DE102016225039A1 - Method for producing an electrical winding of an electrical machine - Google Patents

Abstract

The invention relates to a method (88) for producing an electrical winding (66) of an electrical machine (30) of a motor vehicle (2), in particular of an electromotive refrigerant compressor (12). A first and a second turn (68, 70) are stacked in an axial direction (A) and electrically contacted to form a first contact point (93) by means of a contact material materially. A third turn (72) is stacked in the axial direction (A) on the second turn (70) and electrically contacted to form a second contact point (100) by means of a contact material with the second turn (70), and in which a contact material used whose melting temperature is less than the melting temperature of the first, second and third windings (68, 70, 72). The invention further relates to an electrical winding (66) of an electrical machine (30) of a motor vehicle (2).

Description

The invention relates to a method for producing an electrical winding of an electrical machine of a motor vehicle. The electric machine is in particular a component of an electromotive refrigerant compressor. The invention further relates to an electrical winding of an electrical machine of a motor vehicle.

Motor vehicles usually have an air conditioner, by means of which a temperature control of an interior of the motor vehicle takes place. Also, when powered by an electric motor vehicles, the required energy storage, such as a high-voltage battery, cooled. The air conditioning system has a refrigerant circuit, which comprises a refrigerant compressor, downstream of a condenser and this fluidly downstream of an evaporator. This is fluidly connected downstream of another heat exchanger, which is in thermal contact with a fan line leading into the interior of the motor vehicle, or with any energy cells of the high-voltage energy storage. The refrigeration cycle is filled with a refrigerant, such as R134a, R1234yf or CO2.

During operation, a pressure of the refrigerant is increased by means of the refrigerant compressor, which leads to an increase in the temperature of the refrigerant. This is conducted to the condenser, which is in thermal contact with an environment of the motor vehicle. Here, a temperature reduction of the refrigerant, which is in turn relaxed in the downstream evaporator to the original pressure, which is why the temperature of the refrigerant is further reduced. In the downstream heat exchanger is transferred from the thermally contacted with the heat exchanger component thermal energy to the refrigerant, resulting in a cooling of the component and heating of the refrigerant. The heated refrigerant is again supplied to the refrigerant compressor for closing the refrigerant cycle.

To adjust the performance of the refrigerant compressor regardless of a speed of an internal combustion engine of the motor vehicle, this has an electric motor, by means of which a compressor head is driven, which is for example a scroll compressor head. In other words, the refrigerant compressor is an electromotive refrigerant compressor. The electric motor usually has a number of electrical windings, which are each set to a tooth of a laminated stator core. In this case, grooves are formed between the individual teeth, which are thus filled by means of the electrical windings. To achieve the highest possible electrical power, it is necessary that the grooves are filled substantially completely by means of the electrical windings.

The electrical windings are usually wound from a copper enameled wire. If a comparatively thick electrical wire is used, a current carrying capacity of the electrical windings is increased, and heating of the electrical windings during operation is also reduced. Due to the comparatively thick wire, however, the grooves are only partially filled, which reduces the efficiency of the electric motor. If a comparatively thin electrical wire is used to create the electrical windings, the grooves are sufficiently filled with the electrical windings. In this case, however, the current carrying capacity is reduced due to the reduced cross section of the electric wire, and also a heating is increased due to the increased electrical resistance. In addition, an electrical contact with the comparatively narrow wire is difficult, which increases manufacturing costs.

The invention has for its object to provide a particularly suitable method for producing an electrical winding of an electrical machine of a motor vehicle and a particularly suitable electrical winding of an electrical machine of a motor vehicle, in particular reduced manufacturing costs and preferably an efficiency of the electric machine is increased.

With regard to the method, this object is achieved by the features of claim 1 and with respect to the electrical winding by the features of claim 7 according to the invention. Advantageous developments and refinements are the subject of the respective subclaims.

The method is used to produce an electrical winding of an electrical machine of a motor vehicle. In particular, the electrical winding is an electrical coil and suitably forms or is part of an electromagnet. Suitably, the electrical winding is part of a phase winding. Alternatively, the electrical winding is part of a throttle. The electric machine is for example a generator. Preferably, however, the electric machine is an electric motor. The electric motor is, for example, a brushed electric motor, such as a brushed DC motor. Alternatively, the electric motor is a brushless motor, such as a brushless DC motor (BLDC). Conveniently, the electric motor is a synchronous motor.

The electric machine is suitably part of an accessory of the Motor vehicle and, for example, an adjustment. In operation, an adjustment is spent along an adjustment by means of the adjustment. For example, the adjustment is an electric motor windows, an electric motor operated tailgate or a motorized door, such as a sliding door. Alternatively, the adjustment is an electric motor operated sunroof or an electric motor operated roof. In a further alternative, the accessory is a pump, such as a lubricant pump. In particular, the auxiliary unit is an oil pump, for example an engine oil or a gear oil pump. Conveniently, the accessory is an electric motor steering assistance or an ABS or ESP unit. In a further alternative, the auxiliary unit is an electromotive parking brake or another electric brake. For example, the accessory is a part of a vehicle seat and is used, for example, the adjustment of the seat or a part of the seat, such as a backrest or a headrest.

