DE102004010446A1 - Stator winding`s pole coil for switched reluctance motor, has flat conductor cross section and is made of copper enameled wire that is flat at its edges, where coil is wound around stator pole in same direction - Google Patents

Abstract

The coil has a flat conductor cross section and is made of a copper enameled wire that is flat at its edges. The coil is enclosed by a plastic insulating material (9) before it is placed on stator pole teeth. Start windings of the coil lie radially close to an inner diameter of the coil and finish windings of the coil lie close to stator pole slots such that the coil is wound around the pole in same direction. An independent claim is also included for a method of manufacturing a rectangular wire pole coil.

Description

The The invention relates to pole coils for the stator winding of a switched reluctance motor.

Of the Automotive has been pushing the use of electric motors for years powered assemblies in vehicles, accompanied by a growing Proportion of electronic equipment, the driving dynamics, the ride comfort, the economy and the active and passive safety too improve.

there the automotive sector is on small differentially controlled Dependent on individual drives that respond quickly and powerfully and can be fed from the vehicle electrical system.

The On-board voltage condition leads unavoidable in winding technical design to relatively large conductor cross-sections, to absorb the currents resulting from the power requirements to be able to.

With the possibilities an electronic control have long been known Reluctance motors, in the version of a switched reluctance motor, also called "Switched reluctance engine "or short SR motor designates, a perspective in the automotive sector receive.

Be Construction is even easier than the EC motor and it is cheaper to produce and robust in use.

Also The SR motor has the stator winding pole coils in use big in a vehicle Conductor cross-sections, which it under tight space conditions of the small engines to cope with manufacturing technology applies.

Puts you in this case copper enamel round wires, so you get because of the gusset gap between the wires, which grow with the diameter, an insufficient utilization of the available winding space, which limits the formation of the torque-generating magnetic field. And you reduce the wire diameter by dividing the conductor cross-section in parallel wires, then are twists and distortions in feeding and laying the episode, Also occur impedance differences between successively wound Partials on.

Therefore is the use of flat wires the obvious alternative.

From the DE 42 20 209 A1 ( GB 2 258 765 A . US 5,866,965 . FR 92 07925 ) are known for small SR stator windings flat-pole coils, which are prefabricated outside the stator and pushed radially out of the bore space on the zahnkopflosen stator teeth.

wraps one flat wire to pole coils, so there are two as already explained above Laying variants, depending on whether the flat broadside on Art winding a film winding radially with respect to the pole core, with which the turns receive different lengths, or whether the narrow side of the cross-sectional thickness brings to the core to the plant and the turns screwing over the core height lets rise axially with which all turns are the same length receive.

The former winding variant is also called radial flat winding in contrast to the axial upright winding.

Both the DE 42 20 209 A1 as well as the DE 41 26 019 A1 use flat wound pole coils.

The Flat winding is basically manufacturing technology easier to perform.

disadvantage the flat winding is, however, that when placing the pole coil on the tooth pole of the stator at the transition to the bottom of the pole pocket a right-angle inner Jochring section of the stator must be provided to the Rectangular cross section of the pole coil with its flank too close to contour To be able to bring investment.

One in automotive small engines usually circular yoke with concentric inner and outer edges but would by such a 90 ° section at the bottom of the poles weakened with effect on the formation of the magnetic flux. A Compensating the cross-sectional loss by increasing the External diameter or a polygon contour gives away in the first case not consistently required yoke width and in the second case, it complicates the laminated core manufacturing in the usual way Stanzpaketierverfahren.

The Hochkantwicklung is difficult to perform manufacturing technology. The Bend over the height Edge "requires higher shaping forces and measures against tipping or undesirable cross-sectional deformation of the flat conductor.

Like from the CH 469 388 and the DD 281 894 A5 is known, wrapped in general electrical engineering pole coils made of bright copper but with far greater ratios of width to height of the cross section in a Pilgrims Schrittverfahren, ie a cyclic sequence of linear conductor deduction to form the coil longitudinal sides and a 180 ° bend to form the end faces the pole coil.

disadvantage these processes are compression thickenings at the inner bending radius, which are suitable to compensate or rework. This is with enamel-insulated Flat wire, of course not possible and usually for the smaller values of the ratio Height too Thickness also not required.

