EP3857680A1 - Insulating unit for an electrical machine - Google Patents
Insulating unit for an electrical machineInfo
- Publication number
- EP3857680A1 EP3857680A1 EP19779819.2A EP19779819A EP3857680A1 EP 3857680 A1 EP3857680 A1 EP 3857680A1 EP 19779819 A EP19779819 A EP 19779819A EP 3857680 A1 EP3857680 A1 EP 3857680A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- hairpin
- unit
- openings
- winding
- electrical machine
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/28—Layout of windings or of connections between windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
- H02K11/25—Devices for sensing temperature, or actuated thereby
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/38—Windings characterised by the shape, form or construction of the insulation around winding heads, equalising connectors, or connections thereto
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/09—Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
Definitions
- the present invention relates to an insulating unit for an electrical machine with a winding of a plurality of shaped bars which pass through at least two grooves spaced in the circumferential direction and have contact points on one side of the electrical machine, which are connected to one another to form the winding.
- Such windings are also referred to as hairpin windings or wave windings, only the term hairpin or hairpin windings being used in the following, which also includes shaft windings and the like in the sense of the application.
- the object of the present invention is to provide an insulation of the hair pin ends which is simple and quick to produce and which represents a reliable insulation of the hair pin ends.
- an insulation unit for an electrical machine with a hairpin winding having a plurality of connection pins for the electrical connection with a circuit and a plurality of welded Hairpin ends, which have contact pairs
- the insulating unit having a base body, which has an insulating material and extends at least over part of the circumference of the hairpin winding, characterized in that the base body extends in the axial direction, through openings and that each opening is associated with a hairpin end or a connection pin.
- a hairpin winding is formed from several hairpins or shaped rods which have contact points at their ends on the winding head. At the contact points in pairs are electrically connected to each other in order to produce the coils of the hairpin winding from the hairpins.
- the contact points connected in pairs are referred to as hairpin ends and the respective individual contact points at the start and end of the respective coils are referred to as connection pins.
- the connection pins are connected in an electrically conductive manner in order to connect them to the power electronics for controlling the electrical machine.
- the insulation unit here has a base body which comprises an electrically insulating material.
- Plastic is preferably used as the material, execution forms with other electrically insulating materials, such as rubber or other elastic materials or ceramic materials, are also possible.
- the base body can be made in one piece or in multiple parts and extends at least over part of the circumference. Due to the design, the distances between the connection pins and the hairpin ends may be smaller, in particular in the area of the connection pins, or the distance from the hairpin ends to other electrically conductive components may be small at other points on the circumference, which is why insulation is necessary especially in these areas.
- inventions are therefore possible in which it is sufficient that only a part of the circumference of the hairpin winding is covered by the insulating unit.
- preferred embodiments have a base body that covers the entire circumference of the hairpin winding or the hairpin ends.
- the base body viewed in the axial direction of the electrical machine, has openings which extend over the thickness of the base body and are thus continuous. Due to the through openings, the air can escape when the hairpin ends are encapsulated, as a result of which air pockets and the like can be reliably avoided.
- each opening is assigned a hairpin end or a pair of contacts made of interconnected conductor elements or a connecting pin.
- Embodiments of an insulation unit are characterized in that the base body has projections on its side facing away from the hairpin winding, which serve as spacers for a circuit arrangement.
- projections are provided on the base body, by means of which a minimum distance between the end face of the base body with the openings and a neighboring component is ensured. This ensures that, even in the case of potting, for example after the circuit has been attached and connected, the openings continue to be continuous and potting compound can enter at the openings or air can escape.
- Preferred embodiments of an insulating unit are characterized in that the projections are arranged evenly distributed over the circumference. The minimum distance over the entire circumference is ensured by an even distribution and symmetries can be used.
- Isolation unit are characterized in that the projections are not arranged directly adjacent to an opening for a connecting pin. With a connection connected to a connection pin, a directly adjacent projection can lead to an undesirable shortening of the creepage distance for the insulation. Therefore, there is preferably none of the material of the base body directly surrounding an opening for a connecting pin Projection provided, but the projections are arranged between the opening for hairpin ends.
- an insulating unit is characterized in that the projections are T-shaped. Due to the T-shape, reliable support can be ensured even with relatively few protrusions, and tilting can be avoided even with a system on a single protrusion. Furthermore, T-shaped projections can be arranged well between the openings.
