专利摘要:
The invention relates to a stator component for an electrical machine. The stator component according to the invention comprises a multiplicity of electrical conductor elements, which are arranged in the inner grooves of a stator packet in such a way that an at least one-layered winding is formed. In order to produce the winding layers, the electrical conductor elements are bent in or against the circumferential direction and bent in the radial direction into or away from the main axis of rotation in such a way that conductor elements provided for this purpose are electrically connected to one another at their conductor heads by adjoining layers.
公开号:AT519980A4
申请号:T50715/2017
申请日:2017-08-28
公开日:2018-12-15
发明作者:Falkner Andreas;Primorac Mladen-Mateo;Ing David Scherrer Dipl
申请人:Miba Ag;
IPC主号:
专利说明:

The invention relates to a stator component for an electrical machine. The stator component according to the invention comprises a multiplicity of electrical conductor elements, which are arranged in the inner grooves of a stator packet in such a way that an at least single-layered winding is formed. In order to produce the winding layers, the electrical conductor elements are bent in or against the circumferential direction and bent into or away from the main axis of rotation, such that conductor elements provided for this purpose are electrically connected to one another at their conductor heads by adjoining layers.
Stators for electric motors comprise electrical coils which are designed in the form of windings to an electrically and magnetically conductive core and at current flow of the coils in the stator a magnetic field he testify, which is required to drive the electric motor. These windings may e.g. be generated by that U-shaped curved conductor elements or rod-shaped conductor elements are inserted into the stator and the intended conductor elements are connected to form windings.
In general, the height of a stator in the axial direction, ie in
Direction of the main axis of rotation, as small as possible. Therefore, often protruding from the stator core conductor ends are bent in or against the circumferential direction and / or cranked. The conductor elements, which are radially equidistant from the main axis of rotation, are referred to as a layer. The conductor elements in each case one layer are often bent or entangled so that by electrical connection with designated
Conductor elements of an adjacent layer results in a winding layer. The entire winding can therefore have a plurality of coils or winding layers which are required for the formation of a stator.
The most well-known design of the conductor ends essentially corresponds to a "Z-shape" of the stator ends protruding from the stator core at the end face. In this case, two sections of a protruding end face on the end of the conductor in the direction of the main axis of rotation, while a portion is bent in the circumferential direction, which allows an entanglement with conductor elements adjacent layers. At the same time, the expansion of the stator component in the direction of the main axis of rotation is reduced. Such a design of a stator component, or even winding carrier, is described in DE 10 2014 218 224 A1.
In DE 10 2014 222 608 A1, a component for an electrical machine is alternatively described, comprising a magnetically conductive stator core having a plurality of openings extending along an axial direction of the stator core, a plurality of conductor elements extending in the openings in the axial direction to generate a magnetic field when energized in the magnetically conductive stator core, wherein the conductor elements are inserted into the openings and ends of the conductor elements have been joined together. Sections of the conductor elements, which have the connected ends and which protrude on the end face of the magnetically conductive stator core, are angled toward the main rotation axis in order to form a winding head and then in the direction of a radially outer magnetic yoke.
Thus, a solution is sought for minimizing the overall height of a stator, wherein the overall height of the stator is essentially determined by the necessary length of the connected conductor elements protruding from the stator core.
The object of the present invention was to overcome the disadvantages of the prior art and to provide a stator component, by means of which a compact height of a stator for an electric machine is made possible in a simple manner.
This object is achieved by a stator component according to the claims.
The invention relates to a stator component for an electrical machine, the
A stator component comprising: a hollow cylindrical stator package having a stator package face and a stator package base side, which has a plurality of circumferentially distributed, in
Direction of the main axis of rotation continuously on the inside of the Statorpa kets extending inner grooves, wherein the plurality or all of the inner grooves has a plurality of electrical Lei terelementen, which are electrically isolated from each other in the radial direction inserted in alignment, and wherein all electrical conductor elements with substantially the same radial distance to the main axis of rotation as each present a position and wherein the electrical conductor elements of each radially further outlying layer with a larger radial distance to the main axis of rotation with corresponding Lei terelementen each radially further inlying position with a smaller Ra dialabstand to the main axis of rotation than each radially further out
Layer are formed as a winding layer, and the stator to at least one winding layer having, wherein the electrical conductor elements are formed as protruding from the stator core conductor ends, and at least the protruding from the Statorpaketstirnseite conductor ends of each radially outer layer are bent in a first circumferential direction and the protruding from the Statorpaketstirnseite conductor ends of the adjacent radially adjacent inner layer opposite to the first circumferential direction are bent, each conductor end of the respective radially outer layer having at least partially stripped conductor head having an at least partially stripped conductor head of a planned Ladder end of electrically adjacent in Radialrich adjacent further inner layer is present, and at least the conductor heads of the radially further outward position in the radial direction to Haupttrotati bent onsachse, while the corresponding conductor heads of the radially adjacent inner layer lying in the radial direction of the main axis of rotation are groundbreaking bent. As a result, the known design of the conductor elements in "Z-shape", ie a double bending or bending of protruding from the end face of the conductor package conductor ends in the direction of the main axis of rotation is avoided. The inventive simple bending of the conductor head in the radial direction or pointing away from the main axis of rotation eliminates a portion of each conductor element which would run parallel to the main axis of rotation for electrical connection leading. On the one hand, this represents a significant cost saving, since a shortened length of the conductor elements means a significant saving of material. On the other hand, this significantly reduces the overall height of the stator component on at least the front side since the "overhang" of the conductor heads over the known solutions is eliminated. However, a suitable entanglement and connection of the intended conductor elements is still achieved in a simple manner.
