DE102015201630A1 - Winding arrangement and electrical machine with such a winding arrangement - Google Patents

Abstract

In order to improve a winding arrangement (100) for an electrical machine (103) such that an increase in the efficiency and the power density in a compact design is achieved in the electrical machine (103), a winding arrangement (100) formed with at least one electrical conductor is produced. for the electric machine (103), in particular a stator (101) of this electric machine (103), which has a magnetic yoke (102) with a predetermined, along a circumferential direction (107) of the magnetic yoke (102) with each other, in particular uniformly, a plurality of slots (104) arranged at a predetermined number of slots, comprising a predetermined number of coils (105) each having two groove regions (108) formed at intervals spaced by two groove spacings, and two respective winding heads (109) bridging these two groove spacings ).

Description

The invention relates to a winding arrangement formed with at least one electrical conductor for an electrical machine. The invention further relates to an electrical machine with such a winding arrangement.

State of the art

From the publication DE 10 2009 024 230 A1 a method is known for producing a stator winding of an electric machine, in particular an AC generator, wherein the stator winding has at least n phase windings and a phase winding has a plurality of directly successive wound coils with coil sides and coil side connectors, the coils being divided into first coils and second coils, with a forming tool, in which grooves are present, which are suitable to receive the coils, wherein a first coil in a groove and a second coil is arranged in a different groove. Between the first coil and the second coil n - 1 grooves are arranged.

The publication DE 10 2009 024 230 A1 shows further that the coils in a groove portion and in it to winding head areas of the coil subsequent transition areas embossed, ie deformed such that the wires of the coil no longer have a round cross-section, but the outer contour of the entirety of all coil sides has a trapezoidal envelope. This trapezoidal contour is shaped in the same shape over the entire section that will be inserted into a groove of a stator iron. At each of the end positions of this section, one of the transitional areas begins, which is a few millimeters long. At the end of each of these transition regions facing away from this section, the latter transitions into a cross section in that the wires of the coil have a round cross section. In this case, the transition region is defined and represents a contour which, in relation to the electrical machine in the axial direction, ie in the direction of the axis of rotation of the rotor, continuously changes from the trapezoidal cross section into the round cross section of the individual wires. For embossing the coils are inserted into an embossing groove and embossed by means of a stamping die. The embossing can also be carried out in such a way that all phase windings with all their coil sides are formed simultaneously in an embossing tool. By reshaping the round in the initial state wire is sought that the winding head is not radially increased.

DESCRIPTION OF THE INVENTION: Problem, Solution, Advantages

The invention has the object to improve a winding arrangement for an electrical machine such that in the electric machine, an increase in the efficiency and the power density can be achieved in a compact design.

This object is achieved by a winding arrangement formed with at least one electrical conductor for an electrical machine, in particular a stator of this electric machine having a magnetic yoke with a predetermined along a circumferential direction of the magnetic yoke with each other, in particular uniform, predetermined groove intervals arranged number of grooves comprising a predetermined number of coils, each having two for insertion in spaced by two groove intervals selected grooves of the groove regions and two each of these two groove spacers bridging end windings.

The coils include groove areas and winding heads. Each coil is formed by a conductor which is alternately guided by the Nutbereiche and the winding heads of the coil. Thus, a coil is composed of a juxtaposition of sections of the conductor forming it, also referred to as winding sections together. The groove areas of the coil are composed of winding sections of these groove areas, and the winding heads of the coil are composed of winding sections of the winding heads. Thus, each groove portion and each winding head of a coil comprises a conductor or a conductor bundle.

In this case, the winding portions of the groove portions are those portions of the electrical conductors of the coils, which are adapted to be inserted into one of the grooves of the magnetic yoke. The winding heads are formed by those portions of the electrical conductors of the coils, ie winding sections, which are designed to be guided outside of the slots in the axial direction of the magnetic yoke in front of or behind this. An electrical conductor wound into a coil thus has along its longitudinal extension, which in operation is its main current flow direction, alternately winding sections of the groove areas and winding sections belonging to a winding head. In a coil wound according to the invention, the electrical conductor along its longitudinal extent in a mounted state in the magnet yoke with a first winding portion of a groove portion in a first groove, with an adjoining winding portion in a first winding head, with an adjoining second winding portion of a groove portion in a second Groove, with an adjoining Winding portion in a second winding head, with an adjoining third winding portion of a groove portion again in the first groove, etc. out. In this case, the first and the second groove are spaced apart by two groove distances, ie they skip a groove in a slot pitch of the magnetic yoke. The guided in the winding heads winding sections are accordingly dimensioned so that the winding heads over these two groove distances lead.

The winding arrangement according to the invention makes it possible to achieve a high winding factor. The winding factor indicates how well an ideal spatial field course is actually approximated by the electric machine with the winding arrangement. In the case of the winding arrangement or machine according to the invention, this is a sinusoidal field profile. The winding factor is a parameter determining a power density in the machine. The winding factor thus describes a harmonic content of the spatial field profile. Harmonic waves are the cause of parasitic effects, e.g. Vibrations of the machine during operation or additional power losses.