Particularly preferably, the electric machine is a component of an electromotive refrigerant compressor. Preferably, the electromotive refrigerant compressor is electrically contacted with an electrical system of the motor vehicle and / or operated with an electrical voltage of a few volts up to 1000V, in particular with an electrical voltage of 12V, 24V, 48V, 288V, 450V, 650V or 830V. By means of the electromotive refrigerant compressor, a refrigerant is compressed during operation. The refrigerant is, for example, a chemical refrigerant such as R134a or R1234yf. Alternatively, the refrigerant is CO2. Preferably, the refrigerant compressor is designed such that by means of which the respective refrigerant can be compressed, for example, an increase in pressure between 5bar and 20bar. In particular, the electromotive refrigerant compressor comprises a compressor head, for example a scroll compressor.

The refrigerant compressor is in particular a component of a refrigerant circuit (refrigeration cycle), which serves for example for the air conditioning of an interior or the cooling of an energy store of the motor vehicle, such as a high-voltage battery. The refrigerant circuit further includes, in particular, an (air) condenser, and an evaporator. The condenser is fluidly connected between the electromotive refrigerant compressor and the evaporator. Preferably, the refrigerant circuit comprises a further heat exchanger, which is connected between the evaporator and the electromotive refrigerant compressor, and which is preferably thermally contacted with another component of the motor vehicle, such as a blower line of an air conditioner or an energy storage, such as a high-voltage storage. The refrigerant circuit is filled in particular with a refrigerant, for example a chemical refrigerant, such as R134a, R1234yf, or with CO2.

By means of the electromotive refrigerant compressor, a pressure of the refrigerant is increased during operation, which is subsequently passed to the condenser, which is preferably in thermal contact with an environment of the motor vehicle. Suitably, by means of the capacitor, a temperature equalization of the refrigerant to the ambient temperature or at least a decrease in the temperature of the refrigerant. With the downstream evaporator, the refrigerant is expanded, which is why the temperature of the refrigerant is further reduced. In the downstream further heat exchanger is transferred from the thermally contacted with the other heat exchanger component thermal energy to the refrigerant, resulting in a cooling of the component and heating of the refrigerant. The heated refrigerant is preferably supplied again to the refrigerant compressor for closing the refrigerant circuit.

The method for producing the electrical winding provides that a first and a second winding are provided. The first and second windings are in this case formed by means of an electrical conductor, which is arranged substantially in one plane. In this case, individual parts of the respective turn preferably do not overlap in a projection onto a plane perpendicular to the plane of the arrangement. In other words, the turns are essentially two-dimensional objects, with the turns having a certain thickness. The first and second turns are stacked in an axial direction one above the other, the axial direction being expediently perpendicular to the plane of arrangement of the two turns. In particular, the axial direction designates a direction which is parallel to an axis of the electrical winding, which is expediently designed substantially hollow-cylindrical. The axial direction of the electric coil, hereinafter referred to as axial direction only, is in particular parallel to a radial direction of the electric machine. In particular, the two windings are arranged substantially congruently one above the other. At least, however, the inner or outer edges of the two turns are aligned.

The first and second windings are electrically contacted to form a first contact point. Here, the first and the second turn are conveniently contacted directly with each other electrically. In other words are between the first and the second turn no further components. The electrical contacting takes place cohesively by means of a contact material, wherein the contact point in particular comprises a solder. Preferably, the first and the second turn by means of the contact material, in particular the solder, contacted each other directly electrically. In other words, with the exception of the contact material no further material between the first and the second winding is in the region of the first contact point. The contact material has a melting temperature that is less than the melting temperature of the first turn and smaller than that of the second turn. For example, the melting temperature of the first turn is equal to the melting temperature of the second turn. Suitably, the melting temperature of the contact material is less than or equal to 20%, 30%, 40%, 50%, 60% or 70% of the melting temperature of the first / second turns. For example, the melting temperature of the first / second winding is greater than 900 ° C, 1,000 ° C or 1,100 ° C, and more preferably, substantially equal to 1,200 ° C. Suitably, the melting temperature of the contact material is less than 900 ° C, 800 ° C or 700 ° C and, for example, substantially equal to 600 ° C.

In a further working step, a third turn, which is, for example, identical in construction to the first and / or second turn, is stacked on the second turn in the axial direction. Consequently, the second winding is disposed between the third winding and the first winding. The extension direction of the third turn is substantially in a plane which is in particular perpendicular to the axial direction. Preferably, the third winding is placed congruently on the second winding, but at least aligned, for example, the inner or outer edges of the third winding with the second winding. The contact material has a melting temperature that is less than the melting temperature of the third turn. The second turn is electrically contacted to form a second contact point with the third turn. The contacting also takes place cohesively by means of the contact material, and preferably no further component is present electrically between the second winding and the third winding, with the exception of the contact material, so that the second winding is electrically contacted directly with the third winding.

In particular, the finished electrical winding has a number of such turns. In particular, the total number of such turns is between three turns and twenty turns, between four turns and fifteen turns, or between five turns and ten turns. Preferably, the turns, so in particular the first, second and / or third turn so-called flat conductor. Appropriately, by means of the contact material also takes place a mechanical connection of the turns to each other.

Due to the substantially free form selectivity for the individual turns, these can be manufactured according to the intended mounting position. In particular, the windings are adapted to any grooves of a laminated core of the electrical machine. Here, the turns are suitably chosen such that the grooves have a comparatively large degree of filling. As a result, an efficiency of the electric machine is increased. Also, the turns can be made relatively robust, so that they can also be used for applications in a high current case (greater than 100A). In addition, it is possible to provide a comparatively large electrical contact point of the electrical winding by means of the windings, so that electrical contacting of the electrical winding is simplified, which reduces manufacturing costs.