Furthermore, it may be expedient if the electrical conductor elements each have a projecting from the Statorpaketbasisseite conductor end, each with an at least partially stripped conductor head and bent from the Statorpaketbasisseite conductor ends opposite the Umfangsbiegerich-direction of Statorpaketstirnseite protruding conductor ends the same position bent but the Radialbiegerichtung the conductor heads of the projecting from the Statorpaketbasisseite conductor ends coincides with the Radialbiegerichtung the conductor heads protruding from the Statorpaketstirnseite conductor ends the same position. This allows in addition to the reduction of the height on the front side of the stator component a reduction of the height at the base side with the above-mentioned advantages. Moreover, by this construction, an equally simple contacting or connection of the mutually provided (corresponding) conductor elements on the base side of the stator can be carried out.
It can further be provided that the length of the conductor heads of the stator end faces projecting from the stator end face accounts for more than 5% of the length of the stator ends projecting from the stator core end side and / or the length of the conductor heads of the conductor ends protruding from the stator core base side more than 5% of the length of the conductor ends the Statorpaketpaketseite makes outstanding conductor ends. The total length of the electrical conductor elements can be varied with the height of the stator. By height variations of the stator, only the proportion of the length of the conductor elements has to be adapted, which extends in the main direction of rotation within the internal grooves. However, the length of the conductor heads relative to the respective conductor ends remains largely uninfluenced by the total length of the conductor elements and can be chosen relatively short according to the present invention. However, it has proven to be advantageous if at least 5% of the length of the protruding from the Statorpaketbasisseite conductor ends is used as the length of the conductor heads, so that a bending tool can be positioned appropriately low. An automated production of electrical conductor elements is promoted to this effect and achieved a cost reduction.
Also advantageous is an expression, according to which it can be provided, the length of protruding from the Statorpaketstirnseite and / or Statorpaketbasisseite conductor ends of the radially outer layer different, in particular larger, to the length of the corresponding conductor ends of Statorpaketstirnseite, respectively the Statorpaketbasisseite, in Radial direction adjacent inner layer is located. When using internal grooves with e.g. rectangular cross-section in conductor elements of the same length, the radially outer conductor ends must be bent by a greater distance in the circumferential direction than the conductor ends which are arranged radially further inward on the main axis of rotation. This leads to a shortening of the distance between the electrical connections of the outer winding layers to the Statorpaketstirn- or Statorpaketbasisseite. This results in a "roof-shaped" envelope surface of the electrical connections, which may be advantageous, e.g. by laser not directly in the direction of the main axis of rotation but deviating from it in the radial direction, or even at right angles to the main rotational direction from the radial direction to make the electrical connection. This can offer process engineering advantages. However, the choice of different lengths of corresponding conductor heads brings the
Advantageous, that the electrical connections on a plane, e.g. parallel to the Statorpaketstirnseite and / or Statorpaketbasisseite, can lie. As a result, a very compact height of the stator component can be achieved. Furthermore, an automated contacting of the conductor heads by e.g. Laser or laser deep hole welding simplified, since all electrical connections on one
Lie flat.
In addition, it can be provided that the length of the conductor heads of the Statorpaketstirn- and / or protruding from the Statorpaketbasisseite conductor ends of the radially outer layer different, in particular larger, to the length of the corresponding conductor heads Statorpaketstirnseite, respectively the Statorpaketbasisseite, outstanding conductor ends in radial
Direction adjacent inner location is. By choosing different lengths of conductor heads is a different arrangement of the electrical connections in the radial direction and / or circumferential direction made light. This can bring about some procedural simplifications. In example, this can specifically target the position of the electrical connection
Winding layer can be varied in the radial direction relative to an adjacent winding layer, which allows a greater variety of usable Kontaktie treatment method for generating the electrical connection of the corresponding conductor heads. Furthermore, the engagement of a bending tool for the radial deformation of the conductor heads from the outside or inside, ie in the direction of or pointing away from the main axis of rotation, can be facilitated.
Furthermore, it can be provided that curved ends in or against the circumferential direction have a circumferential bending angle of between 15 ° and 75 °, preferably between 35 ° and 70 °, particularly preferably between 50 ° and 65 ° with respect to the main axis of rotation of the stator core. The orientation of the conductor ends to the one circumferential bending angle allows the use of relatively simple forming tools or forming operations. The choice of the circumferential bending angle can be selected by the person skilled in the art as a function of the conductor element cross-section, whereby the flatest possible orientation of the conductor ends with respect to the stator package end face or stator package base side is in the foreground. The elimination of complicated and thus costly forming tools means a significant reduction in process costs. Furthermore, this design allows easy to implement and thus also easy to automate forming processes, which lead to increased process reliability, component quality and lower process costs.
In addition, it can be provided that the conductor heads bent in the radial direction to or pointing away from the main axis of rotation by a Radialbie angle relative to the respective circumferentially bent conductor ends between 15 ° and 85 °, preferably between 35 ° and 70 °, more preferably between 40 ° and 50 °. The bending of the conductor heads in the radial direction allows accurate positioning of the curved conductor heads in the vertical direction, ie the direction of the main axis of rotation, as well as the horizontal direction, ie the radial direction or circumferential direction. In the context of this invention is to be understood as Leitererkopfachse an imaginary extension of the respective conductor head. However, a slight deviation of the conductor head axes of the corresponding conductor heads does not represent a significant disadvantage in practice. Ideally, the corresponding conductor heads are aligned and the corresponding conductor head axes are parallel to each other in the horizontal direction, ie normal to the direction of the main axis of rotation, parallel or in alignment. This reduces the risk of a defective connection point during the subsequent electrical connection. The risk of producing non-functional stators is thus significantly reduced. Furthermore, clamping tools are often required for the electrical connection, which, for example, in the case of a "Z-shape" of the conductor ends, fulfill the task of pressing the conductor ends against each other in order to allow electrical contacting. By the o.g. Embodiment, this clamping or positioning step can be omitted, which contributes to a reduction of the process duration and costs. The most widely used material for conductor elements is copper and its alloys. The use of copper materials in electrical applications is favored by the good cold workability, but should damage the surface of the conductor elements, as well as the electrical insulation such. a paint layer to be avoided when bending in the circumferential direction or in the radial direction. The Leiterele elements used in the present invention may be U-shaped or rod-shaped with a round, or square, but preferably rectangular cross-section. The springback of the bent conductor elements depends on the cross section in the bending zones of the conductor element. It has been found that bending of the conductor heads about a radial bending angle to the main axis of rotation or pointing away between 15 ° and 85 °, preferably between 35 ° and 70 °, particularly preferably between 40 ° and 50, is most suitable. A bending of the conductor heads in said angular range is technologically easy to accomplish. Furthermore, springback in the radial direction can be well adjusted and thus the position accuracy of the corresponding conductor heads are increased to each other.
