DE102014203945A1 - Stator element for constructing a stator assembly for an electrical machine, stator assembly and method for constructing a stator assembly - Google Patents

Abstract

The invention relates to a stator element for constructing a stator arrangement (3) and a stator arrangement (3) for a polyphase electrical machine (1), wherein the stator element comprises at least one stator tooth (31) which is produced by compression from a soft magnetic composite material, wherein the Stator element is further adapted to be assembled with at least one further stator element to the stator assembly (3).

Description

Technical area

The present invention relates to electric machines for drive units of motor vehicles, in particular machines with disc rotors. The invention further relates to stator arrangements for such electrical machines and to methods for producing stator arrangements.

State of the art

As machines with disc rotors trained electrical machines are characterized by a high power density at a comparatively low weight. For example, from the document WO 2009/115247 A1 a transverse flux machine with a disc rotor known. In a rotor disk of the disk rotor permanent magnets are embedded at a constant distance from a rotation axis, which are magnetized in the circumferential direction. Adjacent permanent magnets are magnetized opposite to each other, so that the mutually facing poles of two adjacent permanent magnets are each similar. The field lines between these similar poles are thus superimposed so that a rotor magnetic field propagating in the axial and radial directions from the pole gap is generated.

The disk rotor is arranged axially between two stator arrangements, each having a stator winding extending around a motor axis. To each of the stator windings offset radially inwardly and outwardly, each of the stator assemblies has circumferentially extending and projecting toward the disk rotor inner and outer stator teeth.

When current is applied to the stator winding of a stator arrangement, a force acts on the magnetic poles of the disk rotor in the direction of the magnetic pole of the opposite magnetization of the stator magnet, by which a torque dependent on the rotor position as well as magnitude and sign of the stator current can be generated.

A particularly cost-effective variant for the production of base bodies for machine components consists in a pressing and subsequent heat treatment of a soft magnetic powdery composite material (WMV, Soft Magnetic Composite, SMC). However, the stator core assemblies for disc rotor machines are typically too large and overly complex to produce with satisfactory economy and quality in terms of sufficient magnetic and mechanical properties by pressing and heat treating a WMV material.

It is therefore an object of the present invention to provide a stator assembly for a machine with disc rotors available that can be produced as reliably and with little effort.

Disclosure of the invention

The above object is achieved by a stator element for constructing a stator assembly for a polyphase electric machine according to claim 1, and by a stator assembly for a polyphase electric machine and a method for manufacturing a stator assembly according to the independent claims.

Further embodiments are specified in the dependent claims.

According to a first aspect, a stator element is provided for constructing a stator assembly for a multi-phase electric machine, in particular for a machine with a disc rotor, wherein the stator element comprises at least one stator tooth, which is produced by compression of a soft magnetic composite, wherein the stator element is further formed is to be assembled with at least one further stator element to the stator assembly.

According to another aspect, a stator assembly for a multi-phase electric machine, in particular for a machine with a disc rotor, is provided, wherein the stator assembly comprises a plurality of stator segments formed as stator, wherein a plurality of the stator elements at their tangential ends by gluing, welding, soldering, pressing or are connected together by means of mechanical connections with rivets, pins or screws to form an annular stator assembly with axially projecting stator teeth.

According to a further aspect, a stator arrangement is provided for a multi-phase electric machine, in particular for a machine with a disk rotor, wherein the stator arrangement has a plurality of stator elements formed as stator segments, wherein abutting tangential ends of adjacent stator segments are provided with corresponding steps, so that their overlapping areas interlock to form an annular stator assembly having axially projecting stator teeth.

According to a further aspect, a stator arrangement is provided for a multi-phase electric machine, in particular for a machine with a disk rotor, wherein the stator arrangement has a plurality of stator elements formed as stator segments, wherein abutting tangential ends of adjacent stator segments are provided with corresponding steps, so that their overlapping areas for engaging the stator segments engage one another, wherein the at least one recess of the overlapping region of one of the plurality of stator segments wholly or partially receives the cross section of the base of at least one of the stator teeth of another of the plurality of stator segments.

