WO2022128426A1 - Anschlusseinheit für einen stator, stator für eine elektrische maschine, statoranordnung, verfahren zur herstellung einer statoranordnung und elektrische maschine zum antreiben eines fahrzeugs - Google Patents
Anschlusseinheit für einen stator, stator für eine elektrische maschine, statoranordnung, verfahren zur herstellung einer statoranordnung und elektrische maschine zum antreiben eines fahrzeugs Download PDFInfo
- Publication number
- WO2022128426A1 WO2022128426A1 PCT/EP2021/083344 EP2021083344W WO2022128426A1 WO 2022128426 A1 WO2022128426 A1 WO 2022128426A1 EP 2021083344 W EP2021083344 W EP 2021083344W WO 2022128426 A1 WO2022128426 A1 WO 2022128426A1
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- WO
- WIPO (PCT)
- Prior art keywords
- sections
- connection unit
- stator
- connection
- contact
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 8
- 239000004020 conductor Substances 0.000 claims abstract description 94
- 238000004804 winding Methods 0.000 claims abstract description 25
- 238000000034 method Methods 0.000 claims description 13
- 230000001419 dependent effect Effects 0.000 claims 1
- 238000003466 welding Methods 0.000 description 5
- 230000004308 accommodation Effects 0.000 description 4
- 238000005304 joining Methods 0.000 description 4
- 230000007935 neutral effect Effects 0.000 description 4
- 230000007704 transition Effects 0.000 description 3
- 230000001154 acute effect Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 230000001360 synchronised effect Effects 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 239000012777 electrically insulating material Substances 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
Classifications
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- 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
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/0056—Manufacturing winding connections
- H02K15/0068—Connecting winding sections; Forming leads; Connecting leads to terminals
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F5/00—Coils
- H01F5/04—Arrangements of electric connections to coils, e.g. leads
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/029—Welded connections
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R9/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
- H01R9/16—Fastening of connecting parts to base or case; Insulating connecting parts from base or case
-
- 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
- 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 a connection unit for a stator with a stator winding having a number N of strands.
- the invention relates to a stator for an electric machine, a stator arrangement, a method for producing a stator arrangement and an electric machine for driving a vehicle.
- Terminal units for a stator with a stator winding having N turns are used to connect terminal sections of the stator winding.
- the connection unit comprises a number of contact sections corresponding to the number of strands and a conductor arrangement.
- the contact sections each have a receiving space which is delimited by two walls and encloses one of the connection sections.
- the conductor arrangement can connect the contact sections in an electrically conductive manner.
- DE 10 2019 122 550 A1 discloses an electrical machine having a stator core and hairpins connected to form windings and form a continuous circuit between a terminal end and a neutral end.
- a neutral link is provided attached to each of the neutral ends and includes an arcuate body having an inside and an outside. The interior defines open grooves, each of the grooves receiving one of the neutral ends therein.
- connection sections are aligned radially in accordance with the essentially cylindrical design of the stator, arranging the connection sections in the receiving spaces is difficult, especially since certain production-related positional tolerances of the connection sections can exist.
- the invention is based on the object of specifying an installation-friendly option for connecting connection sections of a stator.
- connection unit for a stator with a stator winding having N number of phases having: N number of contact sections, each contact section having a first wall and a second wall, a delimited by the first wall and the second wall and for enclosing a receiving space set up by N connection sections of the stator and set up for electrically conductive contacting of the connection section, wherein the first and second walls of the N contact sections are aligned parallel to one another; and a conductor arrangement which either electrically conductively connects the contact sections or comprises N conductor sections which are electrically insulated from one another and are each electrically conductively connected to one of the N contact sections.
- connection unit for a stator with a stator winding having a number N strands has a number N contact sections.
- Each contact section has a first wall and a second wall.
- Each contact section forms an accommodation space.
- the recording space is delimited by the first wall and the second wall.
- the receiving space is also set up to enclose one of N connection sections of the stator.
- Each contact section is set up to make electrically conductive contact with the connection section.
- the first and second walls of the N contact sections are aligned parallel to each other.
- the connection unit also has a conductor arrangement. According to a first alternative, the conductor arrangement connects the contact sections in an electrically conductive manner. According to a second alternative, the conductor arrangement comprises N conductor sections.
- the conductor sections are electrically isolated from one another. Furthermore, the conductor sections are each electrically conductively connected to one of the N contact sections.
- the connection device according to the invention is distinguished in particular by the fact that the walls of the N contact sections are aligned parallel to one another. This makes it possible to bring the connection unit into a position by means of a linear movement, in which the connection sections are arranged in the receiving spaces.