For example, the first turn is substantially identical to the second turn and / or identical to the third turn. Particularly preferably, the second turn is substantially identical to the third turn. Alternatively, the outer dimensions of the windings increase at least in a direction perpendicular to the axial direction successively. Consequently, the electrical winding is conical or wedge-shaped. In other words, the electrical winding has a trapezoidal cross-section parallel to the axial direction. In this way, a degree of filling of the grooves of the possible laminated core is further increased. Conveniently, the first turn, the second turn and the third turn are made of an electrically uninsulated metal plate. Thus, the first, second and third winding is electrically uninsulated. As a result, a creation of the first and second contact point is simplified, since not first any electrical insulation in this area must be broken. For example, the metal plate is made of an aluminum, ie pure aluminum or an aluminum alloy, or a copper, in particular pure copper or a copper alloy. Conveniently, the metal plate is substantially planar, so that the first, second or third turn is substantially flat, which simplifies a creation of the electrical winding. Suitably, the metal plate is between 1mm and 5mm thick and desirably between 2mm and 4mm thick. Preferably, the metal plate is substantially 3mm thick. In this way, the turns have a comparatively large thickness and thus a comparatively high current carrying capacity. For example, the turns are milled from the metal plate. Conveniently, however, the turns are punched out of the metal plate, further reducing manufacturing costs.

For example, the turns electrically contacted with each other are bent in a direction perpendicular to the axial direction. In other words, the bending axis is perpendicular to the axial direction. As a result, the electrical winding in cross-section parallel to the axial direction has a substantially V-shaped (roof-shaped) or arcuate cross-section. In this way, the electrical winding can be connected even with a laminated core with a comparatively small number of teeth, without due to the Sehnung an inner diameter is limited. Suitably, the bending takes place only after the electrical contacting of the individual turns, which is why the creation of the respective contact points are not hindered due to the bending.

Conveniently, a first insulation layer is introduced between the first turn and the second turn. The first insulation layer preferably has a comparatively large electrical resistance and is in particular an electrical insulator. By means of the first insulating layer, the first turn is electrically insulated from the second turn, so that they are only electrically contacted with one another in the region of the first contact point. In this way, an unwanted short circuit between the two windings is avoided, in particular if the two windings are made of an electrically non-insulated material. Alternatively or particularly preferably in combination thereto, a second insulation layer is introduced between the third winding and the second winding, by means of which the second winding is electrically insulated from the third winding with the exception of the second contact point. For example, the first insulation layer is identical to the second insulation layer. In particular, the first insulation layer is mechanically separated from the second insulation layer. In an alternative to this, the two insulation layers are in one piece. Expediently, the insulation layers have a recess in the region of the respective associated contact point, so that a current flow through the electrical winding is made possible. Conveniently, the insulation layers are introduced between the turns after establishing the electrical contact, which simplifies the handling of the windings between the two electrons. For example, the insulation layers are attached to at least one of the respective associated turns, for example by means of gluing, which further increases the robustness of the electrical winding. For introducing the insulation layers, the respective turns are expediently pulled apart mechanically, at least partially.

The insulating layers (insulating layer) are created for example by means of punching or by means of a cutting plotter. In particular, the insulating layers are made of an insulating paper or an aramid fiber fabric. In this way, a comparatively efficient electrical insulation of the windings is given. In particular, the insulating layers are used for tolerance compensation, so that even with a comparatively pronounced first or second contact point, in which the respective turns are relatively widely spaced, a movement of components of the turns to each other by means of the respective insulating layer is prevented.

Conveniently, the first insulating layer is selected such that it projects in a radial direction, ie perpendicular to the axial direction over the first turn and the second turn. The radial direction designates in particular the radial direction of the electrical winding. For example, the first insulation layer overhangs on the radial inside of the two turns. If the electrical winding is mounted for mounting on a tooth of a possible laminated core, the insulating layer is partially deformed in this process, in particular bent, so that a tolerance compensation between the turns and the tooth is created by means of the insulating layer. Also, the tooth is electrically insulated from the first and second turns by means of the first insulation layer, which is why an electrical short circuit is avoided. Alternatively or in combination with this, the first insulation layer projects beyond the first and second turns on the radial outer side. In this way, a starting point for any tool for mounting the electrical winding on the tooth of the possible laminated core is given. Thus, an attack of the tool on the windings of the electric coil itself is not required, so they are not damaged. Particularly preferably, the second insulation layer projects beyond the second and third windings in the radial direction. Here, the second insulating layer is either on the radial inside, on the radial outside or particularly preferably on both sides in the radial direction on the second and the third turn, so on the one hand simplifies installation and on the other hand, a tolerance compensation and electrical insulation is ensured in the assembled state. If the electrical winding has a number of turns which is greater than three, an insulation layer is preferably arranged in each case between adjacent turns. In particular, due to the protrusion on the radial outer side, a creepage distance is maintained and / or any edges of the turns are protected, so that the insulation layer constitutes an edge protection for the turns. Preferably, the supernatant of the insulation layer is not constant. For example, the supernatant is between 0.1 mm and 0.8 mm, between 0.3 mm and 0.6 mm and in particular equal to 0.5 mm.