According to a further aspect, a stator arrangement is provided for a multi-phase electric machine, in particular for a machine with a disk rotor, wherein the stator arrangement comprises a plurality of stator elements formed as stator tooth elements, in particular the stator elements designed as stator tooth elements, wherein a base body made of a soft magnetic material is, on, on or in which the stator tooth elements are arranged by force and / or form and / or material connection.

One idea of the above stator arrangements is to build them from individual stator elements. The stator elements may be inserted into or interconnected with a body to provide an annular stator assembly having axially projecting stator teeth. The connection of the stator elements with each other or with the base body can be achieved by a suitable fastening. In particular, when manufacturing the stator elements from a WMV material, these can be produced in a simple manner. In addition, the effort in the manufacture of a stator assembly of WMV material can be reduced because the stator segments represent significantly smaller components than the entire stator.

Furthermore, the stator element may be formed as a stator segment, which has a ring-segment-shaped return area and one or more stator teeth projecting on one side of the return area.

According to one embodiment, the stator segment may have a step with an overlap region at at least one tangential end in order to overlap a region of the side provided with the stator teeth or the side opposite thereto when assembled with the at least one further stator element formed as a stator segment.

It can be provided that the stator segment has a step with an overlap region at at least one tangential end in order to overlap a region of the side provided with the stator teeth when assembled with the further stator segment, the overlapping region having at least one recess with a contour to receive a cross section of the base of a stator tooth of another stator segment in whole or in part.

Furthermore, the stator segment can have corresponding steps with respective overlapping areas at both tangential ends, so that when combined with a similar further stator segment, the steps intermesh with each other.

According to one embodiment, the overlapping region may be provided with at least one tab which projects radially inwards and / or outwards from the overlapping region.

Furthermore, the stator element may be formed as a stator tooth element which is provided with a fastening device at its base, which corresponds to an end region associated with the return region, in order to be arranged on or in a soft-magnetic base plate designed as a return region.

In particular, the fastening device of the stator tooth element can connect to the base of the stator tooth to be formed and taper at its base and / or have a stop edge.

Furthermore, the stator tooth elements can be attached to the base plate by gluing, welding, soldering and / or pressing.

It can be provided that connect the fastening means of the stator tooth elements to the base of the respective stator tooth. The attachment means may be tapered and / or have a stop edge, wherein the attachment means are received in the body or pass therethrough.

According to a further aspect, a method for producing the above stator arrangement is provided, wherein a plurality of stator elements formed as stator segments are connected together at their tangential ends by gluing, welding, soldering, pressing or by mechanical connections with rivets, pins or screws.

According to a further aspect, a method for producing the above stator arrangement is provided, wherein a plurality of stator elements designed as stator tooth elements are arranged on, on or in a basic body of a soft magnetic material by force, form and / or material connection.

Brief description of the drawings

Embodiments are explained below with reference to the accompanying drawings. Show it:

1a to 1c Representations of different views of a multi-phase electric machine with a disc rotor;

2 a perspective view of an annular stator assembly having projecting stator teeth in the axial direction;

3a to 3c different views of a stator formed as a stator element;

4 a possibility of connecting stator segments by nesting;

5a and 5b a possibility of fixing stator segments by forming tabs;

6 a section of a stator assembly, which is made by inserting stator tooth elements in a base body; and

7a to 7c various possibilities for attaching stator tooth elements to a stator yoke ring.

Description of embodiments

The 1a . 1b and 1c show cross-sectional views of a three-phase electric machine 1 , which in this embodiment as an electric machine with a disc rotor 2 is trained. The electric machine 1 may correspond to a pancake machine such as a transverse flux machine. 1a shows a radial plan view of a cross section in the circumferential direction, 1b a cross-sectional view in the tangential direction and 1c a perspective view of a section of one of the stator assemblies 3 ,

The electric machine 1 includes two stator arrangements 3 between which the disc rotor 2 is arranged rotatably about an axis of rotation which extends along an axial direction A. The disc rotor 2 is formed of a magnetically and electrically non-conductive material, such as a carbon fiber composite material or the like, and includes an annular magnetically active device, for example in the form of embedded therein, annularly arranged, individual permanent magnets 4 , annularly arranged, individual soft magnetic elements or a circumferential electrically conductive ring.