- Embodiments of an insulation unit are characterized in that at least one opening has a widening for receiving a temperature sensor.
- a temperature sensor To monitor the temperature of the hairpin winding during operation, who uses the temperature sensors.
- a temperature sensor In order to enable the most accurate measurement possible, a temperature sensor must be attached as close as possible, preferably touching, to a conductor element of the winding.
- an expansion is provided in at least one continuous opening, as a result of which the clear width of the opening is increased in order to be able to record a temperature sensor in addition to the hairpin end or the connecting pin.
- the temperature sensor is held securely and positioned for hairpin winding. Furthermore, the temperature sensor can be secured by the sealing compound at the same time as the hairpin end.
- Embodiments of an insulation unit are preferably characterized in that the widening tapers along the axial extent of the opening in order to ensure that the temperature sensor bears against the hairpin winding. Due to the resulting wedge effect, the temperature sensor can be better positioned and an insertion that is too deep is avoided until the temperature sensor on the opposite side passes through.
- Embodiments of an insulation unit are characterized in that the base body is constructed in several parts.
- the base body can be designed as a one-piece ring body.
- fertilization of the body from several sub-elements may be advantageous.
- these sub-elements on their mutually facing contact surfaces connec tion means such as tongue and groove connections or other plug and / or Rastverbin connections, whereby the base body can be easily assembled into a structural unit.
- Insulating units according to embodiments are characterized in that a cover plate is provided on the projections, or that the hairpin winding is closed from the ends of the openings facing away from it, or have a reduced clear width which is less than the cross section of a contact pair.
- a cover plate is provided on the projections, or that the hairpin winding is closed from the ends of the openings facing away from it, or have a reduced clear width which is less than the cross section of a contact pair.
- Another aspect of the invention is an electrical machine with a hairpin winding, which is characterized in that an insulation unit according to one of the described embodiments is provided.
- the electrical machine thus has the properties described for the insulation unit, and good insulation of the hairpin ends and secure attachment of the insulation unit to the hairpin winding are ensured.
- an electrical machine is characterized in that the openings are filled with a casting compound.
- the thermal conductivity of the casting compound may be increased by appropriate admixture to the casting compound, whereby the cooling of the hairpin winding can be improved.
- the invention is also a method for producing an electrical machine with an insulation unit according to the invention comprising providing the hairpin winding, positioning the insulation unit on the hairpin winding, the hairpin ends being positioned in the openings of the insulation unit, bringing one Potting compound into the openings from an axial direction, whereby the air escapes from the opposite end of the opening in the axial direction.
- the winding is first provided, in particular the winding of the stator of an electrical machine, and a structure according to the invention can also be used for a rotor or rotor and stator of an electrical machine .
- the insulation unit is positioned on the winding head of the hairpin winding in order to align the hairpin ends and the connection pins to the openings and the interconnection. Through the openings that are common, it is ensured that when the potting compound is introduced from one axial end of the openings, the air can escape from the opposite end of the opening and thus no air pockets occur. A uniform insulation of the hairpin ends is achieved.
- Embodiments of the method are characterized in that a circuit is placed on the insulating unit and the connection pins are connected to the circuit in an electrically conductive manner. Through the connection, the coils of the hairpin winding can be supplied with current in order to operate the electrical machine.
- Preferred embodiments of a method are characterized in that the potting compound is introduced after the connection has been put in place.
- this can advantageously be potted together with the insulating unit. This has the advantage that an additional connection between the circuitry and the insulation unit takes place through a joint encapsulation and at the same time an insulation of the circuitry is generated.
- the interconnection is preferably placed on projections which are provided on the isolating unit, as a result of which the interconnection is spaced apart from the isolating unit. This spacing prevents contact between the circuit and the contact pairs. Furthermore, the through openings remain accessible from both axial ends over the distance, which is why the casting compound can be brought in and the air can escape.
- FIG 1 illustrates an embodiment of an isolation unit.
- Fig. 2 shows a section through an embodiment in the installed state.
- Fig. 3 shows an enlarged detail view of an embodiment of an Isolierein unit.
- Fig. 4 shows an enlarged detail view of an embodiment of an Isolierein unit.
- Fig. 1 shows an embodiment of an insulating unit (1) in a perspective view.