Particularly preferably, the turns which are contacted with one another electrically are provided by means of a coating. The coating is used in particular for electrical insulation. Suitably, a dip coating (dip coating) is used. In particular, first all turns of the electrical winding are contacted with each other electrically. After completion of the electrical contacting and the introduction of any insulation layers, the package created in this way is preferably provided by means of the coating. In this way, the creation of the cohesive connection due to the coating is not hindered. For example, only a certain portion of the turns is provided with the coating. In other words, the turns are only partially coated. Particularly preferably, however, all windings are completely provided with the coating, which essentially completely avoids an electrical short circuit during operation of the electrical winding. Also, by means of the coating, it is possible to avoid corrosion of the electrical winding, if it is used in an aggressive environment, as is the case because of any coolant inside an electromotive refrigerant compressor. The coating is for example a plastic and in particular a lacquer, which reduces production costs. Preferably, the edges of the turns are broken, which in particular ensures an improved adhesion of the coating. Alternatively or in combination, the corners of the turns are rounded or tapered. The shape of the corners is suitably matched to the required electromagnetic compatibility (EMC).

For example, the electrical contacting by means of laser or electron beam welding takes place. The electrical contacting is preferably carried out by means of resistance brazing. In other words, the cohesive electrical contact is created by means of resistance brazing. In summary, the electrical contacting by means of resistance brazing, wherein the contact point in particular comprises the solder. Preferably, the first and the second winding are contacted by means of the solder directly electrically. In other words, with the exception of the solder, there is no further material between the first and second turns in the region of the first contact point.

Suitably, the second contact point is designed accordingly. Suitably, for the production of the first contact point, the first winding is electrically contacted with a first electrode and the second winding is electrically contacted with a second electrode. Preferably, the first turn is electrically contacted with the first electrode and the third turn with the second electrode to create the second contact point.

To produce the first contact point, the first winding is electrically contacted, for example, with a first electrode and the second winding with a second electrode. To produce the first contact point, an electrical voltage is applied between the two electrodes, so that an electrical current flow takes place via the two windings through the first contact point, at which preferably the existing contact material is melted. The current supply is interrupted and the first contact point is cooled so that the contact material reverts to a solid state. For example, the first electrode is electrically contacted directly with the first turn, for which example, the first electrode is mechanically applied directly to the first turn. Preferably, the second electrode is directly contacted with the second winding, and the second electrode, for example, abuts mechanically directly on the second winding. In order to produce the cohesive connection between the second and third windings, in this case the first turn is electrically contacted with the first electrode and the third turn with the second electrode, wherein the electrodes preferably lie mechanically directly against the respective turn. Conveniently, the same second electrode is electrically contacted with the third winding, which was electrically contacted in the previous step with the second winding.

With the two electrodes only the outermost turns of the electrical winding to be created are contacted, so that a heat input takes place only on these turns, which is why the first contact point is not further loaded. Conveniently, this is followed by another turn placed on the third turn and also electrically contacted with this materially by means of the contact material, in which case also the two electrodes are electrically contacted only with the two outermost turns. Appropriately, a number of such turns is used to create the electrical winding, wherein the turns are electrically contacted in each case with the directly adjacent turns materially by means of the contact material, and wherein the creation of each of the outermost turns of the created in this way stack of turns with the electrons electrically be contacted.

The invention further relates to a method for producing an electrical machine, in which the electrical winding is connected, in particular fastened, in particular to a tooth of a laminated core of the electrical machine.

The electrical winding is part of an electrical machine of a motor vehicle. The electric machine is for example a generator or particularly preferably an electric motor. The electric motor is in particular a synchronous machine and, for example, a brushed electric motor, such as a brushed DC motor. Particularly preferably, the electric motor is a brushless DC motor (BLDC). The electric machine is particularly preferably a component of an electromotive refrigerant compressor, by means of which a refrigerant is compressed during operation. In an alternative to this, the electric motor is a component of an adjustment drive of the motor vehicle, such as an electromotive seat adjustment, an electromotive window lift or an electromotive actuated tailgate or door. In a further alternative, the electric motor is part of a pump, such as an oil or water pump. In the assembled state, the electrical winding is particularly preferably mounted on a laminated core of the electrical machine, which is, for example, a laminated stator core or a laminated rotor core. Here, the electrical winding is preferably placed on a tooth of the laminated core.

Suitably, the electric machine comprises a number of such electrical windings. For example, the number of electrical windings between four windings and fifty windings, between six windings and forty windings, between eight windings and thirty-six windings and, for example, twelve windings. In particular, each electrical winding is associated with a tooth of the possible laminated core, wherein the individual teeth are each each other by means of a groove. Preferably, the electric machine is operated at 48V. For example, the electrical winding has a length in an extending direction that is perpendicular to an axial direction of the electric coil between 20mm and 50mm, preferably between 33mm and 44mm.

The electrical coil has a first, a second and a third winding, which are in particular each flat conductor. Here, the first winding is electrically contacted with the second winding and the second winding is electrically contacted with the third winding, for example directly, and in particular the second winding is arranged in the axial direction between the first winding and the third winding. The three windings are thus stacked in the axial direction and preferably the arrangement direction of the windings is perpendicular to the axial direction. The windings themselves are electrically connected to one another by means of a material fit by means of a contact material, wherein a first contact point is formed between the first and the second winding and a second contact point is formed between the second and third windings.

