DE102018009206B3 - Connection component for connecting electrical conductors of a hairpin winding of a stator of an electrical machine and method for producing this connection - Google Patents

Connection component for connecting electrical conductors of a hairpin winding of a stator of an electrical machine and method for producing this connection

Info

Publication number
DE102018009206B3
DE102018009206B3 DE102018009206.3A DE102018009206A DE102018009206B3 DE 102018009206 B3 DE102018009206 B3 DE 102018009206B3 DE 102018009206 A DE102018009206 A DE 102018009206A DE 102018009206 B3 DE102018009206 B3 DE 102018009206B3
Authority
DE
Germany
Prior art keywords
shaped
conductor bars
hairpin conductor
receiving space
cap
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
DE102018009206.3A
Other languages
German (de)
Inventor
Norman Kroll-Gast
Richard A. Rasp
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gehring E Tech GmbH
Gehring E-Tech GmbH
Original Assignee
Gehring E Tech GmbH
Gehring E-Tech GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gehring E Tech GmbH, Gehring E-Tech GmbH filed Critical Gehring E Tech GmbH
Priority to DE102018009206.3A priority Critical patent/DE102018009206B3/en
Application granted granted Critical
Publication of DE102018009206B3 publication Critical patent/DE102018009206B3/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/04Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • H02K3/14Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots with transposed conductors, e.g. twisted conductors
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0056Manufacturing winding connections
    • H02K15/0068Connecting winding sections; Forming leads; Connecting leads to terminals
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0056Manufacturing winding connections
    • H02K15/0068Connecting winding sections; Forming leads; Connecting leads to terminals
    • H02K15/0081Connecting winding sections; Forming leads; Connecting leads to terminals for form-wound windings
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/04Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28Layout of windings or of connections between windings
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/46Fastening of windings on the stator or rotor structure
    • H02K3/50Fastening of winding heads, equalising connectors, or connections thereto
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K2203/00Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/09Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations

Abstract

The invention relates to an electrically conductive connecting component (20, 30, 40) which, in the case of a stator of an electric machine with at least one hairpin winding (3), electrically connects free ends (4) of mutually associated hairpin conductor bars (6). The connecting component (20, 30, 40) has a cap-shaped connecting area (8) with a receiving space (9), in which free ends (4) of at least two mutually assigned conductor bars (6) can be received. To enable the electrical connection to be made in an automated and process-reliable manner, the invention provides that the receiving space (9) of the at least one cap-shaped connecting region (8) of the connecting component (20, 30, 40) has three side walls (10, 11, 12) and a top wall (13) is delimited, and that the top wall (13) has at least one through hole (14) which opens into the receiving space (9). The side walls (10, 11, 12) surround the hairpin conductor bars (6) in a form-fitting manner and a laser beam (33) can be conducted through the through hole (14), which thermally connects the hairpin conductor bars (6) to one another and electrically generated with the connecting member (20, 30, 40). The invention also relates to a method for using these connecting components (20, 30, 40).

Description

  • The invention relates to an electrically conductive connection component for connecting electrical conductors of a hairpin winding of a stator of an electrical machine according to the preamble of claim 1 and a method for producing this connection according to the independent method claim. In addition, the invention relates to a stator of an electric machine, which is equipped with such electrical connection components.
  • For example from the DE 103 21 702 A1 a so-called hairpin wound stator is known, in which the stator has a hollow cylindrical stator core, in the inner lateral surface of which laterally extending slots are formed. In each of these slots, four electrical conductors which are approximately rectangular in cross section are used, which are bent in a U-shape in the middle and are therefore also referred to as hairpin conductors or hairpin conductor bars. In the area of the slots, the legs of the hairpin conductor bars are insulated in order to prevent electrical contact with other hairpin conductor bars arranged in the same stator slot and with the stator core. Only at their free ends is there no insulation material to make electrical contact with other hairpin conductor bars. The free ends of the hairpin conductor bars protrude axially from the stator core, while their bent section forms the winding head of the stator. In order to produce the stator winding, the two free ends of each U-shaped hairpin conductor bar are bent in the circumferential direction of the stator core. The two free ends of each hairpin conductor bar are then connected in an electrically conductive manner to further hairpin conductor bars arranged more or less far away.