- a stator suitable for this purpose which will be explained in detail later, expediently has connection sections which are aligned in a correspondingly parallel manner.
- connection sections greatly facilitates the arrangement of the connection sections in the contact sections and can be easily automated.
- additional tools that hold the connection sections in a predetermined position in order to attach a conventional connection unit to the connection sections can be dispensed with.
- positional tolerances of the connection sections can be easily compensated for by means of the connection unit when the connection sections are located in the receiving spaces.
- assembly of a stator arrangement or electrical machine having the connection unit and the stator can be considerably simplified.
- Adjacent pairs of the contact sections are preferably arranged equidistantly.
- the contact sections are designed as recesses in the conductor arrangement.
- the recesses are delimited by the first wall and the second wall.
- connection unit extends essentially in one plane.
- the first wall and the second wall extend at least in a direction perpendicular to this plane.
- the contact sections each have a guide that is widened compared to a distance between the first wall and the second wall.
- the guide is preferably formed adjoining the first wall and the second wall of the contact section.
- the guide can have a first wall which adjoins the first wall of the contact section and encloses an angle, in particular an obtuse angle, with it.
- the guide can have a second wall which adjoins the second wall of the contact section and encloses an angle, in particular an obtuse angle, with it.
- the first wall and the second wall of the guide can extend along straight lines which enclose an acute angle, in particular an angle between 40 and 80 degrees.
- connection unit each have a third wall, which connects the first wall and the second wall and delimits the receiving space.
- the third wall can, in particular with regard to the linear movement, form a stop for the connection section to be accommodated in the receiving space.
- the third wall preferably runs perpendicularly to the first wall and to the second wall.
- the contact sections can be arranged next to one another in the plane in which the connection unit extends and the first, the second and the third wall can extend at least in one direction perpendicular to this plane.
- the conductor arrangement of the connection unit is preferably designed as a busbar if the conductor arrangement connects the contact sections in an electrically conductive manner. If the conductor arrangement comprises the conductor sections, a respective conductor section can be designed as a busbar.
- the connection unit according to the invention preferably also comprises an insulating body which is arranged on the conductor arrangement, in particular formed thereon, and has openings exposing the contact sections.
- the insulating body can be formed by a sheath surrounding the conductor arrangement in sections and/or continuously.
- the insulating body is preferably formed by overmolding the conductor arrangement. The insulating body can also fix relative positions of the conductor sections to one another.
- connection unit according to the invention can have a fastening section which is designed to engage with a fastening section of a further connection unit in such a way that the connection unit and the further connection unit can be transferred from a loose position into a fastened position, in which the connection unit and the further connection unit are attached to one another and the conductor arrangement of the connection unit and a conductor arrangement of the further connection unit are electrically insulated from one another. All explanations regarding the connection unit according to the invention can be transferred to the further connection unit.
- connection sections of the connection unit and the further connection unit can be in contact with the connection sections of the stator winding.
- This allows the connection sections to be attached to the connection units, for example by welding, without additional tools that position the connection sections.
- the ease of assembly can be further increased.
- the fastening section can form a latching element which is set up to engage in one another with a latching element of the fastening section of the further connection unit in the fastened position, forming a latching connection.
- the latching connection allows the connection units to be fastened to one another with little effort and without additional tools.
- the snap element may be adapted to be elastically deformed in transition from the loose position to the fastened position. It is possible that the attachment section also forms one or more other corresponding latching elements.
- the fastening section forms a projection or forms a recess, in which case the projection can correspond to a fastening section of the further connection unit designed as a recess or the recess can correspond to a fastening section of the further connection unit designed as a projection.
- the fastening sections can engage in one another in the fastened position, forming a form fit.
- the projection and the recess are preferably of opposite design.
- the fastening section can have one or more further projections and recesses.
- the insulating body of the connection unit according to the invention preferably forms the fastening section.
- the insulating body or the conductor arrangement of the further connection unit forms its fastening section.
- the conductor arrangement of the connection unit according to the invention forms the fastening section.
- the insulating body of the further connection unit forms its fastening section.
- a stator for an electrical machine having a stator core with an axial end face and a stator winding, which has a number N of strands and, in sections, of shaped conductors that extend through the stator core, and of first to N-th connection sections, which adjoin part of the form conductor on the end face, are located at different angular positions in a circumferential direction and extend in the axial direction and are set up either to form a star point or to form connections for the strands , where the terminal sections include a pair of parallel ler has side surfaces, the first to (N-1)-th connection sections being deformed relative to the N-th connection section in such a way that the pairs of parallel side surfaces of the first to N-th connection sections are aligned essentially parallel, in particular parallel, to one another.
