DE102013225130A1 - Winding segment for forming a winding of an electric machine, method for producing a winding segment - Google Patents

Abstract

Disclosed is a winding segment (WS) for forming a winding (WL) of an electric machine (EM) with - a first electrically conductive rod-shaped conductor element (L1) for forming the winding (WL), and - an electrically insulating and independently mechanically stable insulating element ( IS) which circumferentially encloses and electrically insulates the first conductor element (L1), - wherein the insulating element (IS) is fixed to the first conductor element (L1). An electrical machine (EM) with such winding segments (WS) is simple and inexpensive to produce.

Description

The present invention relates to a winding segment for forming a winding of a winding carrier, that is, a stator or a rotor, an electric machine. Furthermore, the invention relates to a method for producing a previously mentioned winding segment. Moreover, the invention relates to a winding support and an electrical machine with at least one aforementioned winding segment.

Electrical machines have winding carriers which have a laminated core together with windings wound in the laminated core and are designed as stators or rotors of the electrical machines. The windings are formed from a plurality of hairpin or U-shaped winding pins and folded to form the windings in the laminated core with a spreading step corresponding to a winding step of the winding support and inserted cranked into the corresponding laminated core of the laminated core. In this case, exposed end portions of the two bent legs of the respective winding pins protrude from the laminated core, which are interconnected to form the windings according to the winding step of the winding support and then electrically connected to each other.

Electrical insulation between the windings or the winding pins and the laminated core is produced by means of insulating paper. For this purpose, the insulating paper and the winding pin are successively inserted into respective Polnut of the laminated core. Subsequently, the insulating paper and the winding pin are mechanically connected to each other in an elaborate impregnation or trickle process and fixed in the Polnut.

As an alternative or in addition to the insulating paper, the winding pins are coated with an insulating lacquer layer so that the two legs of each individual winding pin, which are inserted in one and the same laminated core pole, can be electrically insulated from one another and from the laminated core. The insulating lacquer layer is used only for electrical insulation and has no own mechanical stability and requires a carrier, here in the form of the winding pins. Thus, the insulating lacquer layer is vulnerable to external mechanical effects such. As scratching by tools, whereby the paint layer is often damaged during transport or when inserting the winding pins in the Blechpaketpolnuten and thus no longer provides sufficient electrical insulation. Thus, the lacquer layer makes it difficult to form an intact winding and consequently leads to additional expense and costs in the production of electrical machines.

The object of the present invention is therefore to provide a way to produce electrical machines easily and inexpensively.

This object is solved by subject matters of the independent claims. Advantageous embodiments are the subject of the dependent claims.

According to a first aspect of the invention, a winding segment is provided for forming a winding of a winding carrier, that is to say a stator or rotor, of an electrical machine. Accordingly, the winding segment has a first electrically conductive rod-shaped conductor element for forming the winding and an electrically insulating and independently mechanically stable insulating element which encloses the first conductor element and electrically insulated. The insulating element is attached directly and mechanically to the first conductor element.

As an independent mechanical stability of the insulating element is about a mechanical strength of the insulating against external mechanical effects by tools that act in subsequent manufacturing steps for inserting the winding segment in a laminated core or to form the winding on the insulating. This mechanical strength of the insulating the winding segment including the insulating element can be inserted nondestructively in the laminated core and entangled to form the winding, without damaging the insulating, so it continues after inserting and interleaving the winding segment sufficient electrical insulation between the winding segment and the laminated core offers.

Due to the direct mechanical attachment of the insulating element with the conductor element, these two elements form a unitary component which can be easily inserted into the corresponding Blechpaketpolnut in a single manufacturing step following the formation of the winding. Characterized in that the insulating member independently has sufficient mechanical stability, the insulating element is much more stable compared to an insulating varnish and thus easier to handle when transporting and inserting into the Blechpaketpolnut.

With such winding segments thus a possibility is created, the winding support and consequently also the electric machine easier and cheaper to produce.

According to a preferred embodiment of the winding segment, the insulating member is positively, non-positively or cohesively on the attached first conductor element. Preferably, the insulating element is formed as a molded around the first conductor element injection molded part.

As an injection molding, the insulating element can be produced inexpensively. By direct injection molding of a casting material around the conductor element, a mechanically stable connection between the conductor element and the insulating element can be produced at the same time during the molding of the insulating element.