  • Various connection components and connection methods are known for the electrical connection of the hairpin conductor bars. The hairpin conductor bars can be contacted by soldering, welding or crimping. Welding or soldering the free ends of hairpin conductor bars of a stator winding can lead to a very complicated and labor-intensive manufacturing process given the large number of connection points on a stator. As such, it is advantageous to weld the free ends of the hairpin conductor bars to the free Eden of associated other hairpin conductor bars. If, however, only one welded connection is made incorrectly, all hairpin conductor bars must be pulled out of the stator core in order to then refill it with other hairpin conductor bars and carry out the welding again. A stator in which hairpin conductor bars are welded during a manufacturing process is exemplified in the DE 601 29 902 T2 known. The EP 3 088 124 B1 and the US 2003/0 159 269 A1 disclose manufacturing processes in which adjacent hairpin conductor bars are connected to one another by means of a laser beam or electron beam.
  • From the DE 10 2012 219 668 A1 a method is also known in which the free ends of two hairpin conductor bars to be connected are connected purely mechanically by a cap-shaped, electrically conductive connecting component. Finally, this connection component is covered with a cap formed from an insulator. Accordingly, the hairpin windings of the stator should be able to be produced without a welding process. A similar welding-free manufacturing process using cap-shaped, electrically conductive connecting components is known from the US 9 847 683 B2 known.
  • It is also from the DE 103 21 702 A1 a connecting device is known with which the amount of work for establishing the electrical connections between hairpin conductor bars of a hairpin-wound stator should be small. In this connection device, a component is used which has to be placed on the stator and soldered, welded or crimped there. The connection device comprises an insulating plate with a plurality of slots arranged therein. Each of the slots is arranged and arranged to receive a leg end of a hairpin ladder bar. A plurality of electrical connecting elements are arranged on the plate, by means of which leg ends of the hairpin conductor bars assigned to one another can be electrically connected to one another. These connecting elements can be designed, for example, as straight connecting elements, C-shaped connecting elements, Z-shaped connecting elements or S-shaped connecting elements.
  • DE 10 2011 016 115 A1 and US 2018/0 040 392 A1 disclose an electrically conductive connector with the features of the preamble of claim 1 and DE 10 2011 016 115 A1 a method for connecting free ends of hairpin conductor bars with the features of the preamble of claim 15.
  • The known thermally or purely mechanical methods and devices for electrically connecting ends of hairpin conductor bars assigned to one another have all the advantages and disadvantages. The invention was therefore based on the object of presenting a new device for connecting the aforementioned hairpin conductor bars, which has the advantages of purely mechanical electrical connection components with the advantages of thermal connection methods connects. In addition, a manufacturing process should be presented, by means of which these new connecting components can be mechanically and thermally connected quickly and safely to the free ends of hairpin conductor bars assigned to one another.
  • The solution of these tasks is first achieved with a connecting component which has the features of claim 1. An independent procedural claim defines the procedure for how these new connecting components can be mechanically and thermally connected quickly and reliably with free ends of hairpin conductor bars assigned to one another with regard to good electrical conductivity. A usage claim specifies where and how these connecting components can be used particularly advantageously. Associated pending claims define advantageous developments of the invention.
  • Accordingly, the invention is based on an electrically conductive connection component which, in the case of a stator of an electrical machine with at least one hairpin winding, electrically connects free ends of mutually associated hairpin conductor bars to one another, the connection component having a cap-shaped connection region with a receiving space in which free ends can be picked up by at least two mutually assigned conductor bars.
  • To achieve the device-related object, it is provided that the receiving space of the at least one cap-shaped connecting area of the connecting component is delimited by three side walls and a top wall, and that the top wall has at least one through hole which opens into the receiving space.
  • The invention was based on the finding that the free ends of hairpin conductor bars assigned to one another can be most reliably connected to one another in an electrically conductive manner by a mechanical and additionally by a thermal connection. The mechanical and electrical connection of the hairpin conductor rods concerned, which is to be carried out first in terms of time, is carried out by positive locking by means of the cap-shaped connecting components, which ensure that the respective hairpin conductor rods abut one another and on the respective cap-shaped connecting component. This creates a first electrical contact of the hairpin conductor bars, which is the starting point for the thermal connection that then follows. In order to enable the thermal contacting of the hairpin conductor bars assigned to one another, the cap-shaped connecting components used have an opening in their respective top wall of the receiving spaces through which a laser beam can reach the front surface of the paired hairpin conductor bars. The laser beam then welds the respective cap-shaped connecting component to the associated hairpin conductor bars as well as these hairpin conductor bars to one another.