Also advantageous is an embodiment according to which it can be provided that the conductor heads of the stator end face projecting conductor ends have a conductor head end which is electrically connected to the head face of the corresponding conductor head, and / or the conductor heads of the stator ends projecting on the stator core side have a conductor head base side the conductor head base side of the corresponding conductor head is electrically connected. The advantage over the known solutions is that not the flanks or side surfaces of the electrical conductor elements are connected to each other but the electrical connection directly to the ladder head end sides or Leitererkopfbasisseiten. This solution significantly shortens the unusable projection of the electrical conductor elements in the direction of the main axis of rotation and achieves a reduction in the overall height of the stator component or of the stator. The line resistance of the stator component due to the reduced current flow length is also reduced. Furthermore, an effective material saving over known solutions is achieved. A higher efficiency of the stator component can be achieved.
According to a development, it is possible for an electrical connection cross section of a conductor head of the radially outer layer with the corresponding conductor head to be formed by more than 50%, preferably more than 75%, of a conductor cross-sectional area of at least one of the connected conductor heads. In order to ensure an optimal, low-resistance current passage in the electrical conductor elements, it is necessary that a certain cross-sectional area of the electrical conductor elements is available after electrical connection. In this case, it has been found in the stator component according to the invention that the electrical connection is considered sufficient if the connection cross-section, so to speak, the "effective diameter" for the current flow, more than 50% of the cross-sectional area of at least one of the corresponding conductor heads. The advantage is that a certain tolerance in the bending of the conductor heads in the radial direction and the conductor ends in the circumferential direction is permitted. An effective reduction of the time and thus costs in the positioning of the corresponding conductor heads is hereby made possible.
Furthermore, it may be expedient if the conductor heads of the stator ends protruding on the stator core end side and / or the conductor heads of the stator ends projecting on the stator core base side have a stepwise and / or continuous reduction in cross section in the direction of the conductor head front side, respectively the conductor head base side, opposite the cross section of the conductor element at the outlet opening to the inner groove. Normally, the cross-section of the conductor elements remains substantially constant over the length of a conductor element. However, the use of a taper in the region of the conductor head, ie a reduction in the cross section in at least one direction, can be advantageous for the deformation or bending of the conductor head. The engagement of a bending tool can be achieved by e.g. a stepwise and / or continuous reduction in cross section can be facilitated since the bending tool is provided with a defined contact surface. Furthermore, a reduction in cross section in the conductor head area can serve to lower the forces for bending in the radial direction. In addition, a targeted design of the conductor heads allows a largely backlash-free positioning relative to the corresponding conductor head. Here, e.g. stepped or wedge-shaped ladder heads conceivable, which serve to fit the ladder heads after the radial bending fit together. This is particularly advantageous because it allows the contact length of the electrical connection of the corresponding conductor heads can be easily adjusted or increased.
According to a development, it is possible that the electrical connection of the conductor heads of the radially outer layer is carried out with the corresponding conductor heads as a solder joint. The introduction of an additional material with a lower melting point than the melting point of the conductor element material allows the targeted electrical connection of the corresponding conductor heads with a high electrical connection cross-section. Here, soft but especially brazing alloys are conceivable.
In addition, it can be provided that the electrical connection of the conductor heads of the radially further outward position with the corresponding conductor heads is designed as a welded connection. It has been found that welded joints are significant advantages in terms of minimizing electrical resistance. Although electrical connections of the corresponding conductor heads can be carried out by means of a solder or electrically conductive adhesive, welded connections permit the use of the stator components in dynamically stressed surroundings since they generally have a higher fatigue strength. As a method of welding, in particular, methods are used which introduce little heat into the electrical conductor elements. In addition to laser deep welding, electron beam deep welding, plasma deep welding and capacitor discharge welding, or ultrasonic friction welding are conceivable.
Furthermore, it can be provided that the welded connection is designed as a weld drop. Due to the radial bending of the corresponding conductor heads, the conductor head end faces or the ladder head base sides can be connected via a weld drop. Compared with the most commonly encountered lap impact at e.g. juxtaposed "Z-shaped" conductor ends a butt joint is formed by this embodiment, which allows the saving of material of the conductor element. Furthermore, this reduces electrical line losses and increases the efficiency.
According to a particular embodiment, it is possible that the Leiterkopfstirnsei th and / or Leiterkopfbasisseiten the conductor heads of the radially further outward position with the ladder head ends, respectively the ladder head base pages, the corresponding conductor heads by means of a weld, in particular Lasertieflochschweißnaht connected. By means of this embodiment, a planar electrical connection of the corresponding conductor heads, which is preferably carried out in the direction of the main axis of rotation, is achieved in comparison to a punctiform welded connection. The weld seam thereby makes it possible in a simple manner to design an electrical connection cross-section of more than 50%, preferably more than 75%, of the conductor head cross-sectional area of at least one of the conductor heads. As a suitable welding method for the design of
Weld seam are in addition to heat conduction welding by laser beam in particular the laser deep hole welding, or electron beam welding, conceivable. The laser or laser deep welding allows a very local and targeted heat input. This is of particular importance as the insulation layer of the conductor elements at the conductor ends should not be adversely affected by the electrical connec tion. For example, the laser deep-hole welding, or electron beam deep welding, but also allow greater penetration depths and thus an enlarged connection cross-section compared to thermal conduction welding by means of laser beam. This is a considerable advantage, especially with a larger conductor head cross-sectional area. Furthermore, the welding methods mentioned can be easily automated, which in addition to the qualitative advantages, even the higher process speeds have a positive effect on the process costs.