In an alternative preferred embodiment, the insulating element is simply attached by means of an adhesive connection to the first conductor element.

According to another preferred embodiment, the insulating member surrounds the first conductor element circumferentially completely except for a first and a second end region of the first conductor element.

The two end regions, which are not enclosed by the insulating element, serve to form electrical connections from the first conductor element of the winding segment to the conductor elements of other winding segments spaced apart in the winding carrier according to the winding step to form the winding.

According to yet another preferred embodiment, the winding segment comprises a second electrically conductive rod-shaped conductor element for forming the winding, wherein the insulating element also surrounds the second conductor element circumferentially and the first and the second conductor element mechanically interconnects and at the same time electrically insulated from each other.

The number of conductor elements is not limited to two. Depending on requirements, the winding segment may preferably comprise a third and / or further electrically conductive rod-shaped conductor elements for forming the winding, wherein the insulating member surrounds the third and the further conductor elements also circumferentially and the first, the second, the third and / or each further conductor element mechanically interconnected and at the same time electrically isolated from each other. For better understanding, the preferred embodiments are described below always with reference to a winding segment with two conductor elements, these configurations also being valid for winding segments with three or more conductor elements.

The independent mechanical stability of the insulating element is sufficient to fix the first and the second conductor element together so that the winding segment is nondestructively inserted into the corresponding Blechpaketpolnut and entangled according to the winding step of the winding carrier in the spreading step and with other according to the winding step spaced in the laminated core arranged winding segments electrically can be connected without falling apart the two conductor elements of the winding support. Thus, the insulating member also serves as a mechanical support of the two conductor elements.

According to a preferred embodiment of the winding segment, the insulating member is also positively, positively or materially secured to the second conductor element. Preferably, the insulating member is formed as a molded around the first and the second conductor element injection molded part.

In an alternative preferred embodiment, the insulating element is simply attached by means of an adhesive connection to the first and the second conductor element.

According to yet another preferred embodiment, the insulating member circumferentially completely encloses the second conductor member as well, except for third and fourth end portions of the first conductor member, the third and fourth end portions also serving to form electrical connections to the conductor members of other winding segments.

According to a further aspect of the present invention, a winding carrier, that is to say a stator or a rotor, is provided for an electrical machine which has at least one winding which is formed from at least one winding segment described above.

According to yet another aspect of the invention, an electrical machine is provided which has a winding support with at least one winding, wherein the at least one winding is formed from at least one winding segment described above.

• – Bereitstellen eines ersten, elektrisch leitenden stabförmigen Leiterelements zur Bildung der Wicklung,
• – Befestigen eines eigenständig mechanisch stabilen Isolierelements zur elektrischen Isolierung und zur Stärkung der mechanischen Stabilität des ersten Leiterelements an dem ersten Leiterelement zur Bildung eines Wicklungssegments, wobei das Isolierelement das das erste Leiterelement umfangsmäßig umschließt, und
• – Einfügen des Wicklungssegments, das das erste Leiterelement und das Isolierelement umfasst, nach dem Schritt des Befestigens in ein Blechpaket zur Bildung der Wicklung.

According to still another aspect of the present invention, there is provided a method of manufacturing a winding for a coil carrier, that is, a stator or a rotor, an electric machine. The method comprises the following method steps:

• Providing a first electrically conductive rod-shaped conductor element to form the winding,
• - Fixing an independently mechanically stable insulating element for electrical insulation and for strengthening the mechanical stability of the first conductor element to the first conductor element to form a winding segment, wherein the insulating surrounding the first conductor element circumferentially, and
• - inserting the winding segment comprising the first conductor element and the insulating element, after the step of fastening in a laminated core to form the winding.

In order to form the winding, a first electrically conductive rod-shaped conductor element is thus provided. On the first conductor element, an independently mechanically stable insulating element is attached, which also serves to strengthen the mechanical stability of the first conductor element and encloses the first conductor element and thus electrically insulated. After attaching the insulating member to the first conductor member, the first conductor member and the insulating comprehensive winding segment is inserted to form the winding in a laminated core.

According to a preferred embodiment of the method, the insulating element is formed by injection molding a casting compound around the first conductor element and at the same time attached to the first conductor element.