  • The combination of the purely mechanical contacting of the free ends of mutually assigned hairpin conductor bars with the described thermal contacting of the hairpin conductor bars at the end face by means of a laser beam can be ensured with an extremely high degree of certainty that even with fully automatic production of the described bar winding of a stator the electrical connection between two mutually associated ends of hairpin conductor bars will be successful. Such a fully automatic manufacture of the stator winding is necessary in order to be able to manufacture electric motors more cheaply than before, which is an important prerequisite for the fact that they can be used successfully in private vehicles.
  • Due to the fact that the respective receiving space of the connecting components according to the invention is delimited by only three side walls and a top wall, at least two of the three side walls have good elastic deformability, which guarantees a play-free, form-fitting and mechanically stable electrical connection of the connecting components to the associated hairpin conductor bars.
  • According to a first advantageous development of the invention, it is provided that the connecting components have a J-shaped, an S-shaped, a Z-shaped or a C-shaped geometry. As a result, the connecting components are suitable for different tasks, for example, to function as connection lugs for individual stator windings or electrical phases, or for electrically connecting hairpin conductor bars that are more or less distant from one another but are assigned. Insofar as connection components with an S-shaped geometry are referred to in the following, this also means a Z-shaped geometry.
  • It is further preferably provided that the cap-shaped connection area of the J-shaped connection component is designed such that its side wall-free receiving space side in the installed state on the stator points radially inwards that the two cap-shaped connection areas of the C-shaped connection components are designed such that their two side wall-free components Receiving space sides in the installed state on the stator point radially inward, and that the two cap-shaped connecting areas of the S-shaped or Z-shaped connecting components are of such a type are formed so that their two side wall-less receiving space sides point in the installed state in opposite circumferential directions of the stator.
  • In one embodiment, the J-shaped connecting component has a long leg and a short leg, which are connected to one another via a connecting section, and in which at the end of the short leg a cap-shaped connecting area with a receiving space for receiving the free end of hairpin to be electrically connected Conductor rods is formed, and in which a contact plate with a through hole for carrying out a connecting element is formed on the end of the long leg.
  • According to a further development, the cap-shaped connecting area of the J-shaped connecting component has such a receiving space, the wall-less side of which forms the free end of the short leg and the side of the lid remote from the lid wall is wall-less.
  • The long leg of the J-shaped connecting component can also be designed to be flexible and, for this purpose, can consist, for example, of a copper wire mesh. In all embodiments of the J-shaped connecting component, however, it is provided that the effective cross-sectional area of the long leg, the connecting section and the short leg of the J-shaped connecting component is at least as large as the cross-sectional area of the free end of the at least one hairpin to be accommodated in its receiving space. Ladder staff. This ensures sufficient conductivity for an electrical current from one end to the other end of the J-shaped connecting component.
  • This J-shaped connecting component, which serves as a connecting driver, the basic characteristic of which is that it has only one receiving space for at least one hairpin conductor bar, can accordingly also have any other geometry, provided that it fulfills its intended function. What is decisive is the design of its cap-shaped connecting area, which delimits the receiving space for receiving the free end of preferably two directly adjacent conductor bars and is provided with a hole through which a laser beam can be guided for welding the connecting component to the aforementioned conductor bars.
  • The connection component, which is S-shaped or Z-shaped with regard to its geometric wall profile, has a cap-shaped connection area at its two ends, each with a receiving space for receiving the free end of hairpin conductor bars to be electrically connected. With regard to simple and safe assembly, it is considered advantageous if it is provided that the cap-shaped connecting regions of the S-shaped or Z-shaped connecting component each have a receiving space, the wall-free end faces of which are oriented in opposite directions, and that the latter is directed towards the cover wall Facing opposite coverless sides in the same direction.
  • Another advantageous development of the S-shaped or Z-shaped connecting component provides that its cap-shaped connecting areas are connected to one another via a web section, the cross-sectional area of which is at least as large as the cross-sectional area of the respective free end of the hairpin conductor bars to be connected. This ensures sufficient conductivity for an electrical current from one end to the other end of the connecting component and good mechanical stability of the connecting component is achieved.
