamination stack 14. This is the case for embodiments

according to FIGS. 3d and 3]. Because during so-called hot

staking for contacting the laminations L the connection lug 16
is bent to form a hook towards the lamination using a punch

electrode and is melted to the winding wire 17, the insulating

varnish melts off in the region of the eyelets 170 on the
winding wire 17 surrounding the connection lugs 1611. As a
result it is very important that the eyelets 170 are led around
said connection lugs 1611 as tightly as possible and that they
resiliently expand as little as possible after their being hooked

20

the coil S, in each case between two more pole teeth, which lie
closer to the lamination L, at least for a portion of the coils S,
which are continuously wound in succession. In so doing, at
most two pole teeth Z may lie between the lamination L and

the feed through of the winding wire.

In the ?rst exemplary embodiment according to FIGS. 1
and 2, a winding table for a six-pole direct current motor with
25

on, respectively hooked around, said connection lugs 16a.

the following speci?cations is henceforth created according

to the previously described parameters:

This must occur so that in the case of connection lugs 16 lying

close to one another, adjacent laminations L are not short
circuited via the eyelets 170. This is the case in the embodi

ments according to FIGS. 3a, 3b, 3c and 3d, in which the

winding wire is fed from one side to the connection lug and is

30 Number ofpole pairs

Number ofpole teeth

p=3
Z = 10

again guided away to the other side. When hooking according

Number of laminations
Number of coils

L = 20
S = 20

to FIG. 3a, two pole teeth Z lie between the winding wire 17
fed to the lamination L and guided away from said lamination
L. In the embodiment according to FIG. 3b, one pole tooth,

Lamination interstice length

Y=7

Number of windings
Offset angle

WZ = 14, respectively 15
(Pole tooth l to lamination l) v = 00

35

respectively two pole teeth Z, alternately lie(s) between the

winding wire 17 fed to the lamination L and guided away

An undepicted automatic coiling machine now executes

line-by-line the winding table that has been created, the coils
S1 to S20 being continuously wound in succession and in

from said lamination L at the adjacent lamination connec

tions; and in the embodiment according to FIG. 30 one pole

tooth Z lies in each case between the winding wire 17 fed to
the lamination L and guided away from said lamination L. A
narrow eyelet 170 with little resilient expansion also occurs

40

5e, the production of the coils according to the winding table

when hooking around the connection lugs 1611 according to

FIG. 3d, because the winding wire 17 is also in this case fed
from the one side to the connection lug 16a and guided away
to the other side. The problematic embodiments according to
FIGS. 3e and 3f are in contrast to be avoided. When hooking
according to FIG. 3e, only a small acute angle is formed in
each case between the winding wire 17 fed to the connection

lug 16a and that guided away form said connection lug 1611
because the feeding and guiding away of saidwinding wire 17
go out practically vertically from the lamination L to one and
the same slot. With increasing wire gauge, said winding wire
17 will in this case resiliently expand in the region of the
eyelet 170 with the danger of lamination connections. The

from FIG. 4 pursuant to the table sections a to f is schemati

45

50

55

occurs in an embodiment according to FIG. 3], wherein when

employing a hooking around connection said winding wire

17 is fed and guided away between the connection lugs 16a
60

same side across the supporting ring 17 practically parallel to

the respective slot.

In order to be able to optimally utilize the space between
the commutator 16 and the lamination stack 14 of the rotor 13

for the lug connections of the coils S to the laminations L,

particularly in the case of a large number of coils, it can be
useful to contact the ?rst continuously wound portion of the

cally depicted in a developed view of the rotor and described

below:

According to section a, the winding wire 17 is initially

danger of an increasingly resiliently sprung eyelet 170 also

and the coils S in a manner such that it is led to one and the

each case being contacted to the laminations L of the com

mutator 16, which are associated with them. In FIGS. 5a to

65

contacted with its beginning 1711 on the lamination L1. From

there it is fed to the slot 10 and through it to the backside of the
rotor and from there to the pole tooth Z3. The coil S1 is now
wound on the pole tooth Z3 with 14 windings to the lefti
indicated by the arrow. The coil end is now guided across the
backside of the rotor to the slot N5. From there said winding
wire 17 is now fed through the slot 5 to the commutator 16 and
is contacted there to the lamination L8. From there the coil S2
is wound on the pole tooth Z5 with 15 windings to the right,
and the coil end is then fed through the slot N7 to the backside
of the rotor. From there said winding wire 17 now travels
through the slot N8 to said commutator side and is contacted
here to the lamination 15. From there said winding wire 17 is
now fed through the slot N7 to said rotor backside and there
after to the pole tooth Z10. There the coil S3 is wound with 14
windings to the left, and the coil end is thereafter fed across
said rotor backside, through the slot N2 to said commutator
side and is contacted here to the lamination L2. From there the
coil S4 is now wound on the pole tooth Z2 with 15 windings

to the right, and the coil end is thereafter fed through the slot
N4 to said rotor backside. From there said winding wire 17

