CN115224848A - 电动车辆牵引马达以及用于制造电动车辆牵引马达的方法 - Google Patents
电动车辆牵引马达以及用于制造电动车辆牵引马达的方法 Download PDFInfo
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Abstract
本发明涉及一种电动车辆牵引马达(10),具有马达壳体(12)、液体冷却的马达定子(30)和与马达定子(30)液体分离的干式运行的内动子马达转子(20),马达定子(30)由具有径向定子槽(37)的定子体(36)和多个定子线圈(31)构成,定子线圈的轴向线束(32)布置在定子槽(37)中并且定子线圈的绕组头(34)在轴向上从定子槽(37)伸出。提供由灌注材料(40')制成的槽灌注体(40),定子线圈的轴向线束(32)通过槽灌注体以对流体密封的方式被灌注在定子槽(37)中,定子线圈的绕组头(34)设计为未经灌注且绕组头分别直接伸入对流体密封的冷却空间(14,14')。本发明还涉及相应制造方法。通过省略单独的间隙管,实现小气隙并降低制造成本。
Description
技术领域
本发明涉及一种电动车辆牵引马达,该电动车辆牵引马达具有液体冷却的马达定子和干式运行的马达转子。本发明还涉及一种相应的制造方法
背景技术
电动车辆牵引马达提供的驱动功率在2位数到小4位数的千瓦数范围内,从而尤其是在其中布置有定子线圈的马达定子中出现呈热量形式的高功率损失,这些热量必须通过液体冷却来排出。特别有效的是将热量直接从定子线圈排出到冷却液中。为了使内动子马达转子保持干燥,马达转子与马达定子是流体分离的。
为了使马达定子与马达转子流体分离,通常安装有所谓的间隙管,其例如从DE102017102141A1中已知。然而,由于间隙管使得马达定子与马达转子之间的所谓的气隙增大,由此降低了电磁效应。
替代性地,整个马达定子或所有定子线圈可以被灌注在不导电的灌注体中,这例如从DE 102018219819 A1中已知。然而,由此显著恶化了定子线圈与冷却液之间的热量流。
发明内容
相比之下,本发明的目的是提供一种具有高效率和有效定子冷却的电动车辆牵引马达以及一种用于制造这种机动车辆牵引马达的方法。
根据本发明,该目的通过本发明的机动车辆牵引马达以及用于制造机动车辆牵引马达的本发明方法来实现。
根据本发明的电动车辆牵引马达提供在2位数至4位数的千瓦范围内的驱动功率。电动车辆牵引马达具有液体冷却的马达定子和干式运行的内动子马达转子,从而马达定子环状地围绕马达转子。马达转子与马达定子是流体分离的并且与其相屏蔽。马达定子具有带径向定子槽的定子体和多个定子线圈,定子线圈的轴向线束分别布置在定子槽中并且定子线圈的绕组头在轴向上从定子槽伸出。优选地,定子体由多个堆叠的定子叠片构成。
设置有由不导电的、耐流体且对流体密封(fluiddicht)的灌注材料制成的槽灌注体,定子线圈的轴向线束通过该槽灌注体以对流体密封的方式被灌注在定子槽中。相反,定子线圈的绕组头被设计成基本上未经灌注的并且绕组头分别在轴向上直接伸入到填有冷却液的冷却空间中,该冷却空间由马达壳体形成。因此,定子线圈的绕组头在运行中直接被冷却液冷却,而定子线圈的轴向线束则不被冷却液直接冷却。冷却液可以是水或者油。
槽灌注体在马达转子干燥空间与引导液体的冷却空间之间制造流体隔离。不需要单独的间隙管来将液体冷却的马达定子与干式运行的马达转子进行流体分离,因而可以完全省略该间隙管。由此在马达定子与马达转子之间的环绕柱形气隙可以保持得尽可能小,从而实现了高电磁效应或者说高电磁效率。此外,槽灌注体将定子线圈的轴向线束或其各个线圈导线相对彼此机械稳定和固定,从而由此也可靠地避免了因作用到线圈导线上的电磁力而引起的绝缘擦伤或线圈导线损坏的危险。