- the insulating unit (1) comprises a base body (2) which has a multiplicity of openings (3).
- the through-holes in the axial direction (3) are arranged in several of the layers of the winding of the electrical machine corresponding con centric diameter next to each other to receive a hairpin end (7) not shown in FIG. 1.
- the embodiment shown is in the form of a circular ring which extends through 360 °.
- designs as a full-surface disk are also possible, for example for rotor windings or if a simultaneous covering of the inner region is to be provided.
- the openings (3) shown have for the most part a round cross section, but can also have rectangular or other polygonal cross sections. However, the cross-sectional area must be larger than the cross-section of a pair of interconnected hairpin ends (7). Only at the openings (3) for the passage of the connecting pins (6) can the cross section be made smaller, which must still be larger than the cross section of the connecting pins (6).
- the openings (3) for the connection pins (6) are designed as rectangular openings (3) on the inner circumference.
- the connection pins (6) can also be arranged on the outer circumference or on both circumferential surfaces and / or in the center.
- the example shown in FIG. 1 has on its upper side facing away from the winding a plurality of projections (4) distributed over the circumference.
- the projections (4) are T-shaped and are provided between the openings (3), for example to support an interconnection (8) following in the axial direction at a distance from the base body (2) and thus to form a gap between the components. So that especially for the connection pins (6) air gaps or space for insulating potting compound are preserved and creepage distances are avoided, the projections (4) are each in the circumferential direction between the openings for the connection pins (6) and in the opposite Randbe rich, here arranged in the outer peripheral region.
- the outer peripheral surface of the base body (2) is provided in the example shown with optional elevations and grooves which, in addition to saving weight, also as positioning aids during assembly and / or as an anti-rotation device in the installed state, with corresponding counterparts on a housing (9 ), can be used.
- FIG. 2 an upper portion of a stator with a winding head is shown in section.
- the winding head here is that of a hairpin winding, in which a large number of shaped bars are arranged in pairs with their contact points and are connected to one another in an electrically conductive manner, as a result of which the hairpin ends (7) form.
- the connections at the hairpin ends (7) result in the coils of the hairpin winding, which each have individual connection pins (6) on the coil ends, from the shaped rods.
- the hairpin ends (7) are in the continuous Conventional openings (3) of the base body (2), the hairpin ends (7) ending within the openings (3) and thus not projecting over the base body (2).
- the, also in openings (3) NEN connection pins (6) over the base body (2).
- connection pins (6) are connected to a connection (8) placed on the insulation unit (1), with which the various connection pins (6) are connected with each other and with power electronics.
- the circuit (8) is formed from a plurality of ring conductors (12) which are arranged adjacent to one another in the axial direction and are insulated from one another and which have contact points (13) projecting in the direction of the connection pins (6).
- the contact points (13) are electrically conductively connected to the connection pins (6), preferably welded ver.
- the circuit (8) rests on the axial projections (4) of the base body (2) of the insulating unit (1).
- the projections (4) ensure that a free gap remains between the circuit (8) and the base body (2), through which air can escape from the openings (3) or a casting compound into the openings when a potting compound, not shown, is brought in (3) can flow. This ensures that there are no air pockets in the casting compound that can reduce the insulating effect.
- the circuit (8) in the example shown also includes optional support arms (14) which are supported on the housing (9) of the electrical machine in order to improve the positioning of the circuit (8).
- the circuit (8) can also be designed differently, for example with coaxial conductor sleeves.
- Fig. 3 shows a portion of an insulating unit (1) according to an exemplary embodiment.
- the openings (3) and partially a projection (4) can be seen on the top.
- Round and rectangular openings (3) for receiving hairpin ends (7) are shown.
- the openings (3) for the passage of the connection pins (6) have a widening (10) on their upper side. These openings (3) thus have a larger cross-section on the upper side, which decreases along the axial course of the opening (3).
- the widening (10) enables a temperature sensor (1 1) to be accommodated in the opening (3) next to the connection pin (6). Due to the tapering cross-section, the temperature sensor (11) is prevented from being pushed through the opening (3) and is thus positioned. Due to a continuously tapering cross section, the tip of the temperature sensor (11) at the connection pin (6) is approximated in order to achieve the most precise measurements possible.
- the widening (10) can also extend over the entire axial length of the opening (3) or instead of a continuous change in the cross section.