US 8,698,370 B2
7

now travels through the slot N5 to said commutator side and

is contacted here to the lamination L9. From said lamination
L9 the coil wire is carried over onto the developed view of the
rotor in FIG. 5b by means of the indicated arrow. In so doing,

pursuant to FIG. 6 for an electrical machine 10 according to

FIG. 1 is created with the following speci?cations as a modi

?cation to the ?rst exemplary embodiment:

said winding wire is in each case with its sections depicted

with dashed lines carried over from the left side of the devel

oped view of the rotor to the right side.

There the winding wire 17 is guided from the lamination
L9 through the slot N4 to the rotor backside and thereafter to
the pole tooth Z7. The coil SS is wound there with 14 wind
ings to the left, and the coil end is then guided across said rotor
backside through the slot N9 to the commutator side and is
contacted here to the lamination L16. From there the coil S6
is now wound onto the pole tooth Z9 with 15 windings to the

Number ofpole pairs

p=3

Number ofpole teeth

Z = 10

Number of laminations
Number of coils

L = 20
S = 20

Lamination interstice length

Y=7

Number of windings

WZ = 10, respectively 7

Offset angle

v = 00

An automatic coiling machine now executes line-by-line

the winding table according to FIG. 6, wherein the coils S1 to

right, and the coil end is thereafter fed through the slot N1 to
said rotor backside. From there said winding wire 17 now
travels through the slot N2 to said commutator side and is
contacted here to the lamination L3. From there said winding
wire now is fed through the slot N1 to said rotor backside and
thereafter to the pole tooth Z4. The coil S7 is wound there
with 14 windings to the left, and the coil end is led thereafter

S20 are continuously wound in succession and in each case

contacted to the laminations L of the commutator 16, which
are associated with them. In FIG. 7, the production of the coils
S1 to S4 according to section a of the winding table from FIG.

across said rotor backside through the slot N6 to said com

mutator side and is contacted here to the lamination L10.
From there the coil S8 is wound on the pole tooth Z6 with 15

up into two halves S211 and S219 as well as S411 and S419.

6 is schematically depicted in a developed view of the rotor

and described below. The coils S2 and S4 are thereby divided

According to section a), the winding wire 17 is initially

windings to the right, and the coil end is thereafter fed through
the slot N8 to said rotor backside. From there said winding
wire 17 now travels through the slot N9 to said commutator
side and is contacted here to the lamination L17. From said
lamination L17 the coil wire is carried over by the indicated
arrow onto the developed view of the rotor in FIG. Sc.

30

Z5 with 7 windings to the right, and said winding wire is

thereafter guided to pole tooth 8. The second coil half S21) is

In the same manner, the coils S9 to S12 are now continu

ously wound in succession pursuant to section c of the wind

ing table according to FIG. 4, as is depicted in the developed
view of the rotor according to FIG. Sc.
The coils S13 to S16 are also produced in the same manner

according to the developed view of the rotor pursuant to FIG.

5d in accordance with section d of the winding table pursuant
to FIG. 4 as well as the coils S17 to S20 according to the

developed view of the rotor pursuant to FIG. Se in accordance

with section e of the winding table from FIG. 4. After all 20
coils have now been continuously wound in succession, the

40

after to the pole tooth Z5. The second coil half S419 is wound
there with 7 windings to the right, and the coil end is then

lamination L1.
In this exemplary embodiment, all of the coils S are hooked

contacted to the lamination L9. In the same manner, the

45

winding wire at both sides of the lamination is in each case

de?ned in such a way that in all cases a pole tooth Z lies

respectively between the feed of said winding wire and the

guiding away of said wire. In order to also achieve this in the
instances where the coils S lie farther away from their lami
nation connections, the coil ends are fed through the slots N
that lie closer to the respective lamination connections. These
feed throughs of said winding wire have a spacing of at most

addition, the coils are also in this instance hooked on the

laminations L pursuant to the embodiment according to FIG.