- the stator according to the invention for an electrical machine has a stator core.
- the stator core has an axial end face.
- the stator also has a stator winding.
- the stator winding has a number N of strands. Sections of the stator winding are formed from shaped conductors. The form conductors extend through the stator core.
- the stator winding is also formed in sections from first to N-th connection sections.
- the first through the N-th connection sections extend on the end face adjoining part of the shaped conductor.
- the first to N-th terminal portions are located at different angular positions of a circumferential direction and extend in the axial direction.
- the first to N-th connection sections are set up either to form a star point or to form connections for the strands.
- the terminal sections have a pair of parallel side surfaces.
- the first to (N-1)-th connection sections are deformed relative to the N-th connection section in such a way that the pairs of parallel side surfaces of the first to N-th connection sections are aligned essentially parallel, in particular parallel, to one another.
- the stator according to the invention is characterized in particular by the fact that the first to the N-th connection sections are oriented in the same way in such a way that their pairs of parallel sides are aligned essentially parallel to one another. This enables the connection unit according to the invention to be arranged by means of the linear movement, in particular running perpendicularly or parallel to the direction in which the connection sections extend.
- the stator core is preferably formed by a large number of stator laminations that are insulated from one another.
- a plurality of slots arranged along the circumferential direction can be formed, extending from the end face to extend an axially opposite further end face.
- the shaped conductors can be accommodated in the grooves.
- the form conductors are preferably formed by rods made of an electrically conductive metal, in particular copper.
- the shaped conductors are preferably arranged radially in a predetermined even number of layers, in particular four, six, eight, ten or twelve layers, in a respective groove.
- the number of strands typically corresponds to a number of phases of the stator.
- N can be greater than or equal to three, preferably exactly three.
- the stator winding can be designed as a hairpin winding.
- the form conductors of a respective strand can be electrically conductively connected to one another by connectors in such a way that they form a series circuit or a plurality of series circuits.
- Connectors of the first type are preferably formed in one piece with the shaped conductors on the first end face.
- pairs of shaped conductors can be electrically conductively connected by connectors of the second type.
- the connectors of the second type can each have two connecting sections adjoining the shaped conductors of the pair, in particular in one piece.
- the connecting sections can be connected to one another in pairs, in particular in a materially bonded manner, in an electrically conductive manner.
- connection section can comprise a plurality of connection elements, each of which connects to one of the shaped conductors.
- Each connection section preferably has a connection element for each series connection of the strand.
- the stator winding is also partially made up of (N+1)-th to (2N)-th connection sections, which are attached to a part of the shaped conductor at the end face then, extending at different angular positions of a circumferential direction in the axial direction and arranged to form terminals for the strands, wherein the (N+1)th to (2N)-th terminal portion has a pair of parallel side faces, wherein the (N+1 )-th to (2N-1 )-th terminal portions are deformed with respect to the (2N)-th terminal portion such that the pairs of parallel side faces of the (N +1)-th to (2N)-th connection sections are aligned essentially parallel, in particular parallel, to one another.
- a connection unit according to the invention can thus also be connected to the (N+1)th to (2Nth) connection sections.
- the pairs of parallel sides of the first to (2N)-th terminal portions may be aligned parallel to each other. However, it is preferred that the pairs of parallel side surfaces of the first to Nth connection sections on the one hand and the pairs of parallel side surfaces of the (N+1)th to (2N)th connection sections on the other hand are oriented differently, in particular enclose an angle greater than zero .
- connection sections are deformed by torsion about an axis parallel to a longitudinal axis of the stator.
- the first to (N ⁇ 1)th connection sections and/or the (N+1)th to (2N ⁇ 1)th connection sections can have a torsion section which forms the torsion.
- stator arrangement comprising: a stator according to the invention and a connection unit according to the invention, the first to Nth connection sections each being accommodated in the receiving space of a contact section of the connection unit.
- the stator arrangement of the first connection unit to connect the contact sections in an electrically conductive manner to form a star point
- the stator arrangement also comprising: a second connection unit according to the invention, the conductor arrangement of which comprises N conductor sections which are electrically insulated from one another and each form a connection for one of the strands are connected in an electrically conductive manner to one of the N contact sections, the (N+1)th to (2N)th connection sections each being accommodated in the receiving space of a contact section of the second connection unit.
- a fastening means is preferably provided, by means of which the first connection unit and the second connection unit can be transferred from a loose position into a fastened position, in which the first connection unit and the second connection unit are fastened to one another and the conductor arrangement of the first connection unit and the conductor arrangement of the second connection unit are electrically insulated from one another.
- the fastening means can be formed by the fastening sections of the first and second connection units.