In the embodiment shown, the permanent magnets 4 along an annular ring magnet arrangement in the disc rotor 2 provided, wherein the permanent magnets 4 are spaced apart in the magnetic ring in a circumferential direction U from each other.

The polarization of the permanent magnets 4 is aligned in the magnetic ring arrangement in the circumferential direction U, wherein the polarizations of each two adjacent in the circumferential direction U permanent magnet 4 are opposite to each other, so that each homopolar magnetic poles face each other. The mutually in the circumferential direction U facing magnetic poles of the permanent magnets 4 Form rotor poles with a resulting magnetic field, which extends from the area between each two magnetic poles of the permanent magnets 4 in the radial direction R and axial direction A from the disk rotor 2 extends.

It can also be provided two or more than two magnetic ring arrangements, wherein the magnetic ring arrangements can be preferably concentric. In this case, the radial width of each magnetic ring assembly is substantially identical, and preferably the number of permanent magnets 4 in each of the magnetic ring arrangements also the same.

The stator arrangements 3 are arranged opposite each other, wherein the disc rotor 2 freely rotatable so between the stator assemblies 3 is arranged that through the permanent magnets 4 the magnetic ring arrangement formed rotor poles between stator teeth 31 the stator arrangements 3 run.

The stator teeth 31 are in each of the stator arrangements 3 annular along a stator tooth arrangement 36 arranged so that the Statorzahnanordnungen 36 both stator arrangements 3 opposite each other. The stator tooth arrangements 36 both stator arrangements 3 preferably have the same radial width and face each other in the axial direction A.

The stator teeth 31 form together with a magnetic yoke area 35 one Stator body of magnetically conductive material. The stator teeth 31 are each in the axial direction A, ie in the direction of the axis of rotation of the disc rotor 2 projecting from the stator body, ie formed as projections.

The stator teeth 31 extend in the radial direction R possible over the entire radial width of the permanent magnets 4 in the disc rotor 2 , where the stator teeth 31 in the circumferential direction U through gaps 32 are spaced from each other to therein winding strands of the stator windings 34 each with one or more winding wires (depending on the number of turns) record. At every stator arrangement 3 There are a number of separate stator windings 34 that is the number of phases of the machine 1 equivalent.

Each associated with a phase stator windings 34 are with respect to the opposing stator arrays 3 each offset in the circumferential direction U to each other. In this way, the field lines in the air gap resulting from the superposition of the permanent magnets 4 in the disc rotor 2 and from the stator windings 34 in the stator arrangements 3 produced magnetic fields and cause the formation of the engine torque, substantially obliquely to the axial direction A and in the circumferential direction U inclined to the axial direction A extend, that is substantially transversely to the magnetization direction of the permanent magnets 4 ,

As in particular in the 1c can be seen, the stator teeth 31 in the embodiment shown, a radial cross-section R in the longitudinal direction (with respect to the axial direction A), which can taper in the radial direction R inwardly. Radial inner and outer ends 37 . 38 the stator teeth 31 may be rounded so that the corresponding winding strand of the corresponding stator winding 34 can be created at the request to the course of the rounding.

The gaps 32 between the stator teeth 31 serve to magnetically separate the stator teeth from each other and the stator windings 34 take. The winding strands of the stator windings 34 The individual phases are loop-shaped around the stator teeth 31 guided. The height of the stator teeth 31 in the axial direction A is chosen so that at least for each phase of the winding phase of the corresponding stator winding 34 can be inserted. As in 1c the example of the three-phase electric machine 1 is the height of the stator teeth 31 in the axial direction A sufficient to three layers of stator windings 34 to arrange one above the other.