The compared to flat winding in the case of a vertical winding larger production engineering Difficulty when using conventional winding machines Clearly let the developers of switched reluctance motors hesitate, yourself for this Variant to decide.

there offers a high quality wound flat wire pole coil with only a few Turns for not necessarily parallel flanked, ie conical stator teeth, both Cases without protruding tooth head, an advantageous alternative, therefore, because at least the more common parallel-sided pole teeth all Turns the same shape and length and because the coil start is not radially inward on the coil but as well as the coil end parallel to the pole edge above the pile height, axially outward directed and so well contacted.

task In the invention, it is edgewise wound flat conductor pole coils for switched Reluctance motors and a method for its production by Applicative use of process solutions outside the classical technical pool to develop, the method should be suitable, the edgewise wound pole coils in a fully automatic and productive Cycle ready for installation and ready for connection and automatic joining with the stator poles, manufacture.

According to the invention this is achieved by for the stator winding of a switched reluctance motor a flat wire coil is provided with edgewise flat copper enamel wire.

The Stator winding here has a winding identical shape. simultaneously is it designed so that it has the same winding sense and with axially exiting switching terminals is provided.

Further special embodiments of the inventive teaching can be to the claims 2 to see 7.

Of the Stator according to the invention with his pole teeth equipped with the advantageously edgewise wound pole coils.

For the pole coils is used lacquer-insulated copper flat wire of commercial quality.

The Number of turns is low due to the large conductor cross-section. In the built-in or Joining state lie the turns close together. In adaptation to the Base circle radius of the pole pockets are the Polspulenwindungen against a vertical arched to the pole tooth wall of the stator with radius. So the available pole tooth height can be optimal be used by the turns.

The Coils are wound so that their beginning and end are on the same coil head, that is So on the same Statorpaketstirnseite, surrendered. this is a the conditions for a good circuit connection at the winding completion.

In order to lie all ends and beginnings the pole coils on two concentric alignment circles on the one Front side of the stator, this so that for transitional connections between belonging to the same phase Pole coils, here pairs of pole coils, the projected yoke ring area to disposal stands and the beginnings and ends of the phases to which the pole coils are fed by groups Connected in series, located on a hole near alignment circle are located.

The Length of both ends of a pole coil is different, the difference oriented at the width of the flat wire, as explained below. This is all the circuitous beginnings of Coils and all circuit-wise ends the coils each at the same distance level to Statorpaket- front page within the same alignment circle.

On a length of at least one flat conductor width are the coil ends of Insulating lacquer freed to contact them cohesively.

Circuitally belong in the case a six - pole stator with three - phase winding two each in the Stator diametrically opposed Pole coils to the same of the three winding phases and are in series connect to. The ends of the three strands become as well a star point merged.

The Coil sides of adjacent pole coils share the space of a common Poltasche.

At the Winding is ensured that the winding long sides do not bulge.

Since the Hüllenangente runs over the outer contour of the coil side parallel to the Polzahn center line and this is the case for the entire coil side length, approach the radially inner flat Wire cross-sections of the two coil sides statorbohrungsseitig the most.

A sufficient distance zone on either side of Poltaschenmittellinie provided in the dimensioning of the stator and winding geometry been to freedom of joining to ensure the radial placement of the pole coils.

All Coils are identical, there are no winding differences.

requirement for the advantageous property of reluctance is that the Stromflußrichtung for the Function of the winding of a switched reluctance motor irrelevant is.

The is an essential and inventively used advantage, for example compared to EC motors same size with one 3-phase round wire winding.

Also received the pole coils an external circuit, which connects them to the functional winding. This external circuit can be adapted to the respective conditions.

amendments the number of poles are for the principle of this modular winding no problem.

The Plastic insulating parts have the basic shape of a box-shaped frame with an inner contour that corresponds to the Polzahngestalt with joining tolerance.

The Wall thickness of this box frame together with the selection of a suitable injection moldable molding material, for example glass fiber reinforced PPS (polyphenylsulfide resin), is sized so that equally insulating ability, dimensional stability and joint elasticity given are.

guide rails on the narrow sides reduce the frictional resistance to the laminated core of the pole tooth.

The outer contour of the box frame is the inner contour of the pole coil with joint tolerance customized.

The Wall thickness at the end faces is reinforced with a polygon contour, the adapted to the radius of the coil end face.

A The peripheral edge of the box frame merges into a flange collar, the the coil pocket facing the pole pocket insulates against the stator laminated core distances.