- the connection unit described as a further connection unit in relation to the connection unit according to the invention can be the second connection unit of the stator arrangement.
- the fastening means can be set up to force the first connection unit and the second connection unit together in the fastened position by a force acting on the first connection unit and the second connection unit, so that the connection sections of the stator are electrically conductive at the contact sections, in particular by means of a material connection , are attachable.
- the fastening means is therefore provided as an additional component separate from the connection units.
- the fastening means can preferably be detached from the connection units in the fastened position and can preferably be returned to the loose position.
- the object on which the invention is based is also achieved by a method for producing a stator arrangement, comprising the following steps: providing a connection unit according to the invention; providing a stator according to the invention; and arranging the first to N-th terminal sections of the Stators in the receiving spaces of the contact sections of the connection unit.
- the arrangement is carried out by carrying out a relative movement of the connection unit along a direction of movement which runs essentially perpendicularly or parallel, in particular perpendicularly or parallel, to a direction in which the connecting sections extend.
- the conductor arrangement of the first connection unit electrically conductively connects the contact sections to form a star point.
- the method can also include the following steps: providing a second connection unit according to the invention, the conductor arrangement of which comprises N conductor sections which are electrically insulated from one another and are each electrically conductively connected to one of the N contact sections to form a connection for one of the strands; Arranging the (N+1)th to (2N)th connection section of the stator in the receiving space of a respective contact section of the second connection unit.
- the arrangement can take place by performing a relative movement of the second connection unit along a movement direction running essentially perpendicularly or parallel, in particular perpendicularly or parallel, to a direction of extent of the connecting sections.
- connection sections and the contact sections Joining of the connection sections and the contact sections, in particular with the formation of materially bonded joints. Joining preferably takes place by means of welding.
- the following step can be provided: Transferring the first connection unit and the second connection unit from a loose position to a fastened position by means of a fastening means or by means of fastening sections formed by the connection units, the first connection unit and the second connection unit being fastened to one another in the fastened position and the conductor arrangement of the first connection unit and the conductor arrangement of the second connection unit are electrically insulated from one another.
- a step of removing the fastening means by transferring from the fastened position to the loose position after the connection of the terminal sections and the contact sections can be further provided.
- connection unit according to the invention and the stator according to the invention can be transferred to the method according to the invention, so that the advantages described above can also be achieved with this.
- an electric machine for driving a vehicle comprising: a stator arrangement according to the invention or a stator arrangement obtained by the method according to the invention; and a rotor rotatably supported within the stator.
- the electrical machine is preferably designed as a synchronous machine or as an asynchronous machine.
- the rotor is preferably permanently excited.
- connection unit 1 shows a plan view of a first exemplary embodiment of the connection unit according to the invention
- connection unit 2 shows a detailed view of a contact section of the connection unit according to the first exemplary embodiment
- connection unit 3 shows a plan view of a second exemplary embodiment of the connection unit according to the invention
- 4 shows a side view of an exemplary embodiment of the stator arrangement according to the invention with an exemplary embodiment of the stator according to the invention and the first and second exemplary embodiment of the connection unit;
- connection units 5 shows a perspective detailed view of the connection units in the fastened position
- connection units 6 to 8 each show a plan view of the connection units during the transition from a loose position to a fastened position
- connection unit 9 shows a plan view of a third exemplary embodiment of the connection unit according to the invention.
- connection unit 10 shows a plan view of a fourth and a fifth exemplary embodiment of the connection unit according to the invention.
- FIG. 11 shows a plan view of a further exemplary embodiment of the stator arrangement according to the invention with a sixth and a seventh exemplary embodiment of the connection unit according to the invention.
- FIG. 12 shows a schematic diagram of a vehicle with an exemplary embodiment of the electric machine according to the invention.
- Fig. 1 is a plan view of a first embodiment of a connection unit 1a.
- the connection unit 1a has three contact sections 2a, 2b, 2c.
- Each contact section 2a, 2b, 2c has a first wall 3a and a second wall 3b, which are provided with reference numerals at the contact section 2a in Fig. 1 as a representative of the contact sections 2b, 2c.
- Each contact section 2a, 2b, 2c forms a NEN accommodation space 4, which is designed to enclose one of three connection sections 105a, 105b, 105c of a stator 101 (see FIG. 4) and is delimited by the first wall 3a and the second wall 3b.
- the walls 3a, 3b of all contact sections 2a, 2b, 2c are aligned parallel to one another.
- each contact section 2a, 2b, 2c has a third wall 3c, which runs perpendicularly to the first wall 3a and to the second wall 3b and also delimits the receiving space.
- connection unit 1a has a conductor arrangement 5 which electrically conductively connects the contact sections 2a, 2b, 2c.