According to a further preferred embodiment of the method is provided according to the method step of providing that, in addition to the first conductor element, a second electrically conductive rod-shaped guide element for forming the winding is provided. According to the method step of fastening, it is further provided that the insulating element is attached to the first conductor element and to the second conductor element for forming the winding segment, wherein the insulating element surrounds the first and the second conductor element circumferentially. In this case, the insulating member is used for electrical insulation of the first and second conductor element from each other and from the laminated core and to strengthen the mechanical stability in the first and the second conductor element. According to the inserting step, it is further provided that the winding segment comprising the first and second conductor element and the insulating element is inserted into the laminated core after the insulating element has been secured to the first and second conductor elements to form the winding.

According to yet a preferred embodiment, the insulating element is formed by injection molding of the casting compound around the first and the second conductor element.

Advantageous embodiments of the winding segment described above, as far as applicable to the above-mentioned winding support, the above-mentioned electric machine or the method described above, also be regarded as advantageous embodiments of the winding support, the electric machine or the method.

In the following, exemplary embodiments of the invention are explained in more detail with reference to the accompanying drawings. Show it:

1 an electrical machine according to an embodiment of the invention in a schematic cross-sectional view;

2 a stator of in 1 illustrated electrical machine in a schematic bird's eye view;

3 a winding segment of a winding of the in 3 illustrated stator in a schematic bird's eye view; and

4 a process for the preparation of in 3 shown winding segments in a schematic diagram.

First, it will open 1 referenced, in which an electrical machine EM according to an embodiment of the invention is shown in a schematic cross-sectional view. The electric machine EM comprises a housing GH, in which a winding support ST designed as a stator is arranged in a rotationally fixed manner in the housing GH with respect to the housing GH. The electric machine EM further comprises a rotor RT with a rotor shaft RW, which is rotatably mounted in the housing GH via two shaft bearings WL relative to the stator ST.

A detailed illustration of a portion of the stator ST is shown in FIG 2 displayed.

In this case, the stator ST comprises a laminated core BP, which is hollow-cylindrical. The laminated core BP has a number of Blechpaketpolnuten NT, which are uniformly distributed in the direction of the cylinder axis AS on one of the cylinder axis AS facing inside of the laminated core BP from one axial end of the laminated core BP to another axial end of the laminated core BP extending. In the laminated core pole slots NT, the stator ST has windings WL formed of a number of winding segments WS in the manner to be described later. The number of winding segments WS corresponds to the number of Blechpaketpolnuten NT or the number of poles so a two times the number of pole pairs of the stator ST.

One of the winding segments WS is in 3 shown in detail, wherein in the left half of the figure A, the winding segment WS in its original form and in the right half of the figure Winding segment WS is shown schematically in a state of a fully developed winding WL.

As shown in the left half of the figure A, the winding segment WS in its original form comprises a first conductor element L1 and a second conductor element L2 and an insulating element IS surrounding the first and the second conductor element L1, L2 circumferentially and mechanically interconnected.

In this case, the two conductor elements L1, L2 are rod-shaped and have an equal length. Depending on requirements, the two conductor elements L1, L2 can also be designed differently long. In addition, the two conductor elements L1, L2 are arranged spatially next to each other but spaced from each other.

The insulating element IS is formed by injection molding a casting compound around the two conductor elements L1, L2. The casting compound used consists of an electrically insulating material, so that the insulating element IS after hardening the two conductor elements L1 and L2 from each other and electrically isolated from the environment.

After hardening, the casting compound also forms the insulating element IS, which forms an H-shaped insulating body with a central main section HA as a "fuselage" and two sections TA1, TA3 and TA2, TA4 extending from the main section HA along the two conductor elements L1, L2 as "limbs" (that is, as from the main portion HA outgoing portions) on each one of the two sides of the main section HA has. In this case, the insulating element IS preferably has a higher material thickness or thickness in the main section HA than in the four sections TA1, TA3, TA2 and TA4. As a result, the insulating element IS in the main section HA higher independent mechanical stability than in the four sections TA1, TA3, TA2 and TA4, whereby the two conductor elements L1, L2 of this main section HA can be held together with sufficient mechanical forces. Conversely, the insulating element IS has a certain elasticity in the four sections TA1, TA3, TA2 and TA4, so that the four sections TA1, TA3, TA2 and TA4 can also be bent when bending or interleaving the conductor elements L1, L2, without to break apart.