At the opposite peripheral edge of the box frame are symmetrical on the long sides Locking tabs are formed, which are dimensioned so that they spring back the pole coil in the joining direction let pass, but then erected arresting behind her stay.

in the Contrary to the for Round wire windings of EC motors repeatedly submitted inventions solutions, which are based on a maximum conductor occupancy of the pole pocket space have to to compensate for the cross-sectional reductions through the gussets, can the edgewise pole coil winding according to the invention thanks to their well-dimensioned conductor cross-sections trapezoidal free spaces in the Allow middle of Poltaschen reason.

These trapezoidal Free rooms can according to the invention in a variety of ways be used, in particular for the insertion of plastic extruded profile parts, whose hollow interior is usable multivalently and which with a the pole pockets on the stator inner diameter closing head provided are.

As well can this space for a trapezoidal Intervention of the yoke ring can be used.

The Solution according to the invention includes the circuit-compatible Connection of the pole coils to the complete winding.

As already mentioned in the design description of the pole coils lie the two ends axially extending and different lengths on both sides the pole coil on a common circular ring aligned to Poltaschengrund.

To connect the pairs of pole coils with each other, which is a phase form. That is in the case of the 6-pole considered here as an example Stators each diametrically opposed coils.

To be with nutgrundseitigen, so radially outer coil ends with their already stripped coil terminals also end-stripped, centered Bracket off connected to the same flat copper enamel wire.

The flat curved hanger follow in the radius of the inner diameter of the stator yoke ring and lie so that when looking at the Statorstirnseite within the outer contour.

By her central bend their two ends are on each one of the axially superimposed lying circular ring levels.

Apart from this central crank, which helps to neatly interlock the three straps, are the ends are made different by either resting on the reel flat wire on this or being aligned with it with a 90 ° constriction from below.

The three straps are also produced on a stamping and bending machine.

With an auxiliary device adjusted and positively coupled with the Polspulenanschlüssen connected with them. These are the well-known, preferably thermal processes with localized heat input to select.

The radially inward six free ends of the three phases become in contact engagement with a front side aufzusetzenden annular plate which also carries out the star connection of the three phase ends and with the control circuit of the switched reluctance motor communicated.

alternative to use the flat wire connector bracket can also all the connections of Pole coils contacted in such a circuit board integrated be, then the interconnection of Polspulenpaare too Realized phases.

The Flat wire pole coils according to the invention for the Stator winding a switched reluctance motor are using meandering shaping of the edgewise wound flat copper enamel wire produced by the specific work sequence of a stamping and bending machine, where ready to coil arise.

The solution according to the invention consists in applicative application of the stamping and bending technique, as with machines according to DE 27 41 576 C2 is executable.

One Punching and bending machine has Programmed on a vertical worktop via programmable plunger tools acting in this plane, which are focused on a common center in which is located on a rotation axis is the shaping part for the workpiece to be produced. In the case of the pole coils, this is a core with the inner contour of Pole coil. The edgewise flat copper enamelled wire is over a supplied on all sides conductive roller channel tangentially to the core.

In the feed channel Workstations are integrated, in a known manner the funded flat wire stripping at predetermined point sections and this section later can be separated centrally by shearing or the like. This is to serve the required stripping of the switching ends of the pole coil to realize.

The after such shear cutting free end of the flat wire strand is in the usual way tangential to the core longitudinal side along up to one outside promoted stop and then fixed in relation to the core.

at the following rotation, the flat wire is taken from the core and thereby deducted from the supply roll. In the winding training However, according to the invention is applicative the possibility the punch-bending machine used, targeted by the radially deliverable ram tools bending-forming forces and temporally applied to the core rotation, where a roller assembly the plunger Unwinding during relative movement to the core and allows wire. In Hold function prevent them from already formed turns putting on a bulge or lifting off the core.

By Tie rod tools with a force acting perpendicular to the winding plane or Worktop receives the finished pole coil their radii embossing corresponding to the Poltaschen-base radius. At the same time the ready to install pole coil is finally fixed in shape.

she is from the feed line of the flat wire separated.

In particularly advantageous manner the production process according to the invention for producing flat wire pole coils it is necessary for the insulating parts and pole coils with gripper systems of punching and bending machines on the Pole of the stator are placed.

There the pole coils of the punch-bending machine installed for this purpose ready to install can be issued They arranged without manual intervention at the transfer point of a chained joining device to be provided.

These joining device comes with the stator packs, plastic insulating parts and the aforementioned Pole coils as feed parts fed.