In a winding arrangement or a coil contribute to the generation of torque during operation of the equipped with this winding arrangement or coil electric machine only the currents in the winding sections of the groove areas, not against the guided in the winding heads winding sections. In addition, additional power losses occur in the winding sections guided in the winding heads. Therefore, it is advantageous if the guided in the winding heads winding sections can be kept as short as possible. Furthermore, long lengths of the winding sections guided in the winding heads cause the winding heads to take up a large amount of installation space. If the installation space for the electrical machine as a whole is limited, further construction elements of the electrical machine then have to be reduced, in particular a length of the magnetic yoke in its axial direction, in particular a stator length. This shortens the groove areas and consequently also reduces the effective power of the machine.

With the inventively constructed winding arrangement, i. the winding scheme, now on the one hand, a high winding factor and thus a high power density of the electric machine is achieved at a harmonic content, which allows a sufficiently low-loss and low-noise operation. On the other hand, the invention makes it possible to reduce the dimensions of the winding heads and the length of the winding sections guided in the winding heads and thereby to increase the power of the machine. In addition, the inventive design of the winding arrangement allows at least substantial plug-in mounting of the coils in the grooves of the magnetic yoke, whereby the production simplified and cheaper while increasing the product quality, i. the likelihood of manufacturing errors and manufacturing damage is reduced. In particular, the inventive construction of the winding arrangement represents an optimal combination of a high winding factor, low line losses in the winding heads and a large length dimension of the groove areas.

Advantageous embodiments of the invention are characterized in the subclaims.

According to a preferred development of the winding arrangement according to the invention, the groove areas of the coils are formed with at least two circumferentially juxtaposed conductors or with at least two circumferentially juxtaposed, extending in the radial direction of the magnetic yoke rows of conductors, i. the conductors or the rows of conductors are shaped so that they can be inserted into the grooves in a magnetic yoke of the type mentioned in the described orientation. With an arrangement of at least two conductors adjacent to one another in a groove in the circumferential direction, a reduction in power losses caused by current displacement, in particular current displacement by field components which penetrate the slots in the longitudinal direction, so-called slot-longitudinal field components, is advantageously achieved.

In a further preferred embodiment of the winding arrangement according to the invention, the groove areas of the coils are arranged with exactly two circumferentially adjacent, arranged in the radial direction of the magnetic yoke series of conductors and form in particular for each of the coils in the circumferential direction facing each other rows of conductors together with associated conductors in the winding heads an inner coil and form the circumferentially facing away from each other rows of conductors together with associated conductors in the winding heads an outer coil. In the assembled state, each of the coils is thus wound such that the conductors of the outer coil are guided around the inner coil as seen from a center of the inner coil. The center of the inner as well as the outer coil is an imaginary center or center of gravity of a surface spanned and enclosed by the inner coil.

Admittedly, the effect of the current displacement caused by slot-longitudinal field components can be taken along Increasing the number of juxtaposed arranged in the circumferential direction, in the radial direction of the yoke extend decreasing rows of conductors, but thus decreases the so-called Kupferfüllfaktor in the grooves, ie the percentage of cross-sectional areas of all conductors, ie all winding sections of Nutbereiche, a groove on the entire cross-sectional area of the groove, as insulation between the conductors is required. According to the invention, in the preferred arrangement of exactly two adjacent rows of conductors in the circumferential direction, an optimum match is achieved between the suppression of the losses caused by the current displacement and the achieved copper fill factor.

• • sind die Leiter innerhalb der Nutbereiche der Spulen in einer zum Einlegen in die Nut nach deren Querschnittskontur ausgestalteten räumlichen Anordnung zueinander ausgerichtet geführt,
• • sind die Leiter in sich wenigstens nahezu unmittelbar an die Nutbereiche anschließenden ersten Übergangsbereichen innerhalb der Wickelköpfe in eine wenigstens nahezu kreisförmige räumliche Anordnung übergehend zueinander ausgerichtet geführt,
• • sind die Leiter in sich wenigstens nahezu unmittelbar an die ersten Übergangsbereiche anschließenden ersten Leiterführungsbereichen innerhalb der Wickelköpfe in der wenigstens nahezu kreisförmigen räumlichen Anordnung zueinander ausgerichtet weitergeführt,
• • sind die Leiter in sich wenigstens nahezu unmittelbar an die ersten Leiterführungsbereiche anschließenden zweiten Übergangsbereichen innerhalb der Wickelköpfe von der wenigstens nahezu kreisförmigen räumlichen Anordnung in eine wenigstens nahezu dreieckförmige räumliche Anordnung übergehend zueinander ausgerichtet geführt, und
• • sind die Leiter in sich wenigstens nahezu unmittelbar an die zweiten Übergangsbereiche anschließenden zweiten Leiterführungsbereichen innerhalb der Wickelköpfe in der wenigstens nahezu dreieckförmigen räumlichen Anordnung zueinander ausgerichtet weitergeführt,

wobei insbesondere

• • die Leiter innerhalb der ersten Übergangsbereiche und wenigstens eines Teils der ersten Leiterführungsbereiche in wenigstens nahezu gleicher Längsausrichtung sich erstrecken wie innerhalb der Nutbereiche, und
• • die Leiter innerhalb der zweiten Leiterführungsbereiche wenigstens nahezu rechtwinklig zur Längsausrichtung innerhalb der Nutbereiche derart geführt sind, dass sie bei einem Anordnen der Spulen im Magnetjoch wenigstens nahezu in dessen Umfangsrichtung ausgerichtet sind.