30 in the same manner as in the case of the ?rst exemplary

embodiment.

coils provided with an angular error w:f>0 o in relation to the

pole division are now disposed as to be distributed onto two

In a third exemplary embodiment, a ?rst section a of a

winding table is depicted pursuant to FIG. 8, in which merely

the direction of winding of the coils S is changed with regard

pole teeth Z opposite one another in order to reduce the torque

ripple and to avoid radial magnetic forces occurring on one
side of the periphery of the rotor. In the ?rst exemplary
embodiment, this includes every other coil. According to the
calculations of the angular error for all of the coils, it is known

from the aforementioned patent publication that equally sized

On the basis of these known calculations, a winding table

subsequent lines of the winding table according to FIG. 6 are

now executed by the automatic coiling machine. In so doing,
the undivided coils and the divided coils are continuously
wound in an alternating sucession. With this winding table,
the result for the second exemplary embodiment is that
according to FIG. 7 the divided coils S2, S4, S6 are continu
ously wound in succession . . . in each case as coil halves S211,
S219, S411, S419, S611 and S619 . . . in a series connection. In

two pole teeth in order to avoid magnetic asymmetries.

In a second exemplary embodiment of the invention, all

angular errors, respectively no angular errors, occur for each

coil at a plurality of positions that are opposite to one another.

now wound there with 8 windings to the right, and the coil end
is thereafter contacted to the lamination L15. From there said
winding wire is fed through the slot N7 to the backside of the
rotor and then to the pole tooth Z10. The coil S3 is wound
there with 10 windings to the left, and the coil end is thereafter
fed through the slot N2 to said commutator side and is con
tacted here to the lamination L2. From there the ?rst half S4a
of the fourth coil is now wound on the pole tooth Z2 with 7

windings to the right, and said winding wire is guided there

end 17b of the winding wire is ?nally again contacted on the

on the laminations L. According to the hooking procedure
pursuant to FIG. 30, the feeding and guiding away of the

contacted with its beginning 1711 to the lamination L1. From

there said winding wire 17 is now fed through the slot N10 to
the backside of the rotor and thereafter to the pole tooth Z3.
There the coil S1 is wound with 10 windings to the left, and
the coil end is then fed through the slot N5 to the commutator
side and is contacted here to the lamination L8. From there the
?rst coil half S2a of the second coil is wound on the pole tooth

to the second exemplary embodiment. In so doing, a changed

wire guiding between the coils S and the laminations L also
results.
For that reason, FIG. 9 shows that the winding wire 17 is
also contacted in this instance with its beginning 1711 to lami
nation L1. From there the coil S1 is wound onto the pole tooth
Z3 with 10 windings to the right, and the coil end is then
contacted to the lamination L8. From there said winding wire

US 8,698,370 B2
9

10

is now led to the pole tooth Z 5. The ?rst coil half S211 is

through the slot N7 to said backside of the rotor. From there

saidwinding wire travels to the pole tooth Z5. The second coil
half S419 is wound there with 6 windings to the right and the
coil end is thereafter contacted to the lamination L9.
In the same manner, the following lines of the winding
table are henceforth executed with an automatic coiling
machine according to FIG. 10; and in so doing the coils S5 to
S20, half of which are in each case connected in series, are
wound onto pole teeth opposite to one another. In this exem
plary embodiment the coil connections on the laminations are

wound there with 7 windings to the left, and said winding wire
is then led to the pole tooth Z8. The second coil half S219 is
now wound there with 7 windings to the left, and the coil end
is contacted to the lamination L15. From there the coil S3 is
now wound on the pole tooth Z10 with 10 windings to the
right, and the coil end is thereafter contacted to the lamination
L2. From there the said winding wire is then led to the pole
tooth Z2, and the ?rst half S411 of the fourth coil is wound
there with 7 windings to the left. Said winding wire is there
after led to the tooth SS and the second winding half S419 is
wound with 7 windings to the left. The coil end is thereupon
contacted to lamination L9. In the same manner, all remaining
coils, respectively coil halves, are now continuously wound in

implemented using the hooking procedure according to the

succession by the automatic coiling machine pursuant to the

winding table according to FIG. 8. In this embodiment, pas
sages of the coil ends through adjacent slots can be avoided
because a direct hooking of the coil connections onto the
laminations L pursuant to the embodiment according to FIG.