- the conductor arrangement 5 is in the form of a busbar, which is arched or crescent-shaped in this case, for example.
- the contact sections 2a, 2b, 2c are designed as recesses in the conductor arrangement 5 or the conductor rail.
- the connection unit 1a also includes an insulating body 6, which is arranged on the conductor arrangement 5 and has openings 7a, 7b, 7c exposing the contact sections 2a, 2b, 2c.
- the insulating body 6 is formed on the conductor arrangement 5 and is formed by a continuous sheath surrounding the conductor arrangement 5 in sections.
- the insulating body 6 is made of an electrically insulating material, for example a plastic.
- connection unit 1 also shows a fastening section 8 of the connection unit 1a.
- the fastening section 8 is formed here, for example, by two latching elements 9a, 9b.
- the fastening section 8 is designed to engage with a fastening section 10 of a further connection unit 1b (see FIG. 3) in such a way that the connection unit 1a and the further connection unit 1b can be transferred from a loose position into a fastened position.
- the connection unit 1a and the further connection unit 1b are fastened to one another and the conductor arrangement 5 of the connection unit 1a and a conductor arrangement 5 (see FIG. 3) of the further connection unit 1b is electrically isolated from one another.
- the fastening section 8 is formed by the insulating body 6 .
- FIG. 2 is a detailed view of the contact section 2a, the representation of which is representative of the further contact sections 2b, 2c.
- the contact section 2a has a guide 11 which is widened compared to a distance d between the first wall 3a and the second wall 3b.
- the guide 11 joins the first wall 3a and the second wall 3b on a side of the first wall 3a and the second wall 3b opposite the third wall 3c.
- the guide 1 1 in turn has a first wall 12a and a second wall 12b.
- the first wall 12a of the guide 11 adjoins the first wall 3a of the contact section 2a on the side opposite the third wall 3c.
- the second wall 12b of the guide 11 adjoins the second wall 3b of the contact section 2a on the side opposite the third wall 3c.
- the first wall 12a and the first wall 3a enclose an obtuse angle 13 .
- the second wall 3b and the second wall 12b enclose an obtuse angle.
- the walls 12a, 12b of the guide 11 each extend along a straight line. The straight lines intersect at an acute angle of about 60 degrees.
- Fig. 3 is a plan view of a second embodiment of a connection unit 1b. Unless otherwise described in the following, all statements relating to the first exemplary embodiment can be transferred to the second exemplary embodiment.
- the conductor arrangement 5 is formed by a number of conductor sections 14a, 14b, 14c that corresponds to the number of contact sections 2d, 2e, 2f.
- the conductor sections 14a, 14b, 14c are electrically insulated from one another and are each electrically conductively connected to one of the contact sections 2d, 2e, 2f.
- each conductor section 14a, 14b, 14c formed by a busbar.
- the insulating body 6 insulates the conductor sections 14a, 14b, 14b from one another and defines the position of the conductor sections 14a, 14b, 14c relative to one another.
- connection unit 1b according to the second exemplary embodiment also has a fastening section 10 which is formed by latching elements 9c, 9d.
- the stator arrangement 100 has a stator 101, a first connection unit 1a according to the first exemplary embodiment and a second connection unit 1b according to the second exemplary embodiment.
- the stator 101 has a stator core 102, which is formed here by way of example from a multiplicity of axially layered stator laminations which are electrically insulated from one another and are made of a soft-magnetic material.
- the stator 101 has a stator winding 103 which is designed as a hairpin winding.
- the stator winding 103 has three strands here, for example, and is formed in sections from shaped conductors 104a, 104b, which extend through the stator core 102.
- the stator winding 103 is also partially made up of first to sixth connection sections 105a to 105f, which then extend on a first end face 106 of the stator core 102 to a part of the shaped conductors 104a, 104b at different angular positions in a circumferential direction in the axial direction.
- the first to third connection sections 105a, 105b, 105c are set up to form a star point.
- the fourth to sixth connection sections 105d, 105e, 105f are each set up to form a connection for the strands.
- the first to third connection sections 105a, 105b, 105c are arranged, for example, radially on the inside at the respective angular position.
- the fourth to sixth connection sections 105d, 105e, 105f are, for example, arranged radially on the outside at a respective angular position. Referring to Figures 1 and 3, a cross-section of each terminal portion 105a-f has two parallel sides. The associated side faces 107a, 107b extend into the plane of the paper.
- connection section 105a in FIG. 1 and the fourth connection section 105d in FIG. 3 are provided with reference symbols.