For electrical contacting, the first turn is preferably first electrically contacted with the second turn, for which resistance brazing in particular is used. As soon as this has taken place, the third winding is preferably placed on the second winding and electrically contacted with it by means of the contact material. In summary, first the first and the second turn are stacked in the axial direction one above the other and electrically contacted to form the first contact by means of the contact material, wherein in particular the first turn with a first electrode and the second turn is electrically contacted with a second electrode. In a further working step, the third turn is stacked in the axial direction on the second turn and electrically contacted to form a second contact point by means of the contact material with the second turn, suitably the first turn with the first electrode and the third turn with the second electrode electrically contacted. Suitably, the electrical contacting takes place by means of resistance brazing. To carry out the resistance brazing, in each case an electrical voltage is applied between the first electrode and the second electrode. The contact material has a melting temperature that is less than the melting temperature of the first, second and third windings.

The shape of the turns can be chosen essentially freely, which is why a degree of filling of existing between teeth of the possible laminated core grooves can be filled by means of the electrical winding in a relatively large extent. In this way, an efficiency of the electric machine is improved. Due to the successive arranging of the windings as well as a successive electrical contacting, production costs of the electrical winding are reduced.

By way of example, the first contact point and the second contact point lie above one another in the axial direction. Particularly preferably, however, the two contact points are offset from each other in a direction perpendicular to the axial direction. Here, the two contact points are suitably also offset from one another in the axial direction. If the electrical winding has a larger number of contact points, these are arranged, for example step-like to each other. In this way, existing contact points are not destroyed when creating the respective contact points, for example, due to a reflow of the solder of the respective contact point.

Appropriately, a connection is formed on the first turn. In other words, the first turn is integral with a port. For example, the first electrode is electrically contacted with the terminal during production, in particular the first electrode is in the region of the terminal, so that the first winding is electrically contacted by means of the terminal with the first electrode. Appropriately, the connection forms a contacting possibility of the electrical winding in the assembled state. In particular, in the assembled state, a line is electrically contacted with the terminal, by means of which, for example, current is supplied to the electrical winding. Suitably, the electrical winding comprises a further turn, which also has a connection, these two turns preferably forming the end face of the electrical winding. If the electrical winding has only the three turns, the third turn thus has the further connection. For example, the terminals are in the radial direction on the same side or on opposite sides, so that the winding has effective substantially a half-number of turns.

Conveniently, each turn is a ring with a slot. The ring is designed here, for example, round or O-shaped. In the assembled state, the slot is suitably directly adjacent to the respective contact location associated with the winding. In this way, a comparatively large proportion of the respective turn is traversed by electric current during operation, which is why an efficiency of the electric machine is increased during operation. Also, in this way, the electric coil with the exception of the slot on a substantially planar end face, which facilitates installation and avoids damage. In this case, for example, the connection is formed on the first turn, so that while a certain area of the first turn, namely from the connection to the side of the slot which is not electrically contacted via the first contact point with the second turn, does not operate from the first one electric current is flowing through. However, the end face of the electrical winding is substantially planar and the electrical winding has a substantially constant weight distribution, and therefore an imbalance is avoided, as long as the electrical winding is connected in the assembled state to a rotating component of the electrical machine.

The invention further relates to an electrical machine having such an electrical winding, in particular a number of such electrical windings.

The refinements and advantages described in connection with the method are to be transferred mutatis mutandis to the electrical winding and vice versa.

• 1 schematisch ein Kraftfahrzeug mit einem elektromotorischen Kältemittelverdichter,
• 2 in einer Schnittdarstellung schematisch vereinfacht den elektromotorischen Kältemittelverdichter,
• 3 perspektivisch einen Stator des elektromotorischen Kältemittelverdichter, mit einer Anzahl an elektrischen Wicklungen,
• 4 bis 6 perspektivisch eine der elektrischen Wicklungen,
• 7 ein Verfahren zur Herstellung der elektrischen Wicklung,
• 8, 9 die elektrische Wicklung zu unterschiedlichen Herstellungszeitpunkten,
• 10 perspektivisch eine weitere Ausführungsform des Stators,
• 11 perspektivisch eine weitere Ausführungsform der elektrischen Wicklung,
• 12 schematisch die Montage der elektrischen Wicklung, und
• 13 die montierte elektrische Wicklung.

The invention will be explained in more detail with reference to a drawing. Show:

• 1 schematically a motor vehicle with an electromotive refrigerant compressor,
• 2 in a sectional view schematically simplifies the electromotive refrigerant compressor,
• 3 in perspective a stator of the electromotive refrigerant compressor, with a number of electrical windings,
• 4 to 6 one of the electrical windings in perspective,
• 7 a method for producing the electrical winding,
• 8th . 9 the electrical winding at different production times,
• 10 in perspective, another embodiment of the stator,
• 11 in perspective, another embodiment of the electrical winding,
• 12 schematically the assembly of the electrical winding, and
• 13 the assembled electrical winding.

Corresponding parts are provided in all figures with the same reference numerals.