For the operation of the stator assembly 3 it is necessary to form these from a soft magnetic material. However, the size of the stator assemblies is 3 for machines with disc rotors usually too large to be able to produce such a stator assembly with sufficient yield and sufficient tolerance accuracy in one piece. Therefore, it is provided, the stator assembly 3 build up from several individual stator elements.

To build a stator assembly 3 the embodiment of the 1a to 1c separately in 2 is shown in perspective, for example, the stator segment 40 that in the 3a to 3c shown in different views. The 2 shows the stator assembly 3 with an annular return area 35 as the main body and thereon arranged in the axial direction A projecting stator teeth 31 ,

The stator element of 3a to 3c corresponds to a stator segment 40 , which is shaped according to a ring segment. In this way, from several such stator segments 40 the stator assembly 3 be formed.

To ensure stable attachment of the individual stator segments 40 To ensure at their tangential ends (at their pointing in the circumferential direction U ends), these can be connected to each other by suitable connection methods. So can the stator segments 40 by gluing, welding, soldering, pressing or by mechanical connections with rivets, pins or screws.

In particular, to increase the bonding area between two stator segments 40 at least at a tangential end of the stator segments 40 a grading 41 provided, which when fitting to a corresponding tangential end of another stator segment 40 those with the stator teeth 31 provided side or the opposite side of the yoke area 35 overlaps accordingly. In the overlap area 42 can then be a connection in the manner described above, in particular by gluing, welding, soldering, pressing or by mechanical connections with rivets, pins or screws, can be achieved.

Are the gradations 41 at both tangential ends of the stator segment 40 provided, they should be designed to be complementary, so that they when assembling the stator segments 40 for forming the annular stator assembly 3 interlock and form the largest possible interface.

To the largest possible overlap by grading 41 To obtain an overlap area 42 which overlaps or overlaps a corresponding area of the stator teeth 31 provided side of the conclusion area 35 is formed, with a recess 43 be provided, the neck or the shape of a part of the cross section or the entire cross section of a stator tooth 31 equivalent. By connecting two stator segments 40 then joins the relevant tangential end of the stator segment 40 next stator tooth 31 with the contour of its base in the recess 43 so that the overlap area 42 the corresponding area of the stator teeth 31 provided side of the conclusion area 35 overlaps.

Affects the recess 43 the entire cross section of a stator tooth 31 at its base (and thus provides a passage opening in the overlapping area 42 dar), so can the joining of stator segments 40 no longer be achieved by moving against each other in the tangential direction. Rather, a stator tooth 31 at a tangential end of a stator segment 40 through the corresponding recess 43 of the overlap area 42 by an axial movement relative to each other, so that a load on tangential train connection can be created, as for example in the sectional view of 4 is shown. Of course it is possible the overlap area 42 to provide also in a tangential length, in which several recesses 43 (in the example of the 4 two recesses 43 ) for receiving stator teeth 31 another stator segment 40 are provided.

As in the 5a and 5b is shown, at least one tangential end of the stator segment 40 with at least one in the radial direction R inwardly and / or outwardly from the yoke region 35 protruding tab 44 be provided. Preferably, the at least one tab 44 integral with the inference area 35 educated. When connecting two stator segments 40 then can the tabs 44 , as in 5b shown, are flanged so that the two stator segments 40 be connected by force and / or positive connection with each other.

The return region of the stator segments 40 may be preferably provided as a ring segment with a segment angle which is suitable, an integer number of identical stator segments 40 to the stator assembly 3 to connect with each other. For example, the inference areas 35 with segment angles of between 10 and 90 °, in particular between 45 ° and 60 °, are provided, wherein the overlap region 42 is disregarded in the determination of the segment angle. Of course, the stator segments 40 also be provided with different segment angles, which are so selected and assembled that a complete ring of the stator assembly 3 is formed.