- the stator 101 is characterized in that the first and second connection sections 105a, 105b are deformed in relation to the third connection section 105c in such a way that the pairs of parallel side surfaces 107a, 107b of the first to third connection sections 105a, 105b, 105c are aligned essentially parallel to one another .
- connection sections 105a, 105b, 105c would be aligned radially because of the essentially cylindrically symmetrical shape of the stator 101, so that corresponding pairs of parallel side surfaces 107a, 107b would not be parallel but would be inclined to one another according to their position in the circumferential direction.
- connection sections 105d, 105e are deformed relative to the sixth connection section 105f in such a way that the pairs of parallel side surfaces 107a, 107b of the fourth to sixth connection sections 105d, 105e, 105f are aligned essentially parallel to one another.
- the pairs of parallel side surfaces 107a, 107b of all connection sections 105a-f, ie the first to sixth connection sections 105a-f are not aligned parallel to one another.
- the pairs of parallel side surfaces 107a, 107b of the first to third connection sections 105a, 105b, 105c on the one hand and the pairs of parallel side surfaces 107a, 107b of the fourth to sixth connection sections 105d, 105e, 105f on the other hand form an angle with one another that is larger than zero degrees.
- the connecting sections 105a, 105b, 105d, 105e are torsioned about a axis parallel to a longitudinal axis of the stator axis, deformed.
- torsion sections 108 are shown schematically in FIG.
- the stator winding 103 has two series connections of form conductors 104a, 104b for each of the strands, which form parallel paths of the strand.
- each connection section 105a-f comprises two connection elements 109a, 109b, which are provided with a reference number in FIG. 1 for reasons of clarity only in connection section 105c.
- a respective connection element 109a, 109b connects in one piece to one of the outer form conductors 104a, 104b with respect to one of the series connections.
- the stator winding 103 is also formed in sections by a plurality of first-type connectors 110a and second-type connectors 110b.
- the shaped conductors 104a, 104b of a respective strand are connected to one another by the connectors of the first type 110a and connectors of the second type 110b to form the series circuits.
- the connectors of the first type 110a are formed in one piece with pairs of shaped conductors 104a, 104b.
- pairs of shaped conductors 104a, 104b that are not connected by connectors of the first type 110a are connected to one another by connectors of the second type 110b.
- the connectors of the second type have two connecting elements.
- the connecting elements are each formed in one piece with one of the shaped conductors 104a, 104b connected by the connector of the second type 110b.
- the connecting elements are cohesively connected to one another on the second end face 111, for example by welding.
- FIG. 5 is a perspective detailed view of the connection units 1a, 1b of the stator arrangement 100 in a fastened position.
- the fastening sections 8, 10 of the connection units 1a, 1b are connected in the fastened position in an interlocking manner, so that the latching elements 9a, 9c and 9b, 9d form two locking connections.
- the fastening sections 8, 10 form a fastening means 17 of the stator arrangement 100.
- Fig. 6 to Fig. 8 are each a plan view of the terminal units 1a, 1b during the transition from a loose position to the fixed position.
- the advantage of the parallel arrangement of the pairs of parallel side surfaces 107a, 107b is also explained with reference to these figures.
- connection sections 105a, 105b, 105c are arranged essentially parallel to one another if they are not yet received in the receiving spaces 4 of the contact sections 2a, 2b, 2c.
- connection units 1a, 1b are moved towards one another in a direction of linear movement which is perpendicular to the direction in which the connection sections 105a-f extend and which is illustrated by arrows in FIG.
- the guides 11 serve to compensate for the previously mentioned positional tolerances. It should be noted that the accommodation of the connection sections 105a-f in the accommodation spaces 4 is made possible by the deformation of the connection sections 105a, 105b, 105d, 105e. The force required to guide the connection sections 105a-f between the parallel walls 3a, 3b would be too great if the connection sections 105a-f were aligned radially.
- FIG. 8 shows the connection units 1a, 1b in their fastened position, in which the fastening sections 8, 10 engage in one another analogously to FIG. In this position, the contact sections 2a-f and the terminal sections 105a-f can be joined together, for example by welding.
- FIG. 9 is a plan view of a third embodiment of a connection unit 1a. The connection unit 1b also shown corresponds to the second exemplary embodiment. All statements relating to the first exemplary embodiment according to FIGS. 1 and 2 can be transferred to the third exemplary embodiment according to FIG. 9 apart from the deviations described below.
- the fastening section 8 is formed by the conductor arrangement 5, which protrudes from the insulating body 6 for this purpose.
- the attachment section 10 of the connection unit 1b is formed by the conductor arrangement 5 when the attachment section 8 of the connection unit 1a—as in the first exemplary embodiment—is formed by the insulating body 6 .