311 is possible, whereby two pole teeth lie between the points

20

where said winding wire is fed to and guided away from said
laminations L.
In a fourth exemplary embodiment, FIG. 10 shows the
winding table for an electrical machine 10 from FIG. 1, in
which all coils S are henceforth separately wound onto pole
teeth that are arranged in each case opposite one another. The
coil halves are thereby in each case connected in series with

whereby all coils are divided into two coil halves a and b and
allocated in each case onto pole teeth opposite to one another
and wherein the coil halves Sa and Sb are connected in par
allel to their common initial and end laminations La and Le in
25

contrast to the previous exemplary embodiment. In order to

ensure a reliable, orderly arranged wire guidance between the
commutator 16 and the lamination stack 14 of the rotor 13, the
?rst coil halves Sa of the 20 coils S are in each case continu

each other. The following speci?cations pertain to this elec

ously wound by the automatic coiling machine in a ?rst

trical machine:
30

winding sectionA and after that the second coil halves Sb are
continuously wound in succession in a second winding sec

tion B. As a result, the winding wire of the respective coil half

Number of pole pairs

Number ofpole teeth

can be led to the lamination L as well as from said lamination

to the next coil half Sa in each case across a supporting ring

Number of laminations
Number of coils

Lamination interstice length

Number of windings
Offset angle

embodiment pursuant to FIG. 3b, whereby a pole tooth Z in

each case lies between the points where the winding wire is
fed to and guided away from the laminations L for a portion of
the connections and whereby two pole teeth Z in each case lie
between said points where said winding wire is fed to and
guided away from said laminations L for another portion of
said connections.
In a ?fth exemplary embodiment, a winding table is hence
forth created for an electrical machine 10 according to FIG. 1,

35

2 x 6, respectively 7 and 6
12

19, which is disposed on the shaft of the rotor, in the ?rst

section of the coil halves that are continuously wound in
succession.

The following speci?cations pertain to the ?fth exemplary

embodiment:

In FIG. 11 the production of the ?rst four coils S1 to S4

pursuant to section a according to the winding table from FIG.
10 with the 8 partial coils S111, S1!) to S411, S419 is henceforth
schematically depicted in a developed view of the rotor and
described below.
The winding wire 17 is initially contacted on the lamina
tion L1 with its beginning 1711. From there it is now fed
through the slot N10 to the backside of the rotor and the coil
half S111 is thereupon wound on the pole tooth Z1 with 6

40

Number of pole pairs

Number ofpole teeth
45

3
10
20

Number of laminations
Number of coils

Lamination interstice length

Number of windings
Offset angle

a= 20; Sb = 20

7
= 14, respectively 13
0

windings to the right. After that said winding wire is led

across the backside of the rotor through the slot N8 to the
commutator side and from there to the pole tooth Z6. The
second coil half S119 is wound there with 6 windings to the left
and the coil end is then contacted to the lamination L8. From
there the coil half S211 is wound onto the pole tooth Z3 with 7

50

windings to the left, and said winding wire is thereafter fed

55

through the slot N10 to said backside of the rotor and then led
to the pole tooth Z8. The coil half S219 is wound there with 6
windings to the right and the coil end is thereafter contacted to
the lamination L15. From there said winding wire is now fed
through the slot N7 to said backside of the rotor, and the coil
S311 is now wound onto said pole tooth Z8 with 7 windings to
the right. From there said winding wire is now fed through the
slot N5 to said commutator side, and the second pole half S319
is wound on said pole tooth Z3 with 6 windings to the left. The
coil end is thereafter contacted to the lamination L2. From
there the coil half S411 is now wound on the pole tooth Z10

with 7 windings to the left, and said winding wire is then fed

In FIG. 1311 the production of the coil halves S111 to S411

according to the winding table from FIG. 12 pursuant to the
table section a is schematically depicted in a developed view
of the rotor and described below.

The winding wire 17 is initially contacted with its begin

60

65

ning 1711 on the lamination L1. Thereafter said winding wire

is led to the right to the pole tooth Z8. The ?rst coil half S11 is
wound there with 14 windings, and the coil end is in turn led
to the right and contacted to the lamination L8. From there
said winding wire is now led to the right to the pole tooth Z10.
The coil half S211 is wound there with 13 windings to the right,
and the coil end is then led to the right to the and contacted to
the lamination L15. From there said winding wire is now led
to the right to the pole tooth Z5. The coil half S311 is wound
there with 14 windings to the left, and the coil end is there
upon led to the right and contacted to the lamination L2. From
there said winding wire is in turn led to the right to pole tooth
Z7. The coil S411 is wound there with 13 windings to the right,

US 8,698,370 B2
11

12

and the coil end is thereupon led to the right and contacted to
the lamination L9. From there the automatic coiling machine
executes all further lines from the ?rst half of the winding
table in FIG. 12 for the production of the remaining ?rst coil

is henceforth schematically depicted in a developed view of

the rotor and described below.