Preferably, the segment angle of the stator segments 40 to choose so that the stator segments 40 have a size in which they can be integrally formed, for example, by pressing a soft magnetic composite material and then sintering.

In 6 is a section of a stator assembly 3 which is a stator arrangement of the 1a to 1c corresponds, shown in a further structure. The structure of the 6 includes a separately formed annular yoke region 35 in the form of a soft magnetic base plate 51 (Basic body) is formed. The base plate 51 can be formed of iron, steel or an electrical sheet or laminated core (stacked in the axial or radial direction A). The electric sheet can be easily produced by a punching process.

The stator elements 40 for the construction of the stator arrangement 3 are in this case only as individual stator tooth elements 52 formed in an appropriate manner in or on the base plate 51 are arranged. Basically, as Statorzahnelemente 52 trained stator elements 40 by traction and / or positive locking and / or material connection on, or in the base plate 51 be arranged.

The stator tooth elements 52 can be molded from a powdery soft magnetic composite (WMV) material and made by compression and subsequent sintering. Due to the small volume and simple geometry of similar stator tooth elements made in this way 52 High densities and thus very good magnetic properties and strengths are possible. In addition, such a manufacturing process for Statorzahnelemente 52 Cheap. Furthermore, the stability of a stator assembly produced in this way 3 be improved because the base plate 51 can be made of another more dimensionally stable and robust material and does not necessarily have to be made of a compressed soft magnetic composite material.

For example, in 7a illustrated as an embodiment of the stator tooth element 52 in a corresponding recess 53 the base plate 51 used and held there by traction. This is the stator tooth element 52 at one in the depression 53 the base plate 51 inserted end, which serves as a fastening device and to the base of the stator tooth 31 joins, trained to rejuvenate. The attachment of the stator tooth element 52 in the base plate 51 is determined by the corresponding press-in pressure of the Statorzahnelements 52 in the base plate 51 reached.

In 7b is shown a positive connection, wherein a further embodiment of a Statorzahnelements 52 through a passage opening 54 in the base plate 51 is plugged in and by a suitable stop edge 55 or an undercut on the stator teeth 31 opposite side of the base plate 51 is held at this. The stop edge 55 or the undercut thus formed serve as fastening means of the stator tooth element 52 ,

In 7c is shown as an embodiment of a stator tooth element 52 on a surface of the base plate 51 attached by material connection. For example, the Storzahnelement 52 be held by welding or gluing.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• WO 2009/115247 A1 [0002]

Claims (16)