  • The C-shaped connecting component, on the other hand, has a C-shaped leg, at the two ends of which a cap-shaped connecting area is formed, each with a receiving space for receiving the free end of hairpin conductor bars to be electrically connected. With regard to simple and safe assembly, it is advantageous here if it is provided that the cap-shaped connecting regions of the C-shaped connecting component each have a receiving space, the wall-less end faces of which do not point in opposite directions, and the sides of the lid remote from the lid wall are wall-free. The C-shaped leg has a cross-sectional area which is at least as large as the cross-sectional area of the respective free end of the hairpin conductor bars to be connected. This also ensures sufficient conductivity for an electrical current from one end to the other end of this connecting component and good mechanical stability is achieved.
  • In addition, it is preferably provided that the C-shaped connecting component has cranked sections starting from a central section, at the respective ends of which the two cap-shaped connecting areas are formed.
  • The through hole mentioned in the top wall of the respective connection area is preferably arranged and designed such that it covers the area in which the free ends of the hairpin conductor bars to be connected touch within the receiving space. This ensures that a laser beam directed through the through hole onto the hairpin conductor bars can connect them to the connecting component and also directly to one another.
  • Furthermore, it is preferably provided that the thickness of the cover wall of the connecting component is selected such that the cover wall can be welded to the hairpin conductor bars arranged in the receiving space by means of a laser beam. Accordingly, there is sufficient fusible material of the connection component in order to implement the electrical connection to be generated thermally.
  • In order to prevent molten material of the hairpin conductor bars and / or the connecting component from splashing out, it is further preferably provided that the thickness of the cover wall is selected so that, during laser welding, highly spraying metal comes into contact with the wall of the through hole and does not come out splashes out of the through hole. This can be favored by the fact that an annular wall extending away from the receiving space is formed on the edge of the hole.
  • The object relating to a manufacturing method is achieved by a method for electrically connecting the free ends of two hairpin conductor bars of a stator of an electric machine which are assigned to one another, which method has the following method steps:
  1. a) inserting the free ends of two mutually associated hairpin conductor bars of the stator into the at least one receiving space of the cap-shaped connecting area of a connecting component with the features of at least one of the preceding device claims,
  2. b) pressing the top wall of the receiving space onto the free ends of the hairpin conductor bars assigned to one another,
  3. c) generating a laser beam and directing it through a through hole in the top wall of the receiving space onto the front end of the hairpin conductor bars assigned to one another,
that the metallic material of the top wall and the metallic material of the hairpin conductor bars assigned to one another partially melt, thereby welding the top wall to the hairpin conductor bars.
  • It can be provided here that the laser beam is directed at the area at which the through hole in the cover wall ends on the end face of the hairpin conductor bars assigned to one another. As a result, the metal of the cover wall is welded to the metal of the hairpin conductor bars.
  • However, it can also be provided that the laser beam is directed at that end region of the hairpin conductor bars which are assigned to one another and on which they lie laterally against one another. As a result, the hairpin conductor bars assigned to one another are welded directly to one another.
  • It can further be provided that the laser beam is oriented at such an angle that a metallic melt, possibly partially highly sprayed, generated by the laser beam does not leave the through hole, but instead adheres to the wall of the through hole. This ensures that no welding material is caused by the welding process to get onto or into the stator windings.
  • Finally, the invention relates to the use of connecting components, which have the features of at least one of the device claims, on a stator of an electric machine designed as an electric motor and / or generator, the windings of the stator being formed by a plurality of hairpin conductor bars, and in the case of the the free ends of the hairpin conductor bars are electrically connected to one another in phase by means of S-shaped or Z-shaped and C-shaped connecting components, and in the case of the J-shaped connecting components serving as electrical connection elements, each winding of the stator is electrically connected with at least one hairpin conductor bar are connected.