In 1 schematically simplified is a motor vehicle 2 with two front wheels 4 and two rear wheels 6 shown. At least two of the wheels 4 . 6 are driven by a main drive, not shown in detail, for example, an internal combustion engine, an electric motor or a combination thereof. The car 2 includes a refrigerant circuit 8th which is part of an air conditioner. The refrigerant circuit 8th is with a refrigerant 10 filled, for example CO2, R1234yf or R134a. By means of an electromotive refrigerant compressor (eKMV) 12, the refrigerant 10 compressed and a fluidic downstream capacitor 14 supplied, which is acted upon by ambient air, resulting in a decrease in the temperature of the refrigerant 10 leads. The pressure and thus the temperature of the refrigerant 10 is by means of a downstream evaporator 16 lowered, comprising a non-illustrated further heat exchanger, which is thermally coupled to a fan line of the air conditioner. The fan line promotes cooled air in an interior of the motor vehicle as a function of a user setting 2 ,

The electromotive refrigerant compressor 12 is by means of a bus system 18 , which is a CAN bus system or a Lin bus system, signaling with a motor vehicle control 20 coupled, such as an on-board computer. By means of a vehicle electrical system 22 which carries the respective electrical voltage, for example 48V, and by means of a battery 24 is fed, the electromotive refrigerant compressor 12 energized. The electrical system 22 further comprises a securing device 26 , by means of which an electric current flow between the battery 24 and the refrigerant compressor 12 can be prevented. For this purpose, the safety device 26 for example, a load and / or circuit breaker. The safety device 26 is by means of the bus system 18 or otherwise signaling technology with the vehicle control 20 connected so that by means of the vehicle control 20 the load or circuit breaker actuated and thus the electric current flow can be prevented.

2 shows schematically simplified, the electromotive refrigerant compressor 12 in a sectional view along an axis of rotation 28 an electric motor 30 of the refrigerant compressor 12 , The electric motor 30 has a cylindrical rotor 32, the circumference by means of a hollow cylindrical stator 34 is surrounded. The rotor 32 is by means of a wave 36 rotatable about the axis of rotation 28 stored. At the wave 36 is a compressor head on the free end 38 rotatably connected, for example, a scroll compressor. The stator 34 is by means of an electronics 40 energized with the bus system 18 and the electrical system 22 connected is.

The electric motor 30 , the compressor head 38 and the electronics 40 are in a housing 42 arranged from an aluminum die casting, which has a substantially hollow cylindrical shape and concentric with the axis of rotation 28 is. The housing 42 includes an inlet 44 over which the refrigerant 10 enters the housing 42 and along the electric motor 30 to the compressor head 38 is sucked, by means of which an increase in pressure takes place. The compressed by means of the compressor head 38 refrigerant 10 is by means of a process 46 out of the case 34 promoted.

The housing 42 includes a partition 48 , by means of which an electronics housing 50 from that of the refrigerant 10 flowed through part of the housing 42 is separated. Inside the electronics housing 50 is the electronics 40 arranged. The partition 48 has a via 52 on, which is pressure-tight, and over which the energization of the stator 34 he follows. On the partition 48 in the axial direction, that is parallel to the axis of rotation 28 , opposite side includes the electronics housing 50 a housing cover made of a metal 54 by means of screws on other components of the electronics housing 50 is releasably secured, and which an opening of the electronics housing 50 closes.

In 3 is in perspective the electric motor 30 shown in simplified form. The rotor 32 has a rotor core 56 on, within which eight permanent magnets 58 are arranged (buried). The rotor 32 is circumferentially from the stator 34 surrounded, which is a laminated stator core 60 with twelve teeth 62 that points to the rotor 32 are prepared. Between each adjacent teeth 62 Grooves 64 are formed so that the stator 34 a total of twelve such grooves 64 having.

On every tooth 62 is in each case an electrical winding 66 inserted, of which a perspective in the 4 to 6 is shown. The electrical windings 66 are identical to one another. Every electrical winding 66 has a first turn 68 , a second turn 70 , a third turn 72 , a fourth turn 74, a fifth turn 76 and a sixth turn 78 on, which are each punched from a copper plate. Each of the turns 68 . 70 . 72 . 74 . 76 . 78 is plan and a ring with one slot each 80 , In other words, each turn 68, 70, 72, 74, 76, 78 is not closed, but open. At the first turn 68 is a connection 82 formed. At the sixth turn 78 is another connection 83 Molded so that every electrical winding 66 two terminals 82, 84 has. In the assembled state are the two connections 82 . 84 with the electronics 40 electrically contacted. By means of the electrical winding 66 During operation, a magnetic field is generated which is in contact with the permanent magnets 58 of the rotor 32 interacts.

Between the first turn 68 and the second turn 70 is how in 4 you can see a first layer of insulation 84 arranged, which is created from an insulation paper. Between the second turn 70 and the third turn 72 is a second insulation layer 86 arranged. Also between the other turns 72 . 74 . 76 . 78 Further insulation layers are arranged, which are not shown in detail. By means of the insulation layers 84 . 86 are the turns 68 . 70 . 72 . 74 . 76 . 78 electrically isolated from each other.

In 7 is a procedure 88 for producing the electrical winding 66 shown. In a first step 90 become the first turn 68 , the second turn 70 , the third turn 72 and the other turns 74 . 76 . 78 punched from an electrically uninsulated metal plate. The flat metal plate is 3mm thick and made of pure copper. At the first turn 68 Here is the connection 82 already formed. The turns 68 . 70 . 72 . 74 . 76 . 78 show successively a larger extent in a direction parallel to a tangential direction of the stator 34 is.