In a particularly preferred embodiment of the winding arrangement according to the invention

• The conductors within the groove regions of the coils are guided aligned in a spatial arrangement designed for insertion into the groove according to their cross-sectional contour,
• The conductors are guided in at least almost directly adjoining the groove areas first transition areas within the winding heads in an at least approximately circular spatial arrangement transitioning aligned,
• • the conductors are continued in at least almost immediately adjoining the first transition regions first conductor guide areas within the winding heads in the at least nearly circular spatial arrangement aligned with each other,
• • The conductors are guided in at least almost immediately adjoining the first conductor leading areas second transition areas within the winding heads of the at least nearly circular spatial arrangement in an at least almost triangular spatial arrangement transitional aligned, and
• • the conductors are continued in at least almost immediately adjoining the second transition regions second conductor guide areas within the winding heads in the aligned at least almost triangular spatial arrangement to each other,

in particular

• The conductors within the first transition regions and at least a portion of the first conductor guide regions extend in at least substantially the same longitudinal orientation as within the groove regions, and
• • The conductors are guided within the second conductor guide areas at least approximately at right angles to the longitudinal alignment within the groove areas such that they are aligned at an arrangement of the coils in the magnetic yoke at least almost in the circumferential direction.

In other words, the conductors come out of the groove along their length in at least two rows along their length, i. in a spatial position of the conductors to each other - also referred to as conductor position - for insertion into the groove according to their cross-sectional contour - also referred to as groove cross section - change within the first transition areas in a circular arrangement to each other, keep this circular spatial relationship to each other within the first conductor guide areas at, change from this circular spatial assignment within the second transition regions in a triangular arrangement to each other and continue in the horizontal region and thus in the second conductor guide areas in the triangular arrangement, in which case the term horizontally in short form opposite to the longitudinal orientation of the winding sections of Nutbereiche is designated at least approximately right-angled longitudinal orientation of the ladder. This allows a particularly space-saving conductor guidance in the winding heads. In addition, in the inventive design, all the coils of the winding can be made identical, whereby a considerable simplification of the production is achieved. For example, a winding arrangement according to the invention with the particularly space-saving conductor guide with a total of 48 mutually identical coils is made.

According to another embodiment, the winding arrangement according to the invention is characterized in that the conductors are formed within the groove regions of the coils with cross-sectional contours shaped for insertion into the groove according to their cross-sectional contour. The cross-sectional contours of the conductors, also referred to as conductor cross-section, are thus adapted to the groove cross-section individually or preferably in the entirety of all winding sections of the groove regions to be inserted into a groove. The conductor cross sections are preferably adapted to the groove cross section only in the groove regions. This adjustment increases the copper fill factor and thus better utilizes the existing space in the groove through the coil conductors. Due to the higher proportion of conductors on the entire groove cross-section, in particular copper content, ohmic losses in the conductor regions are reduced. This means a higher efficiency of the electric machine, ie by increasing the copper filling factor in the grooves, the efficiency of the electric machine is improved. In addition, a higher proportion of the conductors on the entire groove cross section causes the coils are thermally better connected to the magnetic yoke. Therefore, resulting in the coils Power loss can be dissipated even better. This increases the performance of the electric machine, especially in continuous operation. Although it is to be noted that as the copper fill factor increases, so does the power loss caused by current displacement, as in the case of the winding arrangement according to the invention, this is counteracted by the above-described configuration in the circumferential direction of juxtaposed conductors or rows of conductors.

Particularly advantageously, the winding sections of the groove regions of the coils are configured with conductor cross sections that are particularly flat relative to the radial direction of the magnetic yoke. This can achieve a reduction in power losses caused by current displacement caused by a groove cross field, i. by a portion of the magnetic field directed substantially in the circumferential direction of the magnetic yoke. Due to the particularly flat conductor cross-sections, this current displacement cause is attenuated.

In a further preferred embodiment of the winding arrangement according to the invention, the cross-sectional contours of the conductors within the groove regions of the coils are formed by massive deformation from an initial cross-sectional contour, in particular from an at least approximately circular initial cross-sectional contour, and / or are the cross-sectional contours of the conductors within the groove regions of the coils by casting technology shaped.

In the massive forming of the conductors whose conductor cross-sections, as well as in the document DE 10 2009 024 230 A1 or the publication EP 1 578 002 B1 called, in particular by common embossing of all jointly inserted into the same groove winding sections of the groove portions of the coils in an embossing tool adapted to the groove cross-section. The coils can thus be wound prior to embossing from a particular trained as a round wire conductor. When stamping, another advantage of the above-described configuration in the circumferential direction of juxtaposed arranged conductor or rows of conductors, which makes it possible to maintain a required to achieve the desired conductor cross-sections cross-sectional deformation in manufacturing technology possible limits, ie, as it is not possible manufacturing technology To press the initially round conductor cross-section as desired by the stamping, the above-described, particularly flat conductor cross-sections can be achieved by arranging at least two winding sections of the groove sections in the circumferential direction of the magnetic yoke side by side, whereby each winding section is deformed correspondingly less or needs to be deformed ,

In a casting production of the coils, as in the DE 10 2013 000 899 A1 is called, can produce the required conductor cross-sections, even very flat, directly. An embossing is not required.

The increase in the copper fill factor brings an additional difficulty in that with an increase in the sum of the conductor cross sections of the winding sections of the groove areas, the sum of the conductor cross sections of the winding sections in the winding heads is increased. As a result, in principle, an increase in the space required for the winding heads space can be caused. Due to the particular, described above, inventive leadership of the ladder in the winding heads, however, an improved utilization of the available space is given, so that an increase in the space required for the winding heads space is avoided.