According to an advantageous development can be provided that the electrical connection of the conductor heads protruding from the Statorpaketstirnseite conductor ends of the radially outer layer with the corresponding conductor heads, and / or that the electrical connection of the conductor heads of outstanding from the Statorpaketbasisseite conductor ends of radially further au ßen lying position with the corresponding conductor heads, in the direction of
Main axis of rotation between, in particular centrally between, the lying in the radial direction inside the conductor ends of the radially outer layer and the radially outer side of the conductor ends of the radially inner layer is executed. The different arrangement of the electrical connections in the radial direction can bring about some procedural simplifications. By way of example, the position of the electrical connection of one winding layer in the radial direction relative to an adjacent winding layer can thereby be selectively varied, which permits a greater variety of usable contacting methods for producing the electrical connection of the corresponding conductor heads. Furthermore, the engagement of a bending tool for the radial deformation of the conductor heads from the outside or inside, ie in the direction of or pointing away from the main axis of rotation, can be facilitated.
In the context of this application, the term "electrical conductor element" may also mean several electrical sub-conductors or strands which perform a common function as an electrical conductor element.
Furthermore, the described stator component can have connection ends, conductor bridges, groove jumps and similar elements which are connected by a circuit. Such functionally relevant elements are well known to the person skilled in the art. The person skilled in the art is therefore aware that the described stator component does not have to be rotationally symmetrical over the entire circumference.
For a better understanding of the invention, this will be explained in more detail with reference to the following figures.
In each case, in a highly simplified, schematic representation:
1 shows a stator component with a part of conductor elements in an oblique view (a), and a stator component with ladder elements in the elevation (b).
FIG. 2 shows a detail of a plan view of a stator component with some conductor elements; FIG.
3 shows an exemplary electrical conductor element with a conductor end bent in the circumferential direction and a conductor head bent in the radial direction to the main direction of rotation;
4 shows an exemplary electrical conductor element with conductor ends bent in or against the circumferential direction and conductor heads (a, b) bent in the radial direction to the main direction of rotation;
5 different embodiments of connected conductor heads with different lengths of the conductor heads and / or different radial distance of the electrical connection;
Fig. 6 different embodiments of connected conductor heads with different electrical connection cross-section;
7 shows different embodiments of conductor heads with straight, stepped or continuous decreasing conductor head cross-section;
Fig. 8 different embodiments of electrical connections of the conductor heads.
By way of introduction, it should be noted that in the differently described embodiments, the same parts are provided with the same reference numerals or the same component names, wherein the disclosures contained in the entire description can be mutatis mutandis to the same parts with the same reference numerals or component names. Also, the location information chosen in the description, such as top, bottom, side, etc. related to the immediately described and illustrated figure and these position information in a change in position mutatis mutandis to transfer to the new location.
1 shows a stator component 1 comprising a hollow cylindrical stator core 2, with a multiplicity of internal grooves 6 distributed in the circumferential direction 11 and extending in the direction of the main rotation axis 5, into which electrical conductor elements 7 are inserted.
In Fig. 1a, an oblique view is shown, for better understanding, only a portion of the electrical conductor elements 7 is shown as an example. The stator core 2 has a stator core end face 3, which in the context of this invention is meant as the side of the stator component 1, at which the connections for the energization of the stator component 1 or the electrical connection of any further electrical elements is meant. The Statorpaketstirnseite 3 facing away from the stator 2 has a Statorpaketbasisseite 4 on. The electrical conductor elements 7 which as a conductor ends 10 of the Statorpaketstirnseite 3 each radially outer layer 8a are bent in a first circumferential direction 11 and protruding from the Statorpaketstirnseite 3 conductor ends 10 of the adjacent radially adjacent layer 8b are opposite to the first Circumferentially 11 bent (see Fig. 2). From Fig. 1 it is already apparent that the corresponding conductor heads 13 of different layers are so bent in the radial direction 12 to the main axis of rotation 5 in the radial direction 12 of the main axis of rotation 5 pioneering that a touch or an electrical connection is given.
FIG. 2 shows a section of a stator component 1 in plan view. For better understanding, four electrical conductor elements 7 are shown by way of example only. The electrical conductor elements 7 with substantially the same radial distance from the main axis of rotation 5 are present as a respective layer 8. The electrical conductor elements 7 of a respectively radially outer layer 8a have a greater radial distance from the main axis of rotation 5 with respect to the corresponding conductor elements 7 of a radially further inner layer 8b with a smaller radial distance to the main axis of rotation 5, and form a winding layer 9. The stator component 1 has at least one, preferably a plurality of winding layers 9. In the reduced representation in FIG. 2, a part of two winding layers 9 is sketched. It is clearly evident from FIG. 2 that at least the conductor heads 13 of the radially outer layer 8a are bent in the radial direction 12 toward the main axis of rotation 5, while the corresponding conductor heads 13 of the radially adjacent, further inner layer 8b bend in the radial direction 12 away from the main axis of rotation 5 are.
3 shows a detail of a stator component 1 in an oblique view with only one exemplary electrical conductor element 7. It can be seen that the part of the electrical conductor element 7 protruding from the stator core end face 3 of the stator core 2 at the outlet opening has a peripheral bending angle 16 in FIG Circumferentially 11 is bent. This part of the electrical conductor element 7 is referred to as conductor end 10. Furthermore, it can be seen that a part of the conductor end 10 is bent in the radial direction 12 to the main axis of rotation 5 by a radial bending angle 17. This part of an electrical conductor element 7, or a conductor end 10, is referred to as a conductor head 13. The electrical conductor elements 7 are electrically insulated, e.g. can be executed by a plastic and / or lacquer insulation. As can be seen in FIG. 3, the insulation of the electrical conductor elements 7, respectively the conductor ends 10, can be at least partially removed, ie stripped, only at the conductor head 13 in order to enable an electrical connection to a corresponding conductor head 13.