In a second step 92 becomes the second turn 70 in an axial direction A on the first turn 68 stacked, each in a radial direction R , ie perpendicular to the axial direction A , inner recesses are aligned with each other. Following this are the two turns 68 . 70 training a first contact point 93 contacted by means of resistance brazing with the aid of solder directly electrically. Here lies, as in 8th shown a first electrode 94 at the first turn 68 and a second electrode 96 at the second turn 70 at. In other words, the first turn 68 with the first electrode 94 and the second turn 70 with the second electrode 96 electrically contacted. By applying an electrical voltage between the two electrodes 94 . 96 and due to the resulting current flow, the solder is melted, and the two windings 68, 70 are connected to each other by means of the solder. This is due to the uninsulatedness of the two turns 68 . 70 also a flow of current through other locations except the first contact point 93 possible. To prevent this, the two turns are 68 . 70 by means of the two electrodes 94 . 96 in the area of the first contact point 93 pressed together. The first contact point 93 is located directly adjacent to the slot 80 the first turn 68 as well as to the slot 80 the second turn 70 ,

In a subsequent third step 98 becomes the third turn 72 in the axial direction A on the second turn 70 stacked, leaving the second turn 70 in the axial direction A between the first turn 68 and the third turn 72 is arranged. After positioning the third turn 72 this is by means of resistance brazing to form a second contact point 100 with the second turn 70 electrically contacted. This is the second turn 70 with the exception of a possible lot in the area of the second contact 100 mechanically directly at the third turn 72 and is thus electrically contacted directly with this. The second contact point 100 is with respect to the first contact point 93 perpendicular to the axial direction A offset, wherein the second contact point 100 adjacent to the slot 80 the second turn 70 and to the slot 80 of the third turn 72 is. For the production of the second contact point 100 is the first electrode 94 electrically with the first turn 68 and the third turn 72 with the second electrode 96 electrically contacted. Here, the first electrode 94 is mechanically directly on the first turn 98 and the second electrode 96 mechanically directly at the third turn 72 at. As a result, only on the two outer turns 68 . 72 by means of the electrodes 94 . 96 Heat applied, which is why the first contact point 93 does not open again. Following this are the other turns 74 . 76 . 78 successively in the axial direction A stacked on top of each other and by means of the two electrodes 94 . 96 electrically electrically contacted with the respective preceding turn, so that the in 9 shown package is created. By means of the contact points created in this way, a step shape is created.

In a subsequent fourth step 102 will be between the first turn 68 and the second turn 70 the first insulation layer 84 and between the second turn 70 and the third turn 72 the second insulation layer 86 brought in. Also between the further turns further insulation layers are introduced, which are the adjacent turns 68 . 70 , 72, 74, 76, 78 with the exception of the respective contact points 93 . 100 electrically isolate against each other. As a result, there is a flow of current between the individual turns 68 . 70 . 72 . 74 . 76 . 78 only via the respective contact points 93 . 100 possible. The two insulation layers 84 . 86 stand in the radial direction R concerning the first turn 68 , the second turn 70 and the third turn 72 both outside and inside over. The other, not shown insulation layers are in the radial direction R both inside and outside over the respective adjacent turns 72 . 74 . 76 . 78 above. The supernatant of the insulation layers 84 . 86 is for example on the side of the connections 82 . 83 and enlarged on the opposite side. The insulation layers themselves are created by punching or a cutting plotter from a large layer of insulation material. Further, the turns are contacted with each other electrically 68 . 70 . 72 . 74 . 76 . 78 as well as the interposed insulating layers 84 . 86 with a coating 104 Mistake. The coating 104 is applied by dipping. In other words, the coating 104 is an exchange coating and consists of a lacquer.

If the 10 shown stator 34 with the laminated stator core 60 that only nine teeth 62 and thus only nine grooves 64 is used, becomes a fifth step 106 executed, in which the electrically contacted turns 68 . 70 . 72 . 74 . 76 . 78 in a direction perpendicular to the axial direction A be bent so that the cross section of the electrical winding 66 is essentially V-shaped. In this case, the bending axis is perpendicular to the axial direction A and parallel to the direction to which the slots 80 as well as the contact points 93 . 100 spaced apart from each other. Due to the bend is a desire of the electrical winding 66 reduced, so even with the reduced number of teeth 62 the rotor 32 of the electric motor 30 of the previous embodiment can be used.

Unless the electrical winding 66 on the tooth 62 is to be mounted, becomes a sixth step 108 executed. Here are by means of a gripper 110 the insulation layers 84 . 86 at the over the turns 68 . 70 . 72 . 74 . 76 . 78 in the radial direction R outside protruding end, as in 12 in a sectional view along the axial direction A schematically simplified with a modified electrical coil 66 is shown. The opening formed between the turns 112 gets above the tooth 62 positioned and the turn 66 put on this. By means of the gripper 110 becomes the electrical winding 66 in the axial direction A on the tooth 62 reared. Here are the radial direction R internal projections of the insulation layers 84 . 86 bent over, so that by means of this tolerance compensation between the turns 68, 70. 72, 74, 76, 78 and the tooth 62 is created. In addition, the turns 68 . 72 . 74 . 76 . 78 by means of the bent parts of the insulating layers 84 , 86 electrically against the tooth 62 isolated. The complete mounting condition is in 13 shown. Because the turns 68 . 70 . 72 . 74 . 76 . 78 Flat conductors are, these can be formed relatively free, so a degree of filling of the grooves 64 is reduced. Also, a current carrying capacity of the electric winding 66 due to the comparatively large cross section of the turns 68 . 70 . 72 . 74 , 76, 78 increased. Owing to the overhanging of the insulation layers 85, 86, handleability on the one hand is improved and, on the other hand, stable seating and electrical insulation with respect to the (stator) tooth 62 are made possible.