- the insulation unit (1) can also only extend over a peripheral region of the hairpin winding in which the connection pins (6) are located.
- simple insulation of the hairpin ends (7) without an insulation unit (1) may be sufficient in this area, since these may be sufficiently spaced from one another in the further course of the circumference.
- the further circumference could, for example, be insulated with at least one further insulation unit.
- Fig. 4 shows a portion of another embodiment, wherein the base body (2) is narrower in the radial direction.
- an insulation unit (1) can only be used for the two layers, in the example shown, in which connection pins (6) are arranged.
- This also enables a modular structure, in which an insulation unit (1) consists of a plurality of ring-shaped or ring-shaped segment-like insulation units with different diameters is put together.
- grooves or corresponding elevations are preferably provided on the peripheral surfaces in order to enable a form-fitting interlocking.
- the individual segments can be joined together using separate connecting means, such as screws, clips or adhesive, and the casting compound introduced in the further process can also serve as a connecting means.
- connection pins (6) also shows openings (3) for connection pins (6) with an expansion (10) according to FIG. 3, a temperature sensor (11) being arranged on a connection pin (6).
- a temperature sensor (11) being arranged on a connection pin (6).
- any number of temperature sensors (1 1) can be provided on the hairpin winding.
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing & Machinery (AREA)
- Insulation, Fastening Of Motor, Generator Windings (AREA)
Abstract
Description
Claims
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102018216462 | 2018-09-26 | ||
DE102019207665.3A DE102019207665A1 (en) | 2018-09-26 | 2019-05-24 | Isolation unit for an electrical machine |
PCT/EP2019/075923 WO2020064869A1 (en) | 2018-09-26 | 2019-09-25 | Insulating unit for an electrical machine |
Publications (1)
Publication Number | Publication Date |
---|---|
EP3857680A1 true EP3857680A1 (en) | 2021-08-04 |
Family
ID=69725577
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19779819.2A Withdrawn EP3857680A1 (en) | 2018-09-26 | 2019-09-25 | Insulating unit for an electrical machine |
Country Status (6)
Country | Link |
---|---|
US (1) | US20210344245A1 (en) |
EP (1) | EP3857680A1 (en) |
KR (1) | KR20210065089A (en) |
CN (1) | CN112753154A (en) |
DE (2) | DE102019207665A1 (en) |
WO (2) | WO2020064869A1 (en) |
Families Citing this family (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102020206770A1 (en) * | 2020-05-29 | 2021-12-02 | Zf Friedrichshafen Ag | Arrangement for measuring the temperature of an electrical machine |
DE102020118224A1 (en) * | 2020-06-30 | 2021-12-30 | Schaeffler Technologies AG & Co. KG | stator |
DE102020117464A1 (en) * | 2020-07-02 | 2022-01-05 | Dr. Ing. H.C. F. Porsche Aktiengesellschaft | Stator for an electrical machine, electrical machine, motor vehicle, method for producing a stator |
DE102021115395B3 (en) | 2021-06-15 | 2022-07-21 | Dr. Ing. H.C. F. Porsche Aktiengesellschaft | Method for end winding insulation of an electric traction motor stator |
DE102021208183A1 (en) | 2021-07-29 | 2023-02-02 | Valeo Eautomotive Germany Gmbh | Stator for an electrical machine, method for producing a stator for an electrical machine for a vehicle and method for operating an electrical machine |
DE102022104442A1 (en) | 2022-02-24 | 2023-08-24 | Schaeffler Technologies AG & Co. KG | Insulation ring, stator and method of manufacturing a stator |
DE102022117046A1 (en) | 2022-07-08 | 2024-01-11 | Schaeffler Technologies AG & Co. KG | Method for producing a stator and casting tool for producing a stator |
DE102023200667A1 (en) | 2023-01-27 | 2024-08-01 | Zf Friedrichshafen Ag | Stator with hairpin leads |