Stator element ( 40 . 52 ) for constructing a stator arrangement ( 3 ) for a multi-phase electric machine ( 1 ), wherein the stator element ( 40 . 52 ) at least one stator tooth ( 31 ), which is produced by compression of a soft magnetic composite material, wherein the stator element ( 40 . 52 ) is further adapted to be connected to at least one further stator element ( 40 . 52 ) to the stator assembly ( 3 ) to be put together. Stator element ( 40 ) according to claim 1, wherein the stator element as a stator segment ( 40 ) is formed, which has a ring segment-shaped return region ( 35 ) and one or more on a in the axial direction (A) facing side of the return region ( 35 ) projecting stator teeth ( 31 ) having. Stator element ( 40 ) according to claim 2, wherein the stator segment ( 40 ) at at least one tangential end a graduation ( 41 ) with an overlap area ( 42 ) in order, when assembled with the at least one other as a stator segment ( 40 ) formed stator element a region of the stator teeth ( 31 ) side or overlap this opposite side. Stator element ( 40 ) according to claim 2, wherein the stator segment ( 40 ) at at least one tangential end a graduation ( 41 ) with an overlap area ( 42 ) in order, when assembling with the further stator segment ( 40 ) a region of the stator teeth ( 31 overlapped side, the overlapping area ( 42 ) at least one recess ( 43 ) having a contour to form a cross-section of the base of a stator tooth ( 31 ) of another stator segment ( 40 ) in whole or in part. Stator element ( 40 ) according to claim 3 or 4, wherein the stator segment ( 40 ) at both tangential ends corresponding steps ( 41 ) with respective overlapping areas ( 42 ), so that when assembled with a similar further stator segment ( 40 ) the gradations ( 41 ) mesh. Stator element ( 40 ) according to one of claims 2 to 5, wherein the overlapping area ( 42 ) with at least one tab ( 44 ) provided by the overlap area ( 42 ) protrudes in the radial direction (R) inwardly and / or outwardly. Stator element ( 52 ) according to claim 1, wherein the stator element ( 52 ) as a stator tooth element ( 52 ) is formed at its base, the one the conclusion area ( 35 ) is provided with a fastening device, in order on or in as a conclusion region ( 35 ) formed soft magnetic base plate ( 51 ) to be arranged. Stator element ( 52 ) according to claim 7, wherein the fastening means of the stator tooth element ( 52 ) to the base of the stator tooth ( 31 ) and tapers at its base and / or a stop edge ( 55 ) having. Stator arrangement ( 3 ) for a multi-phase electric machine ( 1 ), wherein the stator arrangement ( 3 ) more than stator segments ( 40 ) formed stator elements according to one of claims 2 to 6, wherein a plurality of the stator elements are connected together at their tangential ends by gluing, welding, soldering, pressing or by mechanical connections with rivets, pins or screws to an annular stator assembly ( 3 ) with stator teeth projecting in the axial direction (A) ( 31 ) to build. Stator arrangement ( 3 ) for a multi-phase electric machine ( 1 ), wherein the stator arrangement ( 3 ) more than stator segments ( 40 ) formed stator elements according to claim 3 or 4, wherein abutting tangential ends of adjacent stator segments ( 40 ) with corresponding gradations ( 41 ), so that their overlapping areas ( 42 ) for connecting the stator segments ( 40 ) engage one another to form an annular stator assembly ( 3 ) with axially projecting (R) stator teeth ( 31 ) to build. Stator arrangement ( 3 ) for a multi-phase electric machine ( 1 ), wherein the stator arrangement ( 3 ) more than stator segments ( 40 ) formed stator elements according to claim 4 or 5, wherein abutting tangential ends of adjacent stator segments ( 40 ) with corresponding gradations ( 41 ), so that their overlapping areas ( 42 ), wherein the at least one recess ( 43 ) of the overlap area ( 42 ) one of the several stator segments ( 40 ) the cross-section of the base of at least one of the stator teeth ( 31 ) of another of the multiple stator segments ( 40 ) in whole or in part. Stator arrangement ( 3 ) for a multi-phase electric machine ( 1 ), wherein the stator arrangement ( 3 ) more than Statorzahnelemente ( 52 ) formed stator elements ( 52 ), in particular stator elements ( 52 ) according to claim 7, wherein a base body made of a soft magnetic material is provided on, on or in which the stator tooth elements ( 52 ) are arranged by force, shape and / or material connection. Stator arrangement ( 3 ) according to claim 12, wherein the stator tooth elements ( 52 ) by gluing, welding, soldering and / or pressing on the base plate ( 51 ) are attached. Stator arrangement ( 3 ) according to claim 12, wherein the fastening means of the stator tooth elements ( 52 ) to the base of the respective stator tooth ( 31 ) and are tapered and / or a stop edge ( 55 ), wherein the fastening means are received in the body or pass therethrough. Method for producing a stator arrangement ( 3 ) according to one of claims 9 to 11, wherein a plurality of stator segments ( 40 ) formed stator elements ( 40 ) according to one of claims 2 to 6 at their tangential ends by gluing, welding, pressing or by mechanical connections with rivets, pins or screws are interconnected. Method for producing a stator arrangement ( 3 ) according to one of claims 12 to 14, wherein a plurality of stator tooth elements ( 52 ) formed stator elements ( 52 ) are arranged according to claim 7, on or in a base body made of a soft magnetic material by force, form and / or material connection.

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