  • To further clarify the invention, the description is accompanied by a drawing in which several exemplary embodiments are shown. This drawing shows
    • 1 3 shows a perspective top view of a stator core with hairpin conductor bars arranged thereon, which are connected in phase to one another or to connection elements in a phase-appropriate manner on a connection and connection side of the stator core via connection components according to the invention,
    • 2nd according to the stator core 1 with a view of its connection and connection side,
    • 3a to 3d perspective views of a J-shaped connecting component which is designed as an electrical connection element,
    • 4a to 4e perspective views of an S-shaped or Z-shaped Connection component which is designed for the electrical connection of hairpin conductor bars,
    • 5a to 5d perspective views of a C-shaped connecting component which is designed for the electrical connection of hairpin conductor bars,
    • 6 2 shows a schematic sectional illustration through a connection area of a connection component according to the invention with two hairpin conductor bars accommodated therein during a welding process on the edge with a laser beam, and
    • 7 is a schematic sectional view through a connection area of a connection component according to the invention with two hairpin conductor bars accommodated therein during a central welding process with a laser beam.
  • In the figures to be described, the same components are provided with the same reference numerals
  • Accordingly, they show 1 and 2nd a hollow cylindrical stator core 2nd of a stator of an electric machine. This electric machine can be an electric motor, a generator or a starter / generator. The stator core 2nd has grooves aligned on its inside parallel to its longitudinal center axis 51 on. In these grooves 51 are U-shaped hairpin conductor bars with a largely rectangular cross-section in their initial geometry 6 arranged. Can be seen in each of the grooves 51 four hairpin ladder bars 6 inserted so that the hairpin ladder bars 6 as a result are arranged in four mutually concentric rings of different diameters. The legs of the respective U-shaped hairpin conductor bars overlap 6 end of each of several of the grooves 51 . In addition, the U-shaped arches of the hairpin ladder bars form 6 at one end of the stator core 2nd a winding head 52 and at the opposite end of the stator core 2nd a connection and connection side of the stator windings 3rd the three-phase electric machine here.
  • Around the stator windings 3rd to be able to produce, the free ends of the respective hairpin conductor bars 6 in the circumferential direction of the stator core 2nd each bent. Subsequently, the free ends of hairpin conductor bars assigned to one another in phase were formed 6 by means of the connecting components according to the invention 20th , 30th , 40 electrically connected. These connecting components connect 20th , 30th , 40 recognizable in each case two radially immediately adjacent hairpin conductor bars 6 with each other. The C-shaped connector 40 overlap other connecting components 20th , 30th , 40 axially and in the circumferential direction of the stator core 2nd . The connecting components 20th , 30th , 40 each have at least one connection area at the end 8th otherwise they are designed in three different geometries, which will be discussed first.
  • The connecting components 20th , 30th , 40 are in the 3a to 3d , 4a to 4e , 5a to 5d such as 6 and 7 shown in different views. Based on 3a to 3d it can be seen that a first embodiment of the connecting components 20th has a substantially J-shaped geometry. In this case, such a connecting component 20th a long leg 21 and a short leg bent away from it 22 as well as one of these thighs 20th , 21 connecting connecting section. On the short leg 22 is a cap-shaped connection area at the end 8th with one recording room each 9 designed to accommodate the free end of two electrically connectable hairpin conductor bars 6. On the long leg 21 is a contact plate at the end 23 with a through hole 24th formed through which a connecting element, for example in the form of a machine screw, can be passed. On this contact plate 23 an electrical line is usually connected, which leads to the outside of the housing of the electric machine. The cap-shaped connection area 8th of the J-shaped connector 20th has a recording room 9 with three side walls 10th , 11 , 12th and a top wall 13 on, with a wallless end face the free end of the short leg 22 forms and the side opposite the top wall 13 is wallless.
  • As the 1 and 2nd illustrate, are three J-shaped connecting members 20th such on the stator core 2nd arranged that the lidless side of the respective recording rooms 9 axially inwards and the wallless end face of the respective short leg 22 point radially inwards. The long leg 21 , the short leg 22 and those two legs 21 , 22 connecting connection areas each have a cross-sectional area which is at least as large as the cross-sectional area of the in the cap-shaped connection area 8th free end to be recorded 4th of the assigned conductor rod 6 .
  • That in the 4a to 4e shown and in terms of its wall geometry S-shaped or Z-shaped connecting component 30th has a cap-shaped connection area at its two ends 8th with one recording room each 9 on, which are also designed to receive the free end of two electrically connectable hairpin conductor bars 6. The cap-shaped connection areas 8th of the S-shaped or Z-shaped connecting component 30th each have a recording room 9 with three side walls 10th , 11 , 12th and a top wall 13 on, the wallless End faces are aligned in opposite directions compared to each other. The opposite of the respective top wall 13 Lying wallless sides point in the same direction.