According to a preferred development of the winding arrangement according to the invention, the cross-sectional contours of the conductors within the groove areas of the coils are formed by massive deformation of one or more of the coils in the assembly. The massive forming can in principle for a single of the winding sections of the groove portions of a coil currently, for several winding sections of the groove areas together, for all winding sections of the groove areas of a coil together or for several or all groove areas of several coils are made simultaneously. In addition, a plurality of coils may preferably in the order in which they are in the electrical machine for which they are intended to be installed or connected to each other in particular in series, wound in one piece, ie with an integrally continuous, ie continuously guided conductor become. In particular, all the coils of a phase of the electric machine between two outer terminals of the winding assembly can be integrally wound, which later separately to be wired contact points and thus saves work and costs and defects are avoided by poorly executed conductor connections, so that the production is more economical and increases the quality of manufacture becomes. A massive deformation of the groove areas of these composite coils, ie connected coils of the winding arrangement according to the invention is then preferably carried out in the manner described above, ie for a single one of the winding sections of the groove areas of a coil at a time, for several winding sections of the groove areas together, or preferably for all winding sections of the Nutbereiche a coil together or for several or all groove areas of several coils at the same time. For this purpose, the coils can initially be wound with integrally connected conductors, ie winding sections, but spatially separated so far that the massive forming, ie the embossing, the conductor is easy to perform because all winding sections to be embossed, in particular all winding sections of Nutbereiche, simply remain reachable with a stamping tool, preferably a die. Only after embossing the contiguous coils are then converted into the shape, ie bent, in which they are to be inserted into the magnetic yoke of the electric machine. It is advantageous in the above-described design of the coils with inner and outer coil and possibly further, interposed coils this separated in the die or together verprägbar.

According to another embodiment of the winding arrangement according to the invention, the conductors are formed within the groove areas of the coils for insertion into the groove after an at least nearly rectangular cross-sectional contour of the grooves, optionally after an at least almost conical cross-sectional contour of the grooves, shaped cross-sectional contours.

In this case, the individual winding sections of the groove regions themselves are preferably themselves with an at least approximately rectangular or conical cross-sectional contour, i. Such a shaped conductor cross-section, shaped, but remains most important goal that all intended for installation in a groove winding sections together in their mounting position in the groove whose cross-sectional contour - rectangular and / or conical - as far as possible closely reshaped, so that after installation of the coils as possible no cavities remain in the groove. This applies to both rectangular and conical grooves, which can be provided in the magnetic yoke optional or at the same time. Here are grooves with conical cross-sectional contour, in short: conical grooves, advantages in the design, i. Dimensioning, the electrical machine, whereas grooves with rectangular cross-sectional contour, in short: rectangular grooves, are easier to handle when mounting the coils in the magnetic yoke.

In another embodiment of the winding arrangement according to the invention, the at least two conductors arranged side by side in the circumferential direction or the at least two rows of conductors of the groove areas of the coils arranged side by side in the circumferential direction form parts of different coils, in particular parts of at least one inner one, in the radial direction of the magnetic yoke and an outer coil, and these different coils are electrically connected in series with each other and / or in parallel with each other. In this case, a series connection of inner and outer coil has the advantage that the currents in the inner and the outer coil coincide. Since the conductor of the outer coil is longer than that of the inner coil, so that the outer coil has a higher ohmic resistance than the inner coil, results in a parallel connection of inner and outer coil, an uneven current distribution between the inner and the outer coil and thus different magnetic field strengths in different spatial areas of the grooves, in particular in a left and a right half of the half, which are avoided in the series connection.

With the formation of sufficiently equal current distribution and thus a sufficiently homogeneous field in the grooves, a parallel connection, in particular of the inner and the outer coil to the same groove can be provided, so that any unequal current distributions and consequent losses sufficiently, preferably negligible, remain low. The parallel connection has the advantage that, in operation, lower electrical voltages occur during operation between adjacent conductors or conductor regions in the coil (s) than in the case of series connection. Therefore, then a less stress-resistant and thus usually less space consuming electrical insulation between the coils is sufficient. Concretely, e.g. waives an insulating paper between the inner and outer coil and the electrical insulation of the conductors against each other only by a coating, e.g. with an insulating varnish. This can further increase the copper fill factor.

The above-mentioned object is further achieved by an electric machine having at least one winding arrangement of the type described above. An electric machine designed in this way has an increased efficiency, an increased power density and a high total power with compact dimensions. Due to the particular embodiment of the winding arrangement according to the invention a simple, quick installation similar to a plug-in installation of individual tooth coils is possible. Compared to such dental coils can also be saved to a considerable extent subsequently separately manufactured contact points. As a result, significant savings in manufacturing costs are achieved and the manufacturing quality is significantly increased.