In summary, the turns 68 . 70 . 72 . 76 . 78 successively secured together by means of resistance brazing and electrically contacted, with the individual turns 68 . 70 . 72 . 76 . 78 are created from the bare, non-insulated metal plate and only in the fourth step 102 get the electrical insulation. By means of the electrodes 94 . 96 In the case of the resistance brazing process, only the heat is transferred to the uppermost turn 68 . 70 . 72 . 76 . 78 brought in. The insulation layers 84 . 86 stand in the radial direction R over and are cut, for example by means of a Schneidplotters. Due to the radial overhang, it is easier, this between the individual turns 68 , 70, 72, 76, 78. For this purpose, the individual turns 68 . 70 , 72, 74, 76, 78 preferably exploded, for which a corresponding tool, for example, at the terminals 82 . 84 intervenes. The individual turns 68 . 70 . 72 . 74 . 76 . 78 are always due to the contact points 93 . 100 connected with each other. Due to the bend perpendicular to the axial direction A , as in 11 Stators can also be shown 34 with a comparatively small number of teeth 62 be used, the rotor 32 has a comparatively large diameter. In particular, the electric motor 30 operated with 48V. Due to the coating 104 is a short circuit between the individual turns 68 . 70 , 72, 74, 76, 78 avoided. Also, the electrical windings can 66 the refrigerant 10 be exposed without causing any corrosion of the individual turns 68 . 70 . 72 . 74 . 76 . 78 he follows.

The invention is not limited to the embodiments described above. Rather, other variants of the invention can be derived therefrom by the person skilled in the art without departing from the subject matter of the invention. In particular, all the individual features described in connection with the individual embodiments are also combinable with one another in other ways, without departing from the subject matter of the invention.

LIST OF REFERENCE NUMBERS

2

motor vehicle

4

front

6

rear wheel

8th

Refrigerant circulation

10

refrigerant

12

electromotive refrigerant compressor

14

capacitor

16

Evaporator

18

Bus system

20

Automotive control

22

board network

24

battery

26

safety device

28

axis of rotation

30

electric motor

32

rotor

34

stator

36

wave

38

compressor head

40

electronics

42

casing

44

Intake

46

procedure

48

partition wall

50

electronics housing

52

via

54

housing cover

56

Laminated core

58

permanent magnet

60

stator lamination

62

tooth

64

groove

66

electrical winding

68

first turn

70

second turn

72

third turn

74

fourth turn

76

fifth turn

78

sixth turn

80

slot

82

connection

83

further connection

84

first insulation layer

86

second insulation layer

88

method

90

first step

92

second step

93

first contact point

94

first electrode

96

second electrode

98

third step

100

second contact point

102

fourth step

104

coating

106

fifth step

108

sixth step

110

grab

112

opening

A

axially

R

radial direction

Claims (11)

Method (88) for producing an electrical winding (66) of an electrical machine (30) of a motor vehicle (2), in particular of an electromotive refrigerant compressor (12), in which a first and a second turn (68, 70) are stacked on top of one another in an axial direction (A) and are electrically contacted to one another with the formation of a first contact point (93) by means of a contact material, a third winding (72) is stacked in the axial direction (A) on the second winding (70) and electrically contacted to form a second contact point (100) by means of a contact material with the second winding (70), and wherein - A contact material is used, the melting temperature is less than the melting temperature of the first, second and third windings (68, 70, 72). Method (88) according to Claim 1 , characterized in that the first turn (68), the second turn (70) and the third turn (72) are made of an electrically uninsulated metal plate, in particular punched. Method (88) according to Claim 1 or 2 , characterized in that the turns (68, 70, 72) electrically contacted with each other are bent in a direction perpendicular to the axial direction (A). Method (88) according to one of Claims 1 to 3 , characterized in that between the first winding (68) and the second winding (70) a first insulating layer (84) and between the second winding (70) and the third winding (72) a second insulating layer (86) is introduced. Method (88) according to Claim 4 characterized in that the first insulating layer (84) and the second insulating layer (86) are selected to extend in a radial direction (R) across the first turn (68), second turn (70) and third turn (72 ) survive. Method (88) according to one of Claims 1 to 5 , characterized in that the turns (68, 70, 72) which are in contact with each other electrically are provided by means of a coating (104). Method (88) according to one of Claims 1 to 6 , characterized in that the electrical contacting takes place by means of resistance brazing. Electric winding (66) of an electric machine (30) of a motor vehicle (2), in particular of an electromotive refrigerant compressor (12), which according to a method (88) according to one of Claims 1 to 7 is made. Electric winding (66) after Claim 8 , characterized in that the first contact point (93) and the second contact point (100) are mutually offset perpendicular to the axial direction (A). Electric winding (66) after Claim 8 or 9 , characterized in that at the first turn (68), a terminal (82) is integrally formed. Electric winding (66) according to one of Claims 8 to 10 characterized in that each turn (68, 70, 72) is a ring having a slot (80), the slot (80) being directly adjacent to the respective contact point (93, 100).

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