The two conductor elements L1, L2 are cast over by the casting compound in such a way that a first end region EB1 and a second end region EB2 of the first conductor element L1 and a third end region EB3 and a fourth end region EB4 of the second conductor element L2 are not separated from the casting compound or the insulating element IS are covered. These four end regions EB1, EB2, EB3 and EB4 are used for electrical connection with other winding segments to form the winding WL.

In a ready-made state of the stator ST, the winding segment WS or its two conductor elements L1, L2 together with the insulating element IS are inserted into a pole groove NT provided for this purpose.

In this case, the two conductor elements L1, L2 are respectively in an inner, the cylinder axis AS of the laminated core BP facing position of a pole groove NT and in an outer, the cylinder axis AS of the laminated core BP remote from the position of the pole groove NT. Viewed from the cylinder axis AS, the two conductor elements L1 and L2 thus lie radially one behind the other.

The main section HA of the insulating element IS is pressed together with the corresponding portions of the two conductor elements L1, L2 enveloped by this main section HA into the pole slot NT of the laminated core BP or lowered into it.

The four subsections TA1, TA3, TA2 and TA4 of the insulating element IS are, together with the sections of the two conductor elements L1, L2 and the four end regions EB1, EB2, EB3 and EB4 of the two conductor elements L1 enveloped by these subsections TA1, TA3, TA2 and TA4. L2 protrude from the pole groove NT and thus from the laminated core BP.

The two portions of the two conductor elements L1, L2 enveloped by the sections TA1, TA3 of the insulating element IS, together with the two sections TA1, TA3, are entangled with a spreading step corresponding to the winding step of the stator ST, as illustrated in the right half of FIG.

Analogously, the two sections of the two conductor elements L1, L2 enveloped by the sections TA2, TA4 of the insulating element IS, together with the two sections TA2, TA4, are entangled with a spreading step corresponding to the winding step of the stator ST. In this case, the two sections of the first conductor element L1 enveloped by the subsections TA1, TA2, together with the two subsections TA1, TA2, are entangled in two mutually opposite directions. Analogously, the two sections of the second conductor element L2 enveloped by the sections TA3, TA4, together with the two sections TA3, TA4, are entangled in two mutually opposite directions.

The first end region EB1 of the first conductor element L1 is directly electrically connected to a third end region EB3 'of a second conductor element L2' of another, corresponding to the winding step of the stator ST spaced from the winding segment WS winding segment WS 'arranged in the laminated core BP.

Analogously, the fourth end region EB4 of the second conductor element L2 is directly electrically connected to a second end region EB2 'of a first conductor element L1' of the other winding segment WS '.

The second end region EB2 of the first conductor element L1 and the third end region EB3 of the second conductor element L2 of the winding segment WS are each arranged with an end region of a further, corresponding to the winding step of the stator ST of the winding segment WS spaced in the laminated core BP, not shown in the figure Winding segment directly electrically connected.

Such an arrangement and such electrical connections of the winding segments WS continue over the entire laminated core BP and thus form a winding WL.

It is also possible to provide winding segments with three or more conductor elements and with an insulating element, the insulating element then peripherally enclosing the three or more conductor elements in the previously described manner, mechanically holding them together and electrically insulating them from each other and the environment.

A method for producing an in 3 shown winding segment WS is described below 4 explained in more detail.

First, according to a method step S100, a first and a second electrically conductive rod-shaped conductor element L1, L2 are provided. In this case, the two conductor elements L1, L2 are cut or punched from a metal wire or metal rail to the same or different predetermined final length.

Subsequently, according to a method step S200, an insulating element IS is fastened to the first and the second conductor element L1, L2. For this purpose, a casting compound made of an electrically insulating material is poured onto the two conductor elements L1, L2 in an injection molding process. After hardening, the casting compound forms the insulating element IS with an independent mechanical stability which electrically isolates and mechanically holds the two conductor elements L1, L2 apart from one another and from the environment. In this case, the two conductor elements L1, L2 are poured over to the respective two end regions EB1, EB2, EB3 and EB4 with the casting compound, so that the end regions EB1, EB2, EB3 and EB4 are not covered by the insulating element IS and are electrically insulated. The insulating element IS thus forms with the first and the second conductor element L1, L2 a one-piece and mechanically stable winding segment WS for forming a winding WL.