- connection unit 10 is a plan view of a fourth embodiment of a connection unit 1a and a fifth embodiment of a connection unit 1b. All statements relating to the first and second exemplary embodiment according to FIGS. 1 to 3 can be transferred to the fourth and fifth exemplary embodiment, with the exception of the deviations described below.
- the fastening section 8 is formed by projections 15a, 15b.
- the fastening section 10 is formed by recesses 16a, 16b, which are designed to be opposite to the projections 15a, 15b.
- the projections 15a, 15b and the recesses 16a, 16b correspond to one another, comparable to two pieces of a jigsaw puzzle, in order to fasten the connection units 1a, 1b to one another by means of a form fit.
- the connection units 1a, 1b are also connected in an interlocking manner by means of a linear movement in order to form the positive connection.
- connection unit 1a is a plan view of a further exemplary embodiment of the stator arrangement 100 according to the invention with a sixth exemplary embodiment of a connection unit 1a and a seventh exemplary embodiment of a connection unit 1b.
- connection units 1a, 1b have no fastening sections.
- the stator arrangement 100 comprises a fastening means 17, shown schematically, by means of which the first connection unit 1a and the second connection unit 1b can be transferred from the loose position into the fastened position.
- the fastening means 17 is designed to force the connection unit 1a and the connection unit 1b together in the fastened position by a force acting on the connection units 1a, 1b, so that the connection sections 105a-f in the fastened position are electrically conductive to the Contact sections 2a-f abut and can then be attached. This can be done, for example, by integral joining, in particular by welding.
- the fastening means 17 is designed as an additional component that is separate from the connection units 1a, 1b. The fastening means can be detached in the fastened position, in particular after the connection sections 105a-f have been fastened to the contact sections 2a-f, so that the fastening means 17 does not remain on the stator arrangement 100.
- FIGS. 1 to 11 Exemplary embodiments of a method for producing a stator arrangement 100 are described below, which are explained in more detail with reference to FIGS. 1 to 11 .
- a step of providing a first connection unit 1a and a step of providing a second connection unit 1b are provided.
- a further step of providing a stator 101 is also provided.
- the method also includes a step of arranging the first to third connection sections 105a, 105b, 105c of the stator 101 in the receiving space 4 of a respective contact section 2a, 2b, 2c of the connection unit 1a and a step of arranging the fourth to sixth connection section 105d, 105e, 105f of the stator 101 in the receiving space 4 of a respective contact section 2d, 2e, 2f of the second connection unit 1b.
- the arranging steps are carried out by performing a relative movement of the first connection unit 1a and the second connection unit 1b along a direction of movement essentially perpendicular to the direction in which the connection sections 105a-f extend if the connection units 1a, 1b correspond to the first to third exemplary embodiments. If the connection units 1a, 1b correspond to the fourth to fifth exemplary embodiment, the direction of movement is, on the other hand, parallel to the direction in which the connection sections 105a-f extend. In the case of the sixth and seventh exemplary embodiments, the direction of movement is arbitrary.
- the method also includes a step of transferring the first connection unit 1a and the second connection unit 1b from a loose position to a fastened position by means of the fastening means 17 or the fastening sections 8, 10, with the first connection unit 1a and the second connection unit 1 b are fastened to one another in the fastened position and the conductor arrangement 5 of the first connection unit 1a and the conductor arrangement 5 of the second connection unit 1b are electrically insulated from one another.
- the method also includes a step of joining the connection sections 105a-f and the contact sections 2a-f with the formation of materially bonded joints in the fastened position of the fastening sections 8, 10 or the fastening means 17.
- FIG. 12 is a schematic diagram of a vehicle 200 including an embodiment of an electric machine 201 configured to propel the vehicle 200 .
- Electric machine 201 includes a stator assembly 100 according to one of the exemplary embodiments described above or a stator assembly 100 obtained by the method and a rotor 202 rotatably mounted within stator assembly 100 .
- Electric machine 201 is designed as part of a drive train of vehicle 200 .
- the electrical machine 201 can be a synchronous machine.
- the rotor 202 is preferably permanently excited.
- the electrical machine 201 is an asynchronous machine.
- the vehicle 200 may be a battery electric vehicle (BEV) or a hybrid vehicle.