The subordinate to the coil-finished punching-bending automaton, already mentioned joining device positions the stators with hoop stress axially on a CNC axis, which can perform an angular step corresponding pole division.

In In a first operating cycle, gripper systems set up the plastic insulating parts the pole teeth.

The Parts are inserted axially into the stator bore and stripped radially onto the pole teeth.

The Movement and function sequence of this joining operation is in the control deposited by teach-in programming.

A essential condition for this joining process is the repeatability and tolerance limitation of the stanzpaketierten Stator lamination. The punching packetizing known by cyclic Angle rotation in sheet metal thickness tolerance compensation and the sheet metal link to the pole tooth area make the pole tooth to a defined Block for the joining process.

In In a second cycle of operation, gripper systems set the pole coils on the isolated pole teeth.

decisive Prerequisite for this is the by the preparation according to the invention given repeatability of dimensions and shape as well as the handling stability of the edged flat conductor pole coil.

At the gripper attaching gripper can without Danger of deformation apply the required holding force. The point of application of the gripper system does not necessarily have to be centered or symmetrical to the coil, but is a detection of the axially freely projecting coil ends possible because of the rectangular cross-section of the conductor gives a clear orientation for the entire coil.

A tactile gripper hand offers alternative conditions here.

The Gripper system leads the coils axially into the stator bore space, aligning its to be loaded and already isolated pole tooth, which by an angular step rotation aligned on the CNC axis of the stator holder for this purpose has been.

With a radial movement towards tooth pole, the coil is finally on its plastic insulating pushed and detent detent from the gripper Approved.

It stays with the solution concept the joining device otherwise, Pre-add plastic insulating part and pole coil first and then together on to put the pole tooth.

A Such manufacturing technology solution is expressly involved in the invention.

requirement is a collision-free adjustment of pole pocket and insulating screen, to which hinged impressed Wing flaps, the springy avoid the neighboring part at the joining passage, a solution are.

As already mentioned, was used in the dimensioning of stator geometry and winding or pole coil Note that collision freedom is ensured when joining, so that the outer contour the piecing coil not the radially innermost turn of the neighboring, already joined Pole coil touched.

With insulated coils fully assembled the stators are output from the system.

The Forming principle of punching-bending technology allows it, even strong round wires through tool change sets to process the pole coils, as above for flat wire has been described. Such a solution according to the invention is defined by the dependent claim 8 recorded.

Of course and for each Professional conceivable and comprehensible result in doing some applicative adjustments, for example when contacting.

The solution according to the invention based on an embodiment and a drawing closer explained become.

It show the

1 : the front view of a completely coil-equipped stator

In 1 the stator plate contour is described by an outer diameter ( 1 ), a groove base diameter ( 2 ), between which the as Jochring ( 3 ), and a bore-side inner diameter ( 4 ), from which the parallel-flanked pole teeth ( 5 ) extend to the radius transition into the groove base diameter ( 2 ). The of the groove base diameter ( 2 ), the flanks of adjacent pole teeth ( 6 ) and the inner diameter ( 4 ) limited area is used as a pole pocket ( 7 ) indicated by their center line ( 8th ) is split symmetrically in partial areas for each coil side.

in the Stanzpaketierverfahren receives the stator a predetermined length congruently connected stator laminations described above contour.

The Length of the Statorpaketes is another determinant of the produced pole coils.

Before fitting the pole coils, the pole teeth with plastic insulating parts ( 9 ), which are made in one piece from a tooth-covering box frame ( 10 ) and a nutgrundseitig subsequent shielding flange ( 11 ) consist. The bore-side peripheral edge of the box frame ( 10 ) has a lockable by the pole coil Arretierwulst ( 12 ).

The pole coil ( 13 ) with a flat conductor cross section ( 14 ), whose inner narrow side is the bending side in the upright winding, is inside and outside parallel flankig to the coil center line ( 15 ), wherein the flat conductor cross section ( 14 ) at an angle to the coil centerline ( 15 ) in the final embossing of the wound coil on the pole pocket-side diameter ( 2 ).

Of the 1 It can also be seen that all pole coils ( 13 ) are similar in the sense of wrapping and that the beginnings ( 16 ) and the ends ( 17 ) on the same end face of the pole coil ( 13 ), while the beginnings ( 16 ) radially close to the inner diameter ( 4 ) and the ends ( 17 ) near the pole pocket or groove base diameter ( 2 ).

The compact flat conductor cross sections ( 14 ) prove to save space without loss of gussets, as they are unavoidable for round wire windings. It remains so passage for an effective air ventilation.