As an alternative to the method steps S100, S200 described above, two "endless" metal wires or metal rails may first be cast with the casting compound and, after the casting compound has hardened, be cut or punched in conductor elements L1, L2. Subsequently, the casting compound can be removed again at the four end regions EB1, EB2, EB3 and EB4 of the two conductor elements L1, L2, so that these four end regions EB1, EB2, EB3 and EB4 are not covered by the casting compound or the insulating element IS.

In an alternative embodiment, the insulating element IS can also be produced by extrusion of a viscous curable composition of an electrically insulating material. In this case, the mass can be applied in an extrusion process to the two conductor elements L1, L2 except for respective two end regions EB1, EB2, EB3 and EB4. After hardening, the mass then forms the insulating element IS.

Thereafter, the winding segment WS is inserted according to a method step S300 in a corresponding Polnut NT of a laminated core BP and then entangled in a manner known to those skilled in the winding step of the stator ST with spreading step and to form the winding WL with further according to the winding step spaced winding segments such previously described electrically connected.

With the method described above, it is also possible to produce winding segments with three or more conductor elements by means of slight adjustments that can be readily carried out by a person skilled in the art.

Claims (12)

 Winding segment (WS) for forming a winding (WL) of an electric machine (EM), which has the following features: - A first electrically conductive rod-shaped conductor element (L1) for forming the winding (WL), and An electrically insulating and independently mechanically stable insulating element (IS), which surrounds the first conductor element (L1) circumferentially and electrically isolated, - Wherein the insulating element (IS) is attached to the first conductor element (L1).  Winding segment (WS) according to claim 1, wherein the insulating element (IS) is positively, positively or materially secured to the first conductor element (L1). Winding segment (WS) according to claim 1 or 2, wherein the insulating element (IS) is formed as a molded around the first conductor element (L1) Spitzgußteil.  Winding segment (WS) according to claim 1 or 2, wherein the insulating element (IS) is attached by means of an adhesive connection to the first conductor element (L1).  A winding segment (WS) according to one of the preceding claims, wherein the insulating member (IS) surrounds the first conductor member (L1) circumferentially except for a first (EB1) and a second (EB2) end portion of the first conductor member (L1).  Winding segment (WS) according to one of the preceding claims, further comprising: A second electrically conductive rod-shaped conductor element (L2) for forming the winding (WL), - Wherein the insulating element (IS) surrounds the second conductor element (L2) circumferentially, and the first conductor element (L1) and the second conductor element (L2) mechanically connects to each other and electrically insulated from each other.  Winding support (ST) for an electrical machine (EM) having at least one winding (WL), wherein the at least one winding (WL) is formed from at least one winding segment (WS) according to one of the preceding claims.  Electric machine (EM), which has a winding support (ST) with at least one winding (WL), wherein the at least one winding (WL) is formed from at least one winding segment (WS) according to one of the preceding claims 1 to 6.  Method for producing a winding (WL) of an electric machine (EM), the method comprising the following method steps: Providing (S100) a first, electrically conductive rod-shaped conductor element (L1) for forming the winding (WL), Attaching (S200) an independently mechanically stable insulating element (IS) to the first conductor element (L1) to form a winding segment (WS) so that the insulating element (IS) surrounds the first conductor element (L1) circumferentially and electrically insulated, - Inserting (S300) of the winding segment (WS) after the step of fastening (S200) in a laminated core (BP) to form the winding (WL).  The method according to claim 9, wherein the step of fixing (S200) further provides that the insulating member (IS) is molded by injection molding a molding compound around the first conductor member (L1).  Method according to claim 9 or 10, - wherein the step of providing (S100) further provides that a second electrically conductive rod-shaped conductor element (L2) is provided to form the winding (WL), and The step of fastening (S200) further provides that the insulating element (IS) for forming the winding segment (WS) is fastened to the first conductor element (L1) and the second conductor element (L2) such that the insulating element (IS) is the first one (L1) and the second (L2) conductor element circumferentially encloses, mechanically interconnects and electrically isolated from each other, and - the step of inserting (S300) further provides that the winding segment (WS) of the first (L1) and the second (L2) conductor element and the insulating element (IS) after the step of fastening (S200) to form the winding (WL ) is inserted into the laminated core (BP).  Method according to claim 11, - wherein the step of fixing (S200) further provides that the insulating member (IS) is formed by molding the molding compound around the first conductor member (L1) and the second conductor member (L2).

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