- BEV battery electric vehicle
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- Manufacturing & Machinery (AREA)
- Windings For Motors And Generators (AREA)
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN202180084272.2A CN116670937A (zh) | 2020-12-15 | 2021-11-29 | 用于定子的连接单元、用于电机的定子、定子布置、用于生产定子布置的方法、以及用于驱动车辆的电机 |
EP21823505.9A EP4264799A1 (de) | 2020-12-15 | 2021-11-29 | Anschlusseinheit für einen stator, stator für eine elektrische maschine, statoranordnung, verfahren zur herstellung einer statoranordnung und elektrische maschine zum antreiben eines fahrzeugs |
US18/257,153 US20240030772A1 (en) | 2020-12-15 | 2021-11-29 | Connection unit for a stator, stator for an electric machine, stator arrangement, method for producing a stator arrangement, and electric machine for driving a vehicle |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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DE102020215908.4A DE102020215908A1 (de) | 2020-12-15 | 2020-12-15 | Anschlusseinheit für einen Stator, Stator für eine elektrische Maschine, Statoranordnung, Verfahren zur Herstellung einer Statoranordnung und elektrische Maschine zum Antreiben eines Fahrzeugs |
DE102020215908.4 | 2020-12-15 |
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WO2022128426A1 true WO2022128426A1 (de) | 2022-06-23 |
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PCT/EP2021/083344 WO2022128426A1 (de) | 2020-12-15 | 2021-11-29 | Anschlusseinheit für einen stator, stator für eine elektrische maschine, statoranordnung, verfahren zur herstellung einer statoranordnung und elektrische maschine zum antreiben eines fahrzeugs |
Country Status (5)
Country | Link |
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US (1) | US20240030772A1 (de) |
EP (1) | EP4264799A1 (de) |
CN (1) | CN116670937A (de) |
DE (1) | DE102020215908A1 (de) |
WO (1) | WO2022128426A1 (de) |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090026859A1 (en) * | 2007-07-24 | 2009-01-29 | Kinoshita Nobuo | Inner-rotor-type brushless motor having built-in bus bar |
FR3054745A1 (fr) * | 2016-08-01 | 2018-02-02 | Valeo Equipements Electriques Moteur | Machine electrique tournante munie d'un interconnecteur a crochets d'ecrouissage |
EP3051671B1 (de) * | 2013-09-26 | 2018-11-14 | Mitsuba Corporation | Busschieneneinheit, verfahren zur herstellung einer busschieneneinheit und bürstenloser motor |
CN109075647A (zh) * | 2016-05-11 | 2018-12-21 | 日立汽车***株式会社 | 旋转电机 |
DE102019122550A1 (de) | 2018-08-23 | 2020-02-27 | Ford Global Technologies, Llc | Elektrische maschine mit haarnadelförmiger wicklung |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10340761B2 (en) | 2015-03-26 | 2019-07-02 | GM Global Technology Operations LLC | Electric device and a stator assembly for the electric device |
US10505423B2 (en) | 2016-09-30 | 2019-12-10 | Faraday & Future Inc. | Nested three phase bus bar unit |
DE102018009206B3 (de) | 2018-11-23 | 2020-03-19 | Gehring E-Tech Gmbh | Verbindungsbauteil zur Verbindung von elektrischen Leitern einer hairpin-Wicklung eines Stators einer Elektromaschine sowie Verfahren zur Herstellung dieser Verbindung |
-
2020
- 2020-12-15 DE DE102020215908.4A patent/DE102020215908A1/de active Pending
-
2021
- 2021-11-29 EP EP21823505.9A patent/EP4264799A1/de active Pending
- 2021-11-29 CN CN202180084272.2A patent/CN116670937A/zh active Pending
- 2021-11-29 US US18/257,153 patent/US20240030772A1/en active Pending
- 2021-11-29 WO PCT/EP2021/083344 patent/WO2022128426A1/de active Application Filing
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090026859A1 (en) * | 2007-07-24 | 2009-01-29 | Kinoshita Nobuo | Inner-rotor-type brushless motor having built-in bus bar |
EP3051671B1 (de) * | 2013-09-26 | 2018-11-14 | Mitsuba Corporation | Busschieneneinheit, verfahren zur herstellung einer busschieneneinheit und bürstenloser motor |
CN109075647A (zh) * | 2016-05-11 | 2018-12-21 | 日立汽车***株式会社 | 旋转电机 |
FR3054745A1 (fr) * | 2016-08-01 | 2018-02-02 | Valeo Equipements Electriques Moteur | Machine electrique tournante munie d'un interconnecteur a crochets d'ecrouissage |
DE102019122550A1 (de) | 2018-08-23 | 2020-02-27 | Ford Global Technologies, Llc | Elektrische maschine mit haarnadelförmiger wicklung |
Also Published As
Publication number | Publication date |
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CN116670937A (zh) | 2023-08-29 |
EP4264799A1 (de) | 2023-10-25 |
DE102020215908A1 (de) | 2022-06-15 |
US20240030772A1 (en) | 2024-01-25 |
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