The winding wire 17 is initially contacted with its begin

ning 1711 on the lamination L1. From there the winding wire
is now fed through the slot N10 to the backside of the rotor
and is thereafter led onto the pole tooth Z8. The coil S111 is
wound there with 12 windings to the right, and the coil end is
then fed through the slot N5 to the commutator side and is
contacted here to the lamination L8. From there said winding
wire is fed through the slot N3 to saidbackside of the rotor and
thereafter through the slot N2 to the pole tooth Z10. The coil
S211 is wound there with 12 windings to the left, and the coil
end is then contacted to the lamination L15. From there said
winding wire is now fed through the slot N7 to said backside
of the rotor and is thereafter led to the pole tooth Z5. The coil
half S311 is wound there with 12 windings to the right, and the

halves S511 to S 2011. In FIG. 1311 the coil wires are thereby
carried over from the right side to the left side of the devel

oped view of the rotor using a dashed line. The contacting of

the coil halves Sa on the laminations L results in this case by

a hooking around procedure according to FIG. 31!, whereby

said winding wire is led between the lamination and the coil
in each case across a supporting ring 19, the coils being offset
to the lamination in each case by at least 90 on the circum

ference of the rotor.

In FIG. 13b the production of the second coil halves Sb

from the winding table according to FIG. 12 pursuant to the
table section b is henceforth schematically depicted in a
developed view of the rotor and described below.
After the ?rst coil half 2011 of the twentieth coil is wound
onto the pole tooth Z3 and the coil end is contacted to lami
nation L1, the winding wire 17 is now led from lamination L1
to the pole tooth Z3. The coil half S119 is wound there with 14
windings to the right and the coil end is then contacted to the
lamination L8. From there said winding wire is now fed
through the slot N5 to the backside of the rotor and the coil
half S211 is thereupon wound onto the pole tooth Z5 with 12
windings to the left. The coil end is then led across said
backside of the rotor through the slot N7 and contacted on the
commutator side to the lamination L15. From there the coil
half S311 is now wound on the pole tooth Z10 with 14 wind
ings to the right and the coil end is contacted to the lamination

L2. From there the winding wire is now fed through the slot
N2 to said backside of the rotor, and the coil S419 is thereupon
wound on the pole tooth Z2 with 12 windings to the left. The
coil end is then led across said backside of the rotor through

20

25

30

35

the slot N4 to said commutator side and is contacted there to

the lamination L9. From there all additional second coil
halves S5!) to S20b are continuously wound in succession on

the pole teeth, and in this manner the second half of the
winding table according to FIG. 12 is executed by the auto
matic coiling machine. The contacting of the coil halves Sb to
the laminations L occurs in this instance by hooking pursuant

connections of the second winding section made by hooking

for the coils S, which are continuously wound in succession,

40

may be of different size. In so doing, the coils of the ?rst

winding section are to be contacted on the laminations L

using the hooking around procedure. It is advantageous if

45

50

nections the hooking in the second section does not interfere

with the hooking around in the ?rst section.
In a modi?cation to the previous exemplary embodiment, a
55

is now created in a sixth exemplary embodiment. In said

winding table, the direction of winding is changed for the

forty coil halves. In addition, the coil connections in the ?rst
section of the continuously wound coil halves S111 to S2011 on
the laminations L are hereby to be implemented not by the

according to FIG. 1 result within the scope of the speci?ca

tions for the number of pole pairs, the number of teeth and the
lamination interstice length. Furthermore, it is possible in the

to be divided into two winding sections, which are as the case

on the laminations L and vice-versa that when making con

winding table, which pursuant to FIG. 14 is partially depicted,

S1!) to S20b are subsequently produced in the same manner.