As can be seen from FIGS. 1 b and 4, it may be advantageous for the electrical conductor elements 7 to each have a conductor end 10 projecting from the stator packet base side 4, each having an at least partially stripped conductor head 13 and the conductor ends 10 projecting from the stator package base side 4 opposite to FIG However, the radial bending direction 15 of the conductor heads 13 of the Statorpaketbasisseite 4 protruding conductor ends 10 with the Radialbiegerichtung 15 of the conductor heads 13 of the Statorpaketstirnseite 3 protruding conductor ends 10 of the same layer 8 coincides circumferential bending direction 14 of the Statorpaketstirnseite 3 protruding conductor ends. This allows alternatively to the use of "U-shaped" pre-bent electrical conductor elements 7, the use of rod-shaped electrical conductor elements 7. The bending in or against the circumferential direction 11, as well as in the radial direction 12 or pointing away from the main axis of rotation 5 is in the rod-shaped electrical Conductor elements 7 thus pronounced on both sides of the stator 2, which allows a reduction in the height of the stator 1. It can be seen from the illustration in FIG. 4 that the circumferential bending angle 16 of the conductor ends 10 bent in or against the circumferential direction 11 is opposite the main rotational axis 5 of the stator core 2
Circumferential bending angle 16 between 15 ° and 75 °, preferably between 35 ° and 70 °, more preferably between 50 ° and 65 ° may have. This essentially applies to conductor ends 10 which protrude on the stator package end face 3 and / or the stator package base side 4.
It can be provided that the length of the conductor heads 13 of the stator end face 3 protruding from the stator ends 10 more than 5% of the length of the Statorpaketstirnseite 3 protruding conductor ends 10 makes up and / or the length of the conductor heads 13 of the Statorpaketbasisseite 4 protruding conductor ends 10th more than 5% of the length of the stator end 10 protruding from the stator core base 4. This can clearly be seen in FIGS. 4a and 4b. The length of the conductor ends 10 is determined in this context from the outlet opening of the inner grooves 6 starting.
Also advantageous may be an expression, according to which it is provided that the length of the projecting from the Statorpaketstirnseite 3 and / or Statorpaketbasisseite 4 conductor ends 10 of the radially outer layer 8a different, especially larger, to the length of the corresponding conductor ends 10 of Statorpaketstirnseite. 3 , respectively, of the stator packet base side 4, which is in the radial direction adjacent inboard layer 8b. If, for example, electrical conductor elements 7 of the same length are inserted radially aligned in the inner grooves 6, a bending in the circumferential direction 11 of the radially outer conductor ends 10 is required by a greater distance than for the conductor ends 10 which are arranged radially further inward. Viewed from the side, ie in the radial direction, the conductor ends 10 or the electrical connections between the corresponding conductor heads 13 would have a "roof-shaped" or "trapezoidal" envelope surface. This embodiment can offer certain manufacturing advantages, such as that a laser used for electrical connection of the conductor heads 13 can be used from the radial direction 12. However, it may be required that the removal of the electrical connections of the conductor heads 13 from the Statorpaketstirnseite 3, and the Statorpaketbasisseite 4, is substantially uniform. Such a case is shown in Fig. 1b, where a stator component 1 with a stator 2, in
An elevation, wherein in the internal grooves 6, a plurality of electrical conductor elements 7 are inserted electrically insulated from each other in the radial direction.
The conductor ends 10 of the aligned in the radial direction electrical conductor elements 7 here have different lengths in the respective different layers 8. This leads to a particularly compact stator component 1 with a low overall height.
FIG. 5 shows exemplary sections of electrical connections of corresponding conductor heads 13, examples of various possible embodiments of the length of the conductor heads 13 being discussed. It can be provided that the length of the protruding from the Statorpaketstirnseite 3 and / or Statorpaketbasisseite 4 conductor ends 10 of the radially outer layer 8a different, especially larger, to the length of the corresponding conductor ends 10 of Statorpaketstirnseite 3, respectively the Statorpaketbasisseite 4, the is in the radial direction adjacent inner layer 8b. In the case of different lengths of the corresponding conductor heads 13, the position of the electrical connection shown in Fig. 5 can be selectively adjusted between, and in this case in particular centrally between, two layers 8a, b. This can be advantageous since the position of the electrical connection of a winding layer 9 in the radial direction 12 and / or circumferential direction 11 can be varied with respect to an adjacent winding layer 9. A greater variety of usable contacting method for generating the electrical connection of the corresponding conductor heads 13 is thereby made possible.
Furthermore, it can be seen particularly well from FIG. 5 in conjunction with FIG. 4 that the conductor heads 13 bent in the radial direction 12 towards or away from the main axis of rotation 5 are at a radial bending angle 17 with respect to the respective conductor ends 10 which are bent in the circumferential direction 11 between 15 ° and 85 °, preferably between 35 ° and 70 °, more preferably between 40 ° and 50 °. The choice of the radial bending angle 17 can be made by those skilled in the art in view of several factors, such as the used diameter of the electrical conductor elements 7, the length of the conductor heads 13, the
Arrangement of the electrical conductor elements 7 in the radial direction 12 and the like. More. However, it is important for a high-quality stator component 1 with a low overall height to ensure that the radial bending angle 17 of the corresponding conductor heads 13 is selected such that the conductor heads 13 have an electrical connection.