马达定子和马达转子布置在马达壳体中,该马达壳体也限定其中布置有定子线圈的绕组头的冷却空间。槽灌注体由适当的电绝缘和耐流体的灌注材料(例如环氧树脂)制成,必要时填充适当的填充物以改进导热性。
虽然定子线圈的轴向线束由于以对流体密封的方式环绕定子线圈的轴向线束的槽灌注体而不能被冷却液直接冷却,但定子线圈中产生的热量的大部分都积聚在直接被液体冷却的绕组头中。此外,线圈导线通常由具有优秀导热性能的材料(例如铜)制成,从而来自轴向线束的热量可以沿轴向充分流入到绕组头中,在绕组头上热量大面积地从线圈导线直接排放到冷却液中。
不产生用于形状精确和机械高度稳定的间隙管的成本,从而由此显著降低了牵引马达的制造成本。
优选地,由定子体形成的定子槽在径向内侧朝着马达转子敞开,从而在由定子体形成的极靴之间不设置材料桥。这些纵长缝隙状的槽开口通过槽灌注体被流体封闭。
优选地,槽灌注体从定子槽起径向向内并不明显地从定子体伸出,从而马达定子的柱形内周面基本上由定子体本身形成。马达定子的柱形内周面限界在马达定子与马达转子之间的环绕柱形气隙。由此可以使得在马达转子与马达定子之间的环绕柱形气隙的径向宽度保持得非常小,这又能够实现高的电磁效率。
替代性地,内周面仅由槽灌注体形成,从而齿头完全被灌注。
优选地,槽灌注体在轴向上以一定的突出部从定子槽中伸出并伸入到对流体密封的冷却空间中。由此,槽灌注体的布置在定子槽内部的所有部分一体地相互连接,由此在整体上改进了槽灌注体的机械稳定性。槽灌注体的轴向突出部还改进了定子线圈相对于定子体的电绝缘,以避免漏电流。
优选地,定子体具有多个轴向冷却通道,冷却液可以通过这些轴向冷却通道从马达定子的一个轴向端部流向马达定子的另一个轴向端部。以这种方式,可以在这两个端侧冷却空间之间实现轴向冷却流,从而使这两个端侧冷却空间在流体上相互连接,例如串联。
优选地,定子体具有多个注射通道,这些注射通道分别将定子槽与定子体的径向外侧流体连接。优选地,注射通道布置在定子体的轴向中心,并且特别优选地填充有灌注材料。注射通道对于槽灌注体的制造特别重要。
一种用于制造电动车辆牵引马达的方法,该电动车辆牵引马达具有实施方式中的特征,该方法具有以下步骤:
首先,制造原始马达定子(Roh-Motorstator),该原始马达定子由定子体和定子线圈构成。定子体在其内周侧上在极靴之间不具有材料桥,从而定子槽可以从径向内部被流体触及。
从径向内部和/或从径向外部将液态灌注材料注入定子槽中,以形成槽灌注体,从而以这种方式使槽灌注体朝向轴向端部的方向发展。注射例如可以大约在轴向中心进行,从而可流动的灌注材料在定子槽中从轴向中心流向定子槽的轴向端部。灌注过程或注入可以被控制成使得液态灌注材料大约同时到达这两个轴向端部。
在灌注材料硬化后,去除灌注工具并且将马达转子置入到马达定子中。在置入之前或之后,将马达定子和(如可能)已经安装好的马达转子装入到马达壳体中。以这种方式,使用简单的手段提供了以下制造方法,利用该制造方法可以以廉价的方式实现干式运行的马达转子与液体冷却的马达定子的流体隔离。
优选地,在注入灌注材料之前,将具有径向注射通道的工具芯置入到原始马达定子中,即置入到为马达转子而设的柱形空腔中。工具芯具有径向注射通道,液态灌注材料通过这些注射通道径向地直接注入到定子槽中。在将灌注材料注入定子槽中之后,再去除工具芯,从而随后可以将马达转子置入到马达定子中。以这种方式,实现了简单的制造方法。
附图说明
下面参照附图更详细地阐述根据本发明的电动车辆牵引马达的实施例以及用于其制造的制造方法。在附图中:
图1示出根据本发明的电动车辆牵引马达的示意性的纵截面,该电动车辆牵引马达具有液体冷却的马达定子和干式运行的马达转子,
图1a示出马达定子和马达壳体的对流体密封连接的细节Ia的放大图,
图2示出图1的牵引马达的示意性的横截面II-II,以及
图3a至图3c示出用于制造图1、图1a和图2的机动车辆牵引马达的方法的三个方法步骤。
具体实施方式
图1和图2示意性地示出了电动车辆牵引马达10,该电动车辆牵引马达具有马达壳体12、液体冷却的马达定子30、以及与马达定子30流体分离的干式运行的内动子马达转子20。马达转子20基本上由转子轴22和抗旋转地安装在转子轴22上的永磁转子体24构成。转子轴22围绕马达轴线11旋转,马达轴线是牵引马达10的中心纵轴线。马达定子30基本上由定子体36和多个定子线圈31构成,该定子体由多个相同的定子叠片36'构成。
每个定子线圈31分别由彼此相邻的两个轴向线束32和分别将这两个轴向线束32在端侧彼此连接的绕组头34构成。定子体36具有多个定子槽37,定子线圈31的轴向线束32被布置在定子槽中。每个轴向线束32分别由多条相对彼此大约沿纵向方向延伸的并相互平行的线圈导线组成,在这些线圈导线之间分别存在小的间隙。所有线圈导线分别具有由绝缘漆形成的电绝缘层。
每个定子槽37基本上由在纵向方向上形成恒定的横截面轮廓的槽壁42、43所限界,其中每个定子槽37在径向内部分别经由纵长缝隙状的槽开口66朝向马达转子20敞开。槽开口66分别将定子体36的极靴彼此分开。
马达定子30具有由灌注材料40'制成的槽灌注体40,该灌注材料在此是环氧树脂。轴向线束32或形成轴向线束的线圈导线以对流体密封的方式被灌注在槽灌注体40中,从而槽灌注体40或灌注材料40'不仅填充了在相应的轴向线束32与相应的槽壁42、43之间的间隙,也填充了线圈导线彼此之间的间隙。槽开口66分别也用灌注体40的灌注材料40'来填充,并以这种方式在流体方面被封闭。
一方面定子体36的柱形内周面38和另一方面转子体24的柱形外周面25限定了在它们之间的柱形的环形气隙50,该柱形的环形气隙将马达定子30与马达转子20相互分开,或者说马达定子30和马达转子20以该气隙在径向上彼此间隔开。
定子体36具有多个轴向冷却通道60,两个环形的冷却空间14、14'通过这些轴向冷却通道相互流体连接。此外,定子体36具有多个径向的注射通道62,其中每个注射通道62分别将定子槽37与定子体36的径向外侧相连接。注射通道62布置在定子体36的轴向中心,并用灌注材料40'完全填充。
定子线圈31的绕组头34被设计成未经灌注的,并且绕组头分别轴向地伸入到对流体密封的环形冷却空间14、14'中。槽灌注体40在轴向上以轴向突出部70分别从定子槽37中伸出并且伸入到相应的冷却空间14、14'中。轴向突出部70至少为几毫米。
马达壳体12具有基本上柱形的内冷却空间壁13,在其柱形的外周面13'上构造有环形缝隙状的密封槽17,在该密封槽中置入密封环16,马达定子30的内周面38以对流体密封的方式在径向上从外部贴靠在该密封环上。
图3a至3c中示出了用于制造电动车辆牵引马达10的方法的三个阶段。首先,制造原始马达定子30',该原始马达定子由定子体36和置入定子体中的定子线圈31构成,如图3a所示。随后,具有中心轴向的供应通道102和多个从该供应通道径向出发的注射通道103的完全柱形工具芯100被置入到原始马达定子30'的柱形空腔中,如图3B所示。每个注射通道103与一个定子槽37对准,从而注射通道103的数量与定子槽37的数量相对应。柱形工具芯100的外直径只比定子体36的柱形内周壁38的内直径略小。