Brief description of the drawings

Embodiments of the invention are illustrated in the drawings and will be described in more detail below, with matching elements in all figures with the same Reference signs are provided and is dispensed with a repeated description of these elements. Show it:

1 a section of a stator of an electric machine, formed with an example of a magnetic yoke and an example of a winding arrangement according to the invention, in a perspective, roughly schematic representation,

2 a section from the stator of the electric machine, made with an example of a magnetic yoke 1 , wherein in the magnetic yoke only a single phase winding of the machine is drawn from four inventively designed coils, in a perspective, roughly schematic representation,

3 an example of an inventively designed coil of the winding arrangement according to 1 and 2 in a roughly schematic representation of a first, perspective view,

4 the example of the inventive design coil after 3 in a roughly schematic representation of a second, perspective view,

5 the example of the inventive design coil after 3 in a roughly schematic representation of a third, perspective view,

6 a section of the inventively embodied coil after 3 to 5 in a perspective, roughly schematic representation,

7 a section of an outer coil of the inventively embodied coil after 6 in the same perspective, roughly schematic representation,

8th a section of an inner coil of the inventively embodied coil after 6 in the same perspective, roughly schematic representation,

9 a section of the stator of the electric machine after 1 in a roughly schematic sectional view of another, perspective view, and

10 the example of the inventive design coil after 3 to 5 in a manufacturing stage, in which outer and inner coil are demolded, in a rough schematic representation of a fourth and fifth, perspective view.

Preferred embodiment of the invention

1 shows a section of a stator 101 an electric machine 103 formed with an example of a magnetic yoke 102 and an example of a winding arrangement according to the invention 100 , in perspective, roughly schematic representation. The electric machine 103 is constructed in the present embodiment, three-phase and has one phase and magnetic pole here four coils 105 comprehensive phase winding, one of which by way of example by the reference numeral 106 is designated and highlighted. The magnetic yoke 102 is with a given, along a circumferential direction 107 of the magnetic yoke 102 spaced apart with uniformly predetermined groove intervals arranged number of grooves 104 educated. These grooves are numbered; the reference number 104 indicates this numbering. In the present embodiment, the magnetic yoke 102 a number of 48 slots 104 on, which are designated in the drawing with the numbers 1 to 48. Accordingly, a number of 48 coils 105 provided for a total of twelve phase windings 106 ie four phase windings 106 each phase, are composed, the electric machine 103 is formed four-pole. In 1 are the coils 105 shown with open, ie not connected coil terminals. Every coil 105 has two groove areas 108 on, for insertion in spaced by two groove intervals selected one of the grooves 104 are formed, and two each of these two groove intervals bridging end windings 109 , The coils are with their groove areas 108 roof-like nested in the grooves 104 inserted that from each coil 105 in the circumferential direction 107 seen first of the two groove areas 108 in the groove base 110 and the second of the two groove areas 108 in front of the first groove area 108 in the order of arrangement of the coils 105 next but one coil 105 is arranged, ie in the radial to the central axis of the magnetic yoke 102 seen from the front area 111 the next but one groove 104 , This is also in 2 shown again.

2 shows the in 1 illustrated section of the stator 101 the electric machine 103 with the magnetic yoke 102 , being in the grooves 104 of the magnetic yoke 102 only a single phase winding 106 the electric machine 103 from four inventively designed coils 105 is drawn in perspective, roughly schematic representation. The phase winding 106 is shown in its correct mounting position, ie the groove areas 108 the coils 105 are like the fully assembled electric machine 103 correctly in the groove base 110 or front area 111 the relevant grooves 104 drawn drawn, and the winding heads 109 are represented with their design and their course as they are after assembly of all phase windings 106 is present. Here are in 2 also the in 1 coil terminals still open at contact points 112 shown connected to each other. The contact points 112 are eg by Welding or soldering formed. All coils are also preferred 105 a phase winding 106 continuously wound from a continuously guided conductor, so instead of the contact points 112 the conductor is made in one piece. From a total of five connection points of a phase winding 106 remain by eliminating the contact points 112 only the end connections 113 . 114 the phase winding 106 forming coil terminals leading to the outer wiring of the phase winding 106 with eg switching rings of the stator 101 the electric machine 103 are provided as described below 9 is indicated.

• • Von einer ersten der Phasenwicklungen 106 für eine erste Phase der elektrischen Maschine 103 ist – eine erste der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 39 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 41 eingelegt, – eine zweite der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 41 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 43 eingelegt, – eine dritte der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 44 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 46 eingelegt und – eine vierte der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 46 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 48 eingelegt.
• • Von einer ersten der Phasenwicklungen 106 für eine zweite Phase der elektrischen Maschine 103 ist – eine erste der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 43 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 45 eingelegt, – eine zweite der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 45 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 47 eingelegt, – eine dritte der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 48 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 2 eingelegt und – eine vierte der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 2 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 4 eingelegt.
• • Von einer ersten der Phasenwicklungen 106 für eine dritte Phase der elektrischen Maschine 103 ist – eine erste der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 47 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 1 eingelegt, – eine zweite der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 1 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 3 eingelegt, – eine dritte der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 4 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 6 eingelegt und – eine vierte der ihr zugehörigen vier Spulen 105 – mit einem ersten ihrer Nutbereiche 108 in den Nutgrund 110 der Nut 104 mit der Nummer 6 und – mit einem zweiten ihrer Nutbereiche 108 in den vorderen Bereich 111 der Nut 104 mit der Nummer 8 eingelegt.