It is also advantageous if the conductor heads 13 of the stator end faces 3 projecting on the stator end faces 10 have a conductor head end face 18 which is electrically connected to the conductor head end face 18 of the corresponding conductor head 13, and / or the conductor heads 13 of the stator core base side 4 projecting conductor ends 10 a ladder head base side 19th which is electrically connected to the conductor head base side 19 of the corresponding conductor head 13. The ladder head ends 18 and ladder head base sides 19 are e.g. shown in Fig. 4 or Fig. 7. The ladder head base sides 19 may be pronounced analogously to the examples shown for the ladder head end faces 18. Due to the electrical connection of the corresponding conductor head end faces 18 and ladder head base sides 19, an excellent electrical connection of the electrical conductor elements 7 is ensured. Furthermore, the total length of the electrical conductor elements 7 is reduced to a minimum, which contributes to an effective reduction of the height of the stator component 1. For certain applications, it may be advantageous for the conductor heads 13 of the conductor ends 10 projecting on the stator package end face 3 and / or the conductor heads 13 of the conductor ends 10 projecting on the stator package base side 4 to be stepped and / or continuous in the direction of the conductor head front side 18, respectively the conductor head base side 19, relative to the cross section of the conductor element 7 at the outlet opening to the inner groove 6 have. Some exemplary embodiments for different conductor heads 13 are shown in FIG. If, for example, the cross section of an electrical conductor element 7 is retained on the conductor head 13, the conductor head end face 18 in the example shown in FIG. 7 can have a rectangular shape at the top left. However, the forces for bending the conductor head 13 in the radial direction 12 can be reduced by a continuous decrease in the cross section in the region of the conductor head 13. This continuous reduction in cross section may e.g. be designed as a wedge or tip shape or pinching of the conductor head. Furthermore, stepped ladder heads 13 are conceivable as shown in FIG. 7 below. The corresponding conductor heads 13 may each have opposite gradations, resulting in an increased electrical connection cross-section 20, as shown in Fig. 6 results. A combination of the above-mentioned geometries for corresponding conductor heads 13 is also possible. The mentioned reduction in cross section of the conductor heads 13, for example, by laser processing, punching, or a Ablängvorgang in the production of the electric Le iterelemente 7 are set and is therefore not further explained at this point.
In a development, it is possible for an electrical connection cross section 20 of a conductor head 13 of the radially outer layer 8 to be formed with the corresponding conductor head 13 of more than 50%, preferably more than 75%, of a conductor head cross-sectional area 21 of at least one of the connected conductor heads 13 , The electrical connection cross-section 20 is illustrated by way of example in FIG. 6a using corresponding conductor heads 13 which are bent exactly in the radial direction 12. An exact overlap of the conductor head end faces 18 and ladder head base sides 19 in the direction of the conductor head axis, ie the imaginary extension of the conductor heads 13, thus ensures the highest "effective diameter" for the current flow. As shown in Fig. 6b, however, alignment deviations of the corresponding conductor heads 13 in the direction of the main axis of rotation 5 and in the circumferential direction 11 may occur, whereby a reduced electrical connection cross-section 20 is formed. It has been shown that production technology should be provided with a certain tolerance, which is why at least 50%, preferably 75%, of the conductor head cross-sectional area 21 of at least one of the corresponding conductor heads 13 should be occupied by the electrical connection cross-section 20.
According to a further development, it is possible that the electrical connection of the conductor heads 13 of the radially outer layer 8a with the corresponding conductor heads 13 is designed as a solder joint 24. For this purpose, the generation of a high electrical connection cross-section 20 via the melting of an additive, which electrically conductively connects the corresponding conductor heads 13 after solidification. A schematic representation of such a solder joint 24 can be seen in FIG. Alternatively, the production of an electrical connection by means of an electrical adhesive is conceivable.
According to another embodiment it can be provided that the electrical connection of the conductor heads 13 of the radially outer layer 8a with the corresponding conductor heads 13 is designed as a welded connection. In Fig. 8, several variants of welding or solder joints are shown. The welding process for the electrical connection should introduce as little heat as possible into the electrical conductor elements. In addition to laser deep welding, electron beam deep welding, plasma deep welding and capacitor discharge welding, or ultrasonic friction welding are conceivable. The weld joint in the form of a weld drop 22 may e.g. be made by thermal conduction welding by means of laser. The weld bead 22 may extend not only superficially but also preferably over part of the conductor heads 13 in the direction of the main axis of rotation 5 to ensure the highest possible electrical connection cross section 20, as in the left half of Fig. 8 by means of an oblique view of the weld drop 22, as well a section through the electrical connection is shown. Welded joints generally have the advantage that they are particularly stable mechanically, thermally and electrically. Reference should be made to different forms of conductor heads 13, which are shown in Fig. 7. The formation of a weld drop 22 (or weld bead) can be achieved by choosing e.g. pointed trimmed conductor heads 13 are favorably influenced.
It may be of particular advantage if the welded joints are made by laser. The heat input into the conductor heads 13, respectively the conductor ends 10 is e.g. influenced by the focusing and dwell time of the laser at one point. In general, lasers have a very low heat input in comparison of e.g. Resistance welding of the conductor heads 13. Therefore, the insulation of the conductor ends 10 can be kept harmless even when establishing the electrical connection.
According to one embodiment, it is possible that the ladder head end faces 18 and / or the ladder head base sides 19 of the ladder heads 13 of the radially outer layer 8a with the ladder head end faces 18, respectively the ladder head side 19, the corresponding ladder heads 13 by means of a weld 23,23a, in particular Lasertieflochschweißnaht 23b, are connected. This expression can be seen very well from Fig. 8, where electrical connections and their sections are shown in the right half of the picture. The formation of a weld 23, 23a thereby allows in a simple manner the design of a high electrical connection cross-section 20. It is to form a weld 23, the juxtaposition of several u.U. overlapping, weld drops 22 conceivable. For the o.g. However, to minimize the heat input, heat conduction welding by electron beam or laser along the conductor head faces 18 or ladder head base faces 19 is preferred. As shown schematically in FIG. 8, the weld seam 23 can be embodied as a laser deep-hole weld seam 23b or else an electron beam weld seam. The length and depth of each weld 23 can now be easily automated and manufactured with high precision. A high electrical connection cross-section 20 can thus be set in a well reproducible manner.