The coil connection on the laminations L takes place here as
a modi?cation to FIG. 1311 by hooking said winding wire on
the laminations L instead of by hooking around on the same.
The invention is not limited to the exemplary embodiments
that are depicted because a plurality of combinations for
implementing the rotor winding of an electrical machine 10

case of winding embodiments without a division of the coils

to the procedure according to FIG. 311, whereby two pole teeth

Z lie in each case between the points where the winding wire
is fed to and guided away from the laminations. By dividing
the coil production into two winding sections according to the
winding table from FIG. 12, it is ensured that the coil con
nections made on the laminations L by hooking around in the
?rst section of the winding table do not interfere with the coil

coil end is led across said backside of the rotor and fed
through the slot N2 to said commutator side and is contacted
here to the lamination L2. From there said winding wire is
now fed through the slot N10 to said backside of the rotor and
from there through the slot N9 to said commutator side. From
there the coil half S4 a is wound on the pole tooth Z7 with 12
windings to the left and the coil end is thereafter contacted to
the lamination L9. All additional coil halves S511 to S2011 and

need be for a trouble-free contacting of the coils S to the

laminations L if coils with an angular error Wf and coils
without an angular error Wf are continuously wound in uni

form succession. Because this would require that the winding

wire be led to the laminations L, respectively from the lami
nations, through a slot situated closer to said laminations L for
a portion of the coils S, it is useful if need be for achieving a
better commutation and less torque ripple if the coil halves Sa
and Sb are wound with different numbers of windings at least
for a portion of the coils S, which are divided up on the pole
teeth situated opposite to each other. This is the case for the
winding tables according to FIGS. 10 and 12. The offset angle
v between the pole tooth 1 and the slit of the lamination L1 is
preferably selected such that the lamination is if possible not
in front of a slot N, through which the winding wire is led
from the lamination L1 to the coil S1.
Further alternatives to the inventive production of the rotor

60

hooking around procedure according to FIG. 1311 but by the

hooking procedure according to FIG. 13b. In order to do this,

coils S of electrical machines occur as a result of the coil

halves of the divided coils being connected in parallel to each

other in a ?rst continuously wound coil section and as a result

the coil ends have to be fed to a greater extent through addi

of the coil halves of the remaining divided coils being con

tional slots N when crossing the backside of the rotor, which

lie closer to the respective lamination connection. In FIG. 15
the production of the coil halves S111 to S411 of the winding

nected in series to each other in a second coil section. A

further alternative in the case of the divided coils would be if
the ?rst coil halves Sa are continuously wound in a ?rst

table according to FIG. 14 and pursuant to the table section a

65

winding section and the second coil halves Sb, which in each

US 8,698,370 B2
14

13

the commutator lamination; wherein the individual

tooth coils are continuously wound in succession, the
winding wire is led from the coil to the lamination, and
then from the lamination to the coil, in each case
between two pole teeth of the number of pole teeth

case are once more divided into two partial coils Sbl and Sb2

connected to each other in series, are continuously wound in

the second winding section.

The invention claimed is:
1. A method for producing a rotor winding of a direct
current motor having at least four exciter poles in the stator
and having a commutator rotor, the commutator rotor includ
ing a number of slots and pole teeth on its circumference, the

situated closer to the lamination so that at most two pole

teeth are situated between the lamination and the feed

through of said winding wire.

number of pole teeth deviating from the number of exciter

poles, and having a number of individual tooth coils and an

10

equal number of commutator laminations, the number of

commutator laminations being twice the number of pole

number of pole teeth deviating from the number of

teeth, the method comprising:

exciter poles:

continuously winding the individual tooth coils onto the

pole teeth so as to be evenly distributed, wherein the
continuously wound coils are wound starting from a ?rst
coil onto in each case that pole tooth with the lowest
electrical angular error in relation to a pole division;
causing the individual tooth coils to contact connection
lugs of the commutator laminations with a predeter

a rotor winding with a number of individual tooth coils

being equal to the number of commutator laminations,

the number of commutator laminations being at least

twice the number of pole teeth,

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mined lamination interstice length, the predetermined

the predetermined lamination interstice length ensuring

wherein continuously winding the individual tooth coils

and at most two pole teeth are situated between the slot

from which the winding wire of the lamination is fed and

the slot at which said winding wire is guided away from

wherein the individual tooth coils are wound onto the pole
teeth so as to be evenly distributed, continuously wound,
and contact connection lugs of the commutator lamina

tions with a predetermined lamination interstice length,

lamination interstice length ensuring that an end of each

coil is contacted to a free lamination;

comprises feeding a winding wire from one side of the

commutator lamination and guiding the winding wire
away from the other side, wherein at least one pole tooth

2. A direct current motor comprising:

at least four exciter poles in the stator;
a commutator rotor including a number of slots and pole
teeth on the commutator rotors circumference, the

25

that an end of each coil is contacted to a free lamination;

wherein the continuously wound coils are wound onto a
pole tooth with a lowest electrical angular error in rela

tion to a pole division;

wherein the rotor winding is produced according to the

distinguishing features of claim 1.
*