According to 2 have the phase windings 106 following winding scheme, ie the following sequence of coils 105 and their groove areas 108 , distributed on the grooves 104 , on, taking on the too 1 and 2 Selected numbering of the grooves 104 However, for clarity of the drawings, not all of these grooves in the image section of the 1 and 2 are shown:

• • From a first of the phase windings 106 for a first phase of the electric machine 103 is - a first of its associated four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with the number 39 and - with a second of its groove areas 108 in the front area 111 the groove 104 with the number 41 inserted, - a second of its associated four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with the number 41 and - with a second of its groove areas 108 in the front area 111 the groove 104 with the number 43 inserted, - a third of its associated four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with the number 44 and - with a second of its groove areas 108 in the front area 111 the groove 104 with the number 46 inserted and - a fourth of its associated four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with the number 46 and - with a second of its groove areas 108 in the front area 111 the groove 104 with the number 48 inserted.
• • From a first of the phase windings 106 for a second phase of the electric machine 103 is - a first of its associated four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with number 43 and - with a second of its groove areas 108 in the front area 111 the groove 104 numbered 45, - a second of its four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with the number 45 and - with a second of its groove areas 108 in the front area 111 the groove 104 with the number 47 inserted, - a third of its associated four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with the number 48 and - with a second of its groove areas 108 in the front area 111 the groove 104 with the number 2 inserted and - a fourth of its associated four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with the number 2 and - with a second of its groove areas 108 in the front area 111 the groove 104 with the number 4 inserted.
• • From a first of the phase windings 106 for a third phase of the electric machine 103 is - a first of its associated four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with the number 47 and - with a second of its groove areas 108 in the front area 111 the groove 104 with the number 1 inserted, - a second of its associated four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with the number 1 and - with a second of its groove areas 108 in the front area 111 the groove 104 with the number 3 inserted, - a third of its associated four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with the number 4 and - with a second of its groove areas 108 in the front area 111 the groove 104 with the number 6 inserted and - a fourth of its associated four coils 105 With a first of its groove areas 108 in the groove bottom 110 the groove 104 with the number 6 and - with a second of its groove areas 108 in the front area 111 the groove 104 with the number 8 inserted.

In 2 is only this last described first of the phase windings 106 for the third phase of the electric machine 103 shown.

These winding schemes repeat for each of the phases with matching second, third and fourth phase windings 106 after every 12 grooves. The phase windings 106 are for the different phases by four groove intervals in the circumferential direction 107 offset from each other, ie the total number of grooves 104 , divided by the number of phase windings 106 ,

The 3 to 5 show different perspective views of a coil 105 one of the phase windings 106 the winding arrangement 100 to 1 and 2 in a rough schematic representation. The groove areas 108 the coil 105 are with two in the circumferential direction 107 arranged side by side, after installation in the stator 101 the electric machine 103 in the radial direction of the magnetic yoke 102 extending rows 115 . 116 trained by ladders. They form in the circumferential direction 107 facing rows 115 of ladders along with associated ladders 117 in the winding heads 109 an inner coil 119 , and in the circumferential direction 107 rows facing away from each other 116 of ladders form together with associated ladders 118 in the winding heads 109 an outer coil 120 , The inner one 119 and the outer coil 120 are in one piece, ie executed with between the coil terminals continuously continuously wound conductor. The rows 115 . 116 of conductors or winding sections in the groove areas 108 are after winding to adapt to the rectangular cross-sectional contour of the grooves 104 massively formed together to rectangular conductor cross-sections. Inside the winding heads are the ladder 117 . 118 as round wires, ie formed with a circular conductor cross-section, wherein at the transitions between the Nutbereichen 108 and the winding heads 109 Also, a transition from the rectangular conductor cross sections to the round wires takes place, as shown in more detail below.

In addition shows 6 a section of the inventively embodied coil 105 to 3 to 5 in a perspective, roughly schematic representation, and the 7 and 8th show for better clarity ever a section of the outer coil 120 or the inner coil 119 in the same perspective, roughly schematic representation as part views of the coil 105 to 6 , Within the groove areas 108 the coil 105 and thus also the inner and the outer coil 119 . 120 are the ladder or rows of ladders 115 . 116 in one for insertion into the groove 104 according to the cross-sectional contour, the groove cross-section, designed spatial arrangement aligned with each other and guided adapted in their conductor cross section by massive forming the groove cross-section. In the 6 to 8th These conductor cross-sections are rectangular in shape, they and their spatial arrangement to each other schematically in the ladder 115 . 116 marked and with the reference number 121 designated.

In itself directly to the groove areas 108 subsequent first transition areas 122 within the winding head 109 are the leaders 117 . 118 in an at least nearly circular spatial arrangement 123 passed in alignment with each other, like this one in 6 to 8th through schematically into the ladder 117 . 118 the winding head 109 drawn conductor cross sections 124 is shown. Also, in the first transition areas 122 also the transition from the rectangular conductor cross-sections 121 the leader 115 . 116 to circular conductor cross-sections, namely designed as round wires conductor cross-sections 124 , executed. In particular, these round wires form an initial cross-sectional contour in the massive forming. In itself directly to the first transition areas 122 subsequent first conductor guide areas 125 within the winding head 109 are the leaders 117 . 118 in the at least nearly circular spatial arrangement 123 continued aligned with each other. Immediately to the first conductor guidance areas 125 close within the winding head 109 second transition areas 126 in which the ladder 117 . 118 from the at least nearly circular spatial arrangement 123 in an at least nearly triangular spatial arrangement 127 are guided in alignment with each other, as this in 6 to 8th through schematically into the ladder 117 . 118 the winding head 109 drawn conductor cross sections 128 is shown. To the second transition areas 126 in turn, immediately closes a second conductor area 129 within the winding head 109 in which the ladder 117 . 118 in the at least nearly triangular spatial arrangement 127 continued aligned with each other. The ladder extends 117 . 118 within the first transition areas 121 and at least a part of the first conductor guide areas 125 in at least nearly the same longitudinal orientation as within the groove areas 108 , Within the second conductor guide area 129 are the leaders 117 . 118 however, at least approximately perpendicular to the longitudinal orientation within the groove areas 108 guided so that they in an arrangement of the coils 105 in the magnetic yoke 102 at least almost in its circumferential direction 107 apart from that too 1 described low, roof tile overlapping oblique position of the winding heads. Overall, therefore, each winding head includes 109 two first transition areas 122 , two first ladder sections 125 and two second transition areas 126 but only a second conductor guide area 129 extending between the two second transition areas 126 extends.