In a particular embodiment, the electrical connection of the conductor heads 13 of the protruding from Statorpaketstirnseite 3 conductor ends 10 of the radially outer layer 8a with the corresponding conductor heads 13, and / or the electrical connection of the conductor heads 13 of the Statorpaketbasisseite 4 protruding conductor ends 10 of radially further outward position 8a with the corresponding conductor heads 13, in the direction of the main axis of rotation 5 between, in particular centrally between, lying in the radial direction inside the conductor ends 10 of the radially outer layer 8a and lying in the radial direction outside of the conductor ends 10 of radially inward lying layer 8b is executed. The resulting position of electrical connections is shown by dashed lines in the exemplary illustrations in FIG. The position of the electrical connection of a winding layer 9 in the radial direction 12 with respect to an adjacent winding layer 9 can thereby be easily varied (compare FIGS. 2 and 5). This allows a greater variety of usable contacting method for generating the electrical connection of the corresponding conductor heads 13. Furthermore, the engagement of a bending tool for the deformation of the conductor heads in the radial direction 12 from the outside or inside, ie in the direction of or pointing away from the main axis of rotation 5 easier become.
The embodiments show possible embodiments, it being noted at this point that the invention is not limited to the specifically illustrated embodiments thereof, but rather various combinations of the individual embodiments are possible with each other and this variation possibility due to the teaching of technical action by representational invention in Can the expert working in this technical field.
The scope of protection is determined by the claims. However, the description and drawings are to be considered to interpret the claims. Individual features or combinations of features from the illustrated and described different embodiments may represent for themselves inventive solutions. The task underlying the independent inventive solutions can be taken from the description. All statements of value ranges in the present description should be understood to include any and all sub-ranges thereof, e.g. is the statement 1 to 10 to be understood that all sub-areas, starting from the lower limit 1 and the upper limit 10 are included, ie. all sub-areas begin with a lower limit of 1 or greater and end at an upper limit of 10 or less, e.g. 1 to 1.7, or 3.2 to 8.1, or 5.5 to 10.
For the sake of order, it should finally be pointed out that for a better understanding of the construction, elements have been shown partially unevenly and / or enlarged and / or reduced in size.
LIST OF REFERENCE NUMERALS 1 stator component 2 stator package 3 stator package face 4 stator package base side 5 main rotation axis 6 inner groove 7 conductor element 8 a, b layer 9 winding layer 10 conductor end 11 circumferential direction 12 radial direction 13 conductor head, conductor heads 14 circumferential bending direction 15 radial bending direction 16 circumferential bending angle 17 radial bending angle 18 conductor head end 19 conductor head base side 20 connection cross section 21 conductor cross sectional area 22 weld drops 23 a weld; b Deep-hole weld 24 Solder connection
权利要求:
Claims (15)
[1]
claims
A stator component (1) for an electric machine, the Statorkompo component (1) comprising: a hollow cylindrical stator (2) having a Statorpaketstirnseite (3) and a Statorpaketbasisseite (4), which a plurality of circumferentially (11) distributed, itself in the direction of the main axis of rotation (5) continuously on the inside of the stator (2) extending inner grooves (6), wherein the plurality or all of the inner grooves (6) has a plurality of electrical conductor elements (7) which are electrically isolated from each other in the radial direction are inserted in alignment, and wherein all the electrical conductor elements (7) with substantially the same radial distance to the main axis of rotation (5) as a respective layer (8) are present and wherein the electrical conductor elements (7) each radially further outlying layer (8a) with a larger Radial distance to the main axis of rotation (5) with corresponding conductor elements (7) of a respective radially further inner layer (8b) with a smaller radial distance from the main axis of rotation (5) than the respective ra dial further outward layer (8a) are formed as a winding layer (9), and the stator component (1) at least one winding layer (9) aufwei send, wherein the electrical Conductor elements (7) as from the stator core (2) forth protruding conductor ends (10) are formed, and at least from the Statorpaketstirnseite (3) projecting conductor ends (10) of each radially outermost layer (8a) in a first circumferential direction ( 11) are bent and the stator ends (10) projecting from the stator package end face (3) are bent in the opposite direction to the first circumferential direction (11) in the radially inward direction, and each conductor end (10) is radially further outward lying position (8a) has an at least partially stripped conductor head (13) with an at least partially stripped conductor head (13) of a planned conductor end (10) the radially inner layer (8b) lying in the radial direction (12) being electrically connected, characterized in that: at least the conductor heads (13) of the radially outer layer (8a) are bent in the radial direction (12) to the main axis of rotation (5), while the corresponding conductor heads (13) of the radially adjacent inner layer (8b) in the radial direction (12) are bent away from the main rotation axis (5).
[2]
2. stator component (1) according to claim 1, characterized in that the electrical conductor elements (7) each one of the Statorpaketbasisseite (4) outstanding conductor end (10) each having an at least partially stripped conductor head (13) and from the Statorpaketbasisseite ( 4) outstanding conductor ends (10) opposite the Umfangsbiegerichtung (14) of the Statorpaketstirnseite (3) protruding conductor ends (10) the same position (8) are bent but the Radialbiegerichtung (15) of the conductor heads (13) of the Statorpaketbasisseite (4) outstanding conductor ends (10) with the radial bending direction (15) of the conductor heads (13) of the Statorpaketstirnseite (3) protruding conductor ends (10) of the same position (8) matches.
[3]
3. stator component (1) according to claim 1 or 2, characterized in that the length of the conductor heads (13) of the Statorpaketstirnseite (3) projecting conductor ends (10) more than 5% of the length of the Statorpaketstirnseite (3) outstanding Conductor end (10) and / or the length of the conductor heads (13) of the stator core base side (4) protruding conductor ends (10) more than 5% of the length of the stator core (4) protruding conductor ends (10).
[4]
4. stator component (1) according to any one of the preceding claims, characterized in that the length of the Statorpaketstirnseite (3) and / or Statorpaketbasisseite (4) outstanding conductor ends (10) of the ra dial further outward position (8 a), in particular larger, to the length of the corresponding conductor ends (10) of Statorpaketstirnseite (3), respectively the Statorpaketbasisseite (4), which is adjacent in the radial direction further inboard layer (8b).