DE102023201223A1 (en) | 2023-02-14 | 2024-08-14 | Zf Friedrichshafen Ag | Circuit arrangement with a positioning device, use of the positioning device and method for assembling the circuit arrangement |
Family Cites Families (19)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP3921859B2 (en) | 1999-01-18 | 2007-05-30 | 株式会社デンソー | Insulating structure of joint, insulating structure of rotating electrical machine, and manufacturing method thereof |
JP3933840B2 (en) * | 2000-03-16 | 2007-06-20 | 三菱電機株式会社 | Vehicle alternator stator and method of manufacturing the same |
US20030214190A1 (en) * | 2002-05-15 | 2003-11-20 | Delco Remy America | Connection device for hairpin wound electric machines |
DE112012001929T5 (en) * | 2011-04-29 | 2014-04-17 | Remy Technologies, Llc | Insulating system and method for electric machine module |
DE102011078026A1 (en) * | 2011-06-23 | 2012-12-27 | Siemens Aktiengesellschaft | Circuit carrier for the wiring of the tooth coil windings of a stator of an electrical machine and kit, comprising such a circuit carrier |
US9467010B2 (en) * | 2011-11-17 | 2016-10-11 | Remy Technologies, L.L.C. | Method of winding a stator core with a continuous conductor having a rectangular cross-section and a stator core |
FR2995739A1 (en) * | 2012-09-17 | 2014-03-21 | Valeo Equip Electr Moteur | SPOOL INSULATION FOR RECEIVING TEMPERATURE SENSOR, INTERCONNECTOR FOR STATOR, AND SUPPORT FOR CORRESPONDING TEMPERATURE SENSOR |
JP5971125B2 (en) * | 2013-01-09 | 2016-08-17 | 株式会社デンソー | Stator and rotating electric machine having the same |
JP5693686B2 (en) | 2013-09-09 | 2015-04-01 | 三菱電機株式会社 | Rotating electric machine |
JP6052244B2 (en) * | 2014-06-30 | 2016-12-27 | 日本精工株式会社 | Motor, electric power steering apparatus equipped with the motor, and vehicle |
EP3038236B1 (en) * | 2014-12-22 | 2017-10-11 | Magneti Marelli S.p.A. | Electric machine and related assembly method |
DE102015200095A1 (en) * | 2015-01-07 | 2016-07-07 | Robert Bosch Gmbh | Stator for an electric machine and method of manufacturing such |
ITBO20150188A1 (en) * | 2015-04-16 | 2016-10-16 | Magneti Marelli Spa | ELECTRIC MACHINE WITH A STATORIC WINDING WITH RIGID BARS |
EP3255759A1 (en) * | 2016-06-10 | 2017-12-13 | Goodrich Control Systems | Stator assembly |
CN107786022B (en) * | 2016-08-30 | 2023-08-25 | 北京佩特来电器有限公司 | Square wire stator and cross wire insulating support thereof |
DE102016225503A1 (en) * | 2016-12-19 | 2018-06-21 | Bayerische Motoren Werke Aktiengesellschaft | Stator for a rotary electric machine |
US11205936B2 (en) * | 2017-03-31 | 2021-12-21 | Nidec Corporation | Bus bar unit and motor including the same |
JP6787245B2 (en) * | 2017-04-28 | 2020-11-18 | 株式会社デンソー | Rotating machine |
CN107276327B (en) * | 2017-06-30 | 2019-06-04 | 广东美芝精密制造有限公司 | The preparation method and its stator, motor and compressor of distribution volume motor stator |
-
2019
- 2019-05-24 DE DE102019207665.3A patent/DE102019207665A1/en not_active Withdrawn
- 2019-05-24 DE DE102019207666.1A patent/DE102019207666A1/en active Pending
- 2019-09-25 KR KR1020217004761A patent/KR20210065089A/en unknown
- 2019-09-25 EP EP19779819.2A patent/EP3857680A1/en not_active Withdrawn
- 2019-09-25 CN CN201980062608.8A patent/CN112753154A/en active Pending
- 2019-09-25 WO PCT/EP2019/075923 patent/WO2020064869A1/en unknown
- 2019-09-25 US US17/280,285 patent/US20210344245A1/en not_active Abandoned
-
2020
- 2020-05-19 WO PCT/EP2020/063982 patent/WO2020239545A1/en active Application Filing
Also Published As
Publication number | Publication date |
---|---|
DE102019207665A1 (en) | 2020-03-26 |
DE102019207666A1 (en) | 2020-03-26 |
US20210344245A1 (en) | 2021-11-04 |
WO2020064869A1 (en) | 2020-04-02 |
CN112753154A (en) | 2021-05-04 |
KR20210065089A (en) | 2021-06-03 |
WO2020239545A1 (en) | 2020-12-03 |
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