9 shows a section of the stator of the electric machine after 1 in a roughly schematic sectional view of another, perspective view. In this case, a Wired mounting state is reproduced, in which the end connections 113 . 114 with switching rings 130 are connected. For each of the three phases and for mass is ever a switching ring 130 provided and axially in front of the winding heads 109 the coils 105 arranged. The cutting plane lying in the drawing plane leads through the first ladder control areas 125 two of the coils 105 with the circular spatial arrangement 123 the leader 117 . 118 in the winding head 109 to each other and by the between these two first conductor guide areas 125 the two coils 105 centrally guided second conductor guide area 129 a third of the coils 105 with the triangular spatial arrangement 127 the leader 117 . 118 in the winding head 109 to each other. By this arrangement each of a second conductor guide region 129 a coil 105 with the triangular spatial arrangement 127 the leader 117 . 118 between two first conductor guide areas 125 two coils 105 with the circular spatial arrangement 123 the leader 117 . 118 arises according to the invention particularly space-saving ladder, which in particularly compact end windings 109 results.

Optionally for the described common bulk forming of the rows of conductors 115 . 116 in the groove areas 108 the coils 105 can the rows 115 and 116 the conductor also on the molded-out inner and outer coils 119 . 120 be massively formed, without causing a separation of the conductors of the inner coil 119 from the conductors of the outer coil 120 requirement. In addition shows 10 in a first sub-figure a) in a fourth, perspective view and in a second sub-figure b) in a fifth, perspective view of the example of the inventively embodied coil 105 according to the 3 to 5 in a manufacturing stage, in which outer 120 and inner coil 119 are demolded, in a rough schematic representation. Although the conductor of the inner and outer coil 119 . 120 continue to be continuously wound and thus formed in one piece, so no separately produced contact point between them is required, so can the rows 115 . 116 the head of the groove areas 108 the coil 105 also spatially separated from each other in parallel or in succession executed Verpräfahrens massive. In this way, in addition, the ladder 115 . 116 several contiguous continuously wound coils 105 , in particular all coils 105 a phase winding 106 , be massively formed in the composite. Optionally, it is possible, the cross-sectional contours of the ladder 115 . 116 within the groove areas 108 the coils 105 by massive deformation of one or more of the coils 105 to form in a composite, with a stamping of one or more of the conductors 115 . 116 , the leader 115 the inner coil 119 and the leader 116 the outer coils 120 each in common, all leaders 115 . 116 a coil 105 together and for each of the coils 105 a phase winding in succession, but also of all conductors 115 . 116 several coils 105 , in particular all preferably one-piece, ie continuous, wound coils 105 a phase winding 106 can be done together as needed. After a spatially separated embossing of the rows 115 . 116 the leader in the 10 shown, demolded mounting state of the coils 105 become the inner ones 119 and the outer one 120 Coil while bending over its conductor connection 131 for forming the finished coil 105 inserted into each other.

LIST OF REFERENCE NUMBERS

100

Winding arrangement of 101

101

Stator of 103

102

Magnetic yoke of 101

103

Electric machine

104

Groove of 102

105

Coil of 100

106

phase winding

107

Circumferential direction of 102

108

Groove area of 105

109

Winding head of 105

110

Groove bottom of 104

111

Front area of 104

112

Contact point of 106

113

End connection of 106

114

End connection of 106

115

Row of ladders in 108 to 119

116

Row of ladders in 108 to 120

117

Head in 109 to 119

118

Head in 109 to 120

119

Inner coil too 105

120

Outer coil of 105

121

Rectangular conductor cross-section of 115 . 116 in 108

122

First transition area in 109

123

Circular spatial arrangement of 117 . 118 in 109 to each other

124

Conductor cross section of 117 . 118 : Round wire

125

First ladder area in 109

126

Second transition area in 109

127

Triangular spatial arrangement of 117 . 118 in 109

128

Conductor cross sections of 117 . 118 in 129 from 109

129

Second conductor management area in 109

130

switching ring

131

Conductor connection between 119 and 120

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

• DE 102009024230 A1 [0002, 0003, 0020]
• EP 1578002 B1 [0020]
• DE 102013000899 A1 [0021]

Claims (10)