In 1 is not shown the circuit connection of the pole coils ( 13 ) to pair a phase or strands by means of curved and cranked flat wire stirrups. Advantageously, the three connecting stirrups lie in the region of the stator yoke ring (FIG. 3 ), at their crossing points by uplifting bent over or led down or on concentric circular arcs past each other.

Remain for integration in the aforementioned and not shown here end-mounted patch circuit board known as U, V, W, X, Y and Z coil terminals ( 16 respectively. 17 ) of the strand - pole pairs, which are contacted with her.

The circuit board, a circular ring in metal-plastic composite design, produced by injection molding in multiple layers, provides passages for the abovementioned coil terminals and, as a 90 ° bend, contact lugs protruding from the line pattern. These are connected to the strand coil terminals ( 16 respectively. 17 ) connected in a suitable contacting method. The line pattern, embedded in the plastic cover layers, realizes the star connection and provides interfaces for the control electronics of the motor.

alternative to use the flat wire connector bracket can also all the connections of Pole coils contacted in such a circuit board integrated be, then the interconnection of Polspulenpaare too Realized phases.

One Plastic extrusion profile can be wedge-shaped free spacing space of adjacent pole coil sides are pressed in axially, offers an internal channel for multivalent use and umbrella-like one between the Polzahnspitzen extending pile pocket closure.

Of the Application according to the invention which combined programmable with a stamping and bending machine Operations due to the produced edgewise wound coil their joining and Functional properties.

The same applies to the manufacture of the connector stirrups, their contacting by means of well-known resistance welding process or the like. can be done.

The let example described stator winding and its production a broad embodiment of the principle that expressly in the idea of the invention is incorporated.

The Forming principle of punching-bending technology allows it, even strong round wires through tool change sets to process the pole coils, as above for flat wire has been described. Of course and for every professional imaginable and comprehensible results in some applicative Adjustments for example when contacting.

1

outer diameter

2

groove base

3

yoke

4

hole-sided Inner diameter

5

Parallelflankiger pole tooth

6

Polzahnflanke

7

Poltasche

8th

Polepockets - centerline

9

Plastic- Insulation

10

box frame

11

Schirmflansch

12

Arretierwulst

13

pole coil

14

Flat conductor cross-section

15

Coil center line

16

coil start

17

coil end

Claims (10)

Pole coil for the stator winding of a scarf teten reluctance motor, characterized in that it is a flat wire coil of edgewise wound flat-enameled wire, has winding identical shape and is provided with axially exiting switching terminals. Pole coil according to claim 1, characterized in that that by a radii embossing the winding perpendicular to the winding plane a conformal adjustment, associated with a bead-like shape stabilization on the Pole pockets, is achieved. Pole coil according to claim 1, characterized in that that an insulating part with box-shaped Umgriff of the pole tooth and an integrally adjoining flange screen over the Poltaschengrund is placed on the pole tooth, the insulating part a Ratchet seat for the pole coil offers, the flange screen with or without wrap to the coil outer edge, including a hinged or spring-back acting thinner Groove can be designed. Pole coil according to claim 1, characterized in that that phased interconnection the pole coils by flat wire strap done over the yoke ring front side of the stator in parallel circular arcs and by cranking cruising are flat and at the radially outside lying coil ends are contacted and that the remaining beginnings and ends of the three-phase winding via a printed circuit board, which is docked on the front side and in which they contact in engagement are brought, are switched. Pole coil according to claim 1, characterized in that that the functional interconnection to the total winding, waiving flat wire bracket after Claim 4, exclusively via a Printed circuit board takes place. Pole coil according to claim 1, characterized in that that the pole teeth have tapered flanks to each other and the pole coil adapted to accomplished is. Pole coil according to claim 1, characterized in that that a plastic extruded profile in the wedge-shaped free Distance space adjacent pole coil sides is pressed axially, an inner channel for multivalent use and a running between the Polzahnspitzen Poltaschenabschluss possesses. Pole coil according to claim 1, characterized in that that it consists of round-copper wire. Method for the production of flat wire pole coils according to claim 1, characterized in that the winding forming Shaping the edgewise wound flat copper wire with the specific work sequence of a stamping and bending machine takes place and ready to fit Coils arise. Method for the production of flat wire pole coils according to claim 9, characterized in that the insulating parts and Pole coils with gripper systems of the punching and bending machine on the poles of the stator are placed.