[5]
5. stator component (1) according to any one of the preceding claims, characterized in that the length of the conductor heads (13) from the stator paketstirn- (3) and / or from the Statorpaketbasisseite (4) protruding conductor ends (10) of the radially further outer layer (8a) different, in particular larger, to the length of the corresponding conductor heads (13) Statorpaketstirnseite (3), respectively the Statorpaketbasisseite (4), outstanding conductor ends (10) in the radial direction adjacent further inner layer (8b) ,
[6]
6. stator component (1) according to any one of the preceding claims, characterized in that in or against the circumferential direction (11) gebo own conductor ends (10) relative to the main axis of rotation (5) of the stator (2) a circumferential bending angle (16) between the 15th ° and 75 °, preferably between 35 ° and 70 °, more preferably between 50 ° and 65 °.
[7]
7. stator component (1) according to any one of the preceding claims, characterized in that in the radial direction (12) to or pointing away from the main axis of rotation (5) curved conductor heads (13) by a Radialbie angle (17) relative to the respective in the circumferential direction (11) bent conductor ends (10) between 15 ° and 85 °, preferably between 35 ° and 70 °, more preferably between 40 ° and 50 °.
[8]
8. stator component (1) according to any one of the preceding claims, characterized in that the conductor heads (13) on the Statorpaketstirn page (3) projecting conductor ends (10) have a conductor head end face (18) which with the conductor head end face (18) of the corresponding conductor head (13) is electrically connected, and / or the conductor heads (13) of the stator packet base side (4) projecting conductor ends (10) have a conductor head base side (19) which is electrically connected to the conductor head base side (19) of the corresponding conductor head (13).
[9]
9. stator component (1) according to any one of the preceding claims, characterized in that an electrical connection cross-section (20) of a conductor head (13) of the radially outer layer (8) with the corresponding conductor head (13) of more than 50%, preferably more than 75%, a conductor head cross-sectional area (21) of at least one of the connected conductor heads (13) is formed.
[10]
10. stator component (1) according to one of claims 8 to 9, characterized in that the conductor heads (13) on the Statorpaketstirnseite (3) forth forth projecting conductor ends (10) and / or the conductor heads (13) of the Statorpa ketbasisseite (4) projecting conductor ends (10) have a stepwise and / or continuous cross-section decrease in the direction of the conductor head end face (18), respectively the conductor head base side (19) relative to the cross section of the conductor element (7) at the outlet opening to the inner groove (6).
[11]
11. stator component (1) according to any one of the preceding claims, characterized in that the electrical connection of the conductor heads (13) of the radially outer layer (8a) with the corresponding conductor heads (13) is designed as a solder joint (24).
[12]
12. stator component (1) according to any one of the preceding claims, characterized in that the electrical connection of the conductor heads (13) of the radially outer layer (8a) with the corresponding conductor heads (13) is designed as a welded connection.
[13]
13. stator component (1) according to claim 12, characterized in that the welded connection is designed as a weld drop (22).
[14]
14. stator component (1) according to claims 8 and 12, characterized in that the conductor head end faces (18) and / or the Leiterkopfbasisseiten (19) of the conductor heads (13) of the radially outer layer (8 a) with the Leiterkopfstirnseiten (18 ), respectively the ladder head base side (19), the corre sponding conductor heads (13) by means of a weld (23, 23a), in particular laser deep-hole weld (23b) are connected.
[15]
15. stator component (1) according to any one of the preceding claims, characterized in that the electrical connection of the conductor heads (13) of the Statorpaketstirnseite (3) projecting conductor ends (10) of the radially outer layer (8a) with the corresponding conductor heads ( 13), and / or that the electrical connection of the conductor heads (13) of the Statorpaketbasisseite (4) protruding conductor ends (10) of the radially outer layer (8a) with the corresponding conductor heads (13), in the direction of the main axis of rotation (5 ) between, in particular centrally between, the radially inner side of the conductor ends (10) of the radially outer layer (8a) and lying in the radial direction outside of the conductor ends (10) of the radially inner layer (8b) is executed ,
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同族专利:
公开号 | 公开日
AT519980B1|2018-12-15|
AT519980A9|2019-05-15|
WO2019040956A1|2019-03-07|
引用文献:
公开号 | 申请日 | 公开日 | 申请人 | 专利标题
US20120025660A1|2010-07-30|2012-02-02|Dhaval Patel|Multiple conductor winding in stator|
FR3020219A1|2014-04-17|2015-10-23|Valeo Equip Electr Moteur|METHOD FOR CONFORMING CHUCKS OF A WINDING OF ELECTRIC MACHINE AND CORRESPONDING STATOR|
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JP4571685B2|2008-12-12|2010-10-27|本田技研工業株式会社|Stator coil of axial gap type rotating electrical machine|
JP5319407B2|2009-06-04|2013-10-16|本田技研工業株式会社|Press-fitting device and method for manufacturing stator of axial gap type rotating electrical machine|
JP5848156B2|2012-02-21|2016-01-27|トヨタ自動車株式会社|Stator manufacturing method and stator manufacturing apparatus|
DE102014218224B4|2014-09-11|2017-11-02|Continental Automotive Gmbh|Winding support, electric motor with a winding support|
EP3051669B1|2015-01-27|2018-08-22|Brusa Elektronik AG|Winding for a stator, electric machine, and method for manufacturing the winding for a stator|
JP2016214010A|2015-05-12|2016-12-15|株式会社小松製作所|Stator and rotary electric machine having them|
DE102015217936A1|2015-09-18|2017-03-23|Continental Automotive Gmbh|Method and one-piece tool assembly for manufacturing a stator for an electric machine|DE102020208130A1|2020-06-30|2021-12-30|Siemens Mobility GmbH|Winding system for an electrical machine|
法律状态:
优先权:
申请号 | 申请日 | 专利标题
ATA50715/2017A|AT519980B1|2017-08-28|2017-08-28|Stator component for an electric machine|ATA50715/2017A| AT519980B1|2017-08-28|2017-08-28|Stator component for an electric machine|
PCT/AT2018/060179| WO2019040956A1|2017-08-28|2018-08-06|Stator component for an electric machine|
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