Winding arrangement formed with at least one electrical conductor ( 100 ) for an electric machine ( 103 ), in particular a stator ( 101 ) of this electric machine ( 103 ), which is a magnetic yoke ( 102 ) with a predetermined, along a circumferential direction ( 107 ) of the magnetic yoke ( 102 ) with each other with, in particular uniform, predetermined groove intervals spaced number of grooves ( 104 ) comprising a predetermined number of coils ( 105 ) each having two for insertion in spaced by two Nutabstände selected grooves ( 104 ) formed groove areas ( 108 ) and two each of these two slot spacers bridging end windings ( 109 ). Winding arrangement ( 100 ) according to claim 1, characterized in that the groove areas ( 108 ) of the coils ( 105 ) with at least two in the circumferential direction ( 107 ) arranged side by side ladders ( 115 . 116 ) or at least two in the circumferential direction ( 107 ) arranged side by side, in the radial direction of the magnetic yoke ( 102 ) extending rows of conductors ( 115 . 116 ) are formed. Winding arrangement ( 100 ) according to claim 1 or 2, characterized in that the groove areas ( 108 ) of the coils ( 105 ) with exactly two in the circumferential direction ( 107 ) arranged side by side, in the radial direction of the magnetic yoke ( 102 ) extending rows of conductors ( 115 . 116 ) are formed and that in particular to each of the coils ( 105 ) in the circumferential direction ( 107 ) facing each other rows of conductors ( 115 ) together with associated ladders ( 117 ) in the winding heads ( 109 ) an inner coil ( 119 ) and in the circumferential direction ( 107 ) facing away from each other rows of conductors ( 116 ) together with associated ladders ( 118 ) in the winding heads ( 109 ) an outer coil ( 120 ) form. Winding arrangement ( 100 ) according to claim 1, 2 or 3, characterized in that • the conductors ( 115 . 116 ) within the groove areas ( 108 ) of the coils ( 105 ) in one for insertion into the groove ( 104 ) are guided according to their cross-sectional contour designed spatial arrangement aligned with each other, • the ladder ( 117 . 118 ) in at least almost directly to the groove areas ( 108 ) subsequent first transitional areas ( 122 ) within the winding heads ( 109 ) in an at least nearly circular spatial arrangement ( 123 ) are guided in a mutually aligned manner, • the conductors ( 117 . 118 ) at least almost directly to the first transition regions ( 122 ) subsequent first conductor management areas ( 125 ) within the winding heads ( 109 ) in the at least nearly circular spatial arrangement ( 123 ) are aligned with each other, • the conductors ( 117 . 118 ) at least almost directly to the first conductor-guiding regions ( 125 ) subsequent second transition areas ( 126 ) within the winding heads ( 109 ) of the at least nearly circular spatial arrangement ( 123 ) in an at least nearly triangular spatial arrangement ( 127 ) are guided in a mutually aligned manner, and • the conductors ( 117 . 118 ) in at least almost directly to the second transition regions ( 126 ) subsequent second conductor guide areas ( 129 ) within the winding heads ( 109 ) in the at least nearly triangular spatial arrangement ( 127 ) are continued aligned with each other, in particular • the ladder ( 117 . 118 ) within the first transition areas ( 122 ) and at least a part of the first conductor guide areas ( 125 ) extend in at least substantially the same longitudinal orientation as within the groove areas ( 108 ), and • the ladder ( 117 . 118 ) within the second conductor routing areas ( 129 ) at least approximately at right angles to the longitudinal orientation within the groove areas ( 108 ) are guided in such a way that when arranging the coils ( 105 ) in the magnetic yoke ( 102 ) at least almost in its circumferential direction ( 107 ) are aligned. Winding arrangement ( 100 ) according to one or more of the preceding claims, characterized in that the conductors ( 115 . 116 ) within the groove areas ( 108 ) of the coils ( 105 ) with for insertion into the groove ( 104 ) according to the cross-sectional contour shaped cross-sectional contours ( 121 ) are formed. Winding arrangement ( 100 ) according to claim 5, characterized in that the cross-sectional contours ( 121 ) the ladder ( 115 . 116 ) within the groove areas ( 108 ) of the coils ( 105 ) by massive forming from an initial cross-sectional contour, in particular from an at least approximately circular initial cross-sectional contour ( 124 ), are formed, and / or that the cross-sectional contours ( 121 ) the ladder ( 115 . 116 ) within the groove areas ( 108 ) of the coils ( 105 ) are formed by casting technology. Winding arrangement ( 100 ) according to claim 6, characterized in that the cross-sectional contours ( 121 ) the ladder ( 115 . 116 ) within the groove areas ( 108 ) of the coils ( 105 ) by massive deformation of one or more of the coils ( 105 ) are formed in the composite. Winding arrangement ( 100 ) according to claim 5, 6 or 7, characterized in that the conductors ( 115 . 116 ) within the groove areas ( 108 ) of the coils ( 105 ) with for insertion into the groove ( 104 ) after an at least almost rectangular cross-sectional contour of the grooves ( 104 ), optionally according to an at least almost conical cross-sectional contour of the grooves ( 104 ), shaped cross-sectional contours ( 121 ) are formed. Winding arrangement ( 100 ) according to one or more of claims 2 to 8, characterized in that the at least two in the circumferential direction ( 107 ) juxtaposed conductors ( 115 . 116 ) or the at least two in the circumferential direction ( 107 ) arranged side by side, in the radial direction of the magnetic yoke ( 102 ) extending rows of conductors ( 115 . 116 ) of the groove areas ( 108 ) of the coils ( 105 ) Parts of different coils ( 119 . 120 ), in particular parts of at least one inner ( 119 ) and an outer ( 120 ) Coil, and these different coils ( 119 . 120 ) are connected in series with each other and / or in parallel with each other electrically. Electric machine ( 103 ), characterized by at least one winding arrangement ( 100 ) according to one or more of the preceding claims.

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