随后,液态灌注材料40'从径向内部通过径向注射通道103并从径向外部通过工具注射通道63和与之径向齐平的定子体注射通道62注入到定子槽37的轴向中心中,从而液态灌注材料40'在定子槽37中从轴向中心出发在向着两个冷却空间14、14'的两个轴向方向上扩散。以这种方式,定子槽37内部的所有空腔都填充有由液态灌注材料40'制成的灌注体40”。一旦灌注材料40'在两个冷却空间14、14'中形成了足够的突出部70,就停止灌注过程。
最后将包括工具芯100在内的所有灌注工具去除,从而在槽灌注体40硬化后,马达定子30就被制成了。最后将马达定子30装入到马达壳体12中,并且将马达转子20装入到马达定子30中。
Claims (10)
1.一种电动车辆牵引马达(10),具有马达壳体(12)、液体冷却的马达定子(30)和与所述马达定子(30)流体分离的、干式运行的内动子马达转子(20),其中所述马达定子(30)由具有定子槽(37)的定子体(36)和多个定子线圈(31)构成,所述定子线圈的轴向线束(32)布置在所述定子槽(37)中并且所述定子线圈的绕组头(34)在轴向上从所述定子槽(37)伸出,
其特征在于
所述电动车辆牵引马达(10)包括由灌注材料(40')制成的槽灌注体(40),所述定子线圈的轴向线束(32)通过所述槽灌注体以对流体密封的方式被灌注在所述定子槽(37)中,其中所述定子线圈的绕组头(34)被设计为未经灌注,并且所述定子线圈的绕组头分别直接伸入到对流体密封的冷却空间(14,14')中。
2.根据权利要求1所述的电动车辆牵引马达(10),其中所述定子槽(37)在径向内部朝向所述马达转子(20)敞开。
3.根据前述权利要求中任一项所述的电动车辆牵引马达(10),其中所述马达定子(30)的将所述马达定子(30)与所述马达转子(20)之间的柱形气隙(50)限界出的柱形内周面(38)基本上由所述定子体(36)形成。
4.根据权利要求1或2所述的电动车辆牵引马达(10),其中所述马达定子(30)的将所述马达定子(30)与所述马达转子(20)之间的柱形气隙(50)限界出的柱形内周面(38)仅由所述槽灌注体形成。
5.根据前述权利要求中任一项所述的电动车辆牵引马达(10),其中所述槽灌注体(40)在轴向上以突出部(70)从所述定子槽(37)伸出。
6.根据前述权利要求中任一项所述的电动车辆牵引马达(10),其中所述定子线圈绕组头(34)在所述冷却空间(14,14')中被液体冷却。
7.根据前述权利要求中任一项所述的电动车辆牵引马达(10),其中所述定子体(36)具有多个轴向冷却通道(60)。
8.根据前述权利要求中任一项所述的电动车辆牵引马达(10),其中所述定子体(36)具有多个注射通道(62),所述注射通道分别将定子槽(37)与所述定子体(36)的外侧相连,其中所述注射通道(62)优选地布置在所述定子体(36)的轴向中心,并且其中所述注射通道(62)特别优选地填充有所述灌注材料(40')。
9.一种用于制造电动车辆牵引马达(10)的方法,所述电动车辆牵引马达具有前述权利要求中任一项的特征,所述方法具有以下方法步骤:
制造由定子体(36)和定子线圈(31)构成的原始马达定子(30'),
将液态灌注材料(40”)从径向内部和/或从径向外部注入定子槽(37)中,以形成槽灌注体(40),
将马达转子(20)置入到马达定子(30)中,以及
将马达转子(20)和马达定子(30)装入马达壳体(12)中。
10.根据权利要求9所述的方法,其中在注入之前,将具有径向注射通道(103)的工具芯(100)置入到原始马达定子(30')中,通过所述径向注射通道将液态的灌注材料(40')径向地注入到所述定子槽(37)中。
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