  • How in particular 4c clearly shows are the two cap-shaped connection areas 8th of the S-shaped or Z-shaped connecting component 30th over a web section 31 connected to one another, the cross-sectional area QF of which is at least as large as the cross-sectional area of the respective free end 4th of the hairpin ladder bars to be connected 6 . As a result, the connecting component 30th a comparatively high mechanical stability and sufficient conductivity for an electrical current from one end to the other end of the connecting component.
  • The 5a to 5d show a third embodiment in which the connecting member 40 has a substantially C-shaped geometry. This connector 40 has a C-shaped leg 41 on, at both ends of which a cap-shaped connection area 8th with one recording room each 9 is formed, in which the free ends 4th of two electrically connectable hairpin conductor bars 6 can be used. The recording rooms 9 are each by three side walls 10th , 11 , 12th and a top wall 13 bounded. The wallless front of the two recording rooms 9 of the C-shaped connector 40 do not point in opposite directions. The opposite of the respective top wall 13 lying wallless sides of the two recording rooms 9 are open in the same direction. When installed, therefore, the wall-free end faces of the two recording rooms 9 of the C-shaped connector 40 on the stator radially inwards and opposite the respective cover wall 13 lying wallless sides of the two recording rooms 9 axially inwards.
  • The C-shaped leg 41 of the connecting component 40 has a cross-sectional area which is at least as large as the cross-sectional area of the respective free end 4th of the hairpin conductor bars 6 to be connected. This achieves good mechanical stability and sufficient conductivity for an electrical current.
  • In addition, in the 5a to 5d recognizable that the C-shaped connecting component 40 Cranked sections starting from a central section 42 , 43 has at its respective end the two cap-shaped connection areas 8th are trained. This will secure the C-shaped connecting components 40 on the radially aligned hairpin conductor bars, which are rectangular in cross section 6 facilitated.
  • All of these connection components 20th , 30th , 40 have a specialty according to the invention. Accordingly, it is provided that the recording rooms 9 the cap-shaped connection areas 8th the connecting components of three side walls 10th , 11 , 12th and a top wall 13 is bounded, the top wall 13 at least one through hole 14 has, which in the recording room 9 flows. As the 6 and 7 To illustrate particularly well, it is provided that the through hole 14 is arranged and designed in such a way that it covers that area in which the free ends 4th of the hairpin conductor bars 6 to be connected are located within the receiving space 9 touch on the side.
  • The fat D the top wall 13 the cap-shaped connection areas 8th is selected so that the top wall is welded 13 with those in the recording room 9 arranged hairpin conductor bars 6 by means of a laser beam 33 is possible. For this purpose, the top wall has 13 for example a thickness D from 1 mm to 3 mm so that there is sufficient cover wall material which can be melted during a welding process and still keep contact with the rest of the cover wall material in its molten phase.
  • The fat D the top wall 13 is also preferably selected such that during welding with a laser 32 highly splashing metal 36 not from the through hole 14 splashes out, but on the wall 34 of the through hole 14 arrives at the plant and solidifies there. This prevents metal particles generated by the welding process from reaching impermissible areas of the stator.
  • The described structure of the connecting elements according to the invention 20th , 30th , 40 enables a combined mechanical and thermal connection of at least two mutually assigned hairpin conductor bars 6 in a particularly process-reliable and fully automatic manner. These fasteners 20th , 30th , 40 are therefore particularly suitable for fast and inexpensive manufacture of stators in an electrical machine. The use of these connecting elements 20th , 30th , 40 is also possible and just as advantageous in the manufacture of rotors of an electric machine.
  • The invention also relates to a method for electrically connecting the free ends 4th of two mutually assigned hairpin conductor bars 6 of a stator of an electric machine, which has the following steps:
    1. a) attaching at least one cap-shaped connection area 8th a connecting component 20th , 30th , 40 with the features of at least one of the previous device claims for the free end 4th of at least two mutually assigned hairpin conductor rods 6 of the stator, the free ends 4th in an assigned recording room 9 of the cap-shaped connection area 8th to be ordered,
    2. b) Press on the top wall 13 of the recording room 9 on the free ends of the hairpin conductor bars 6 assigned to one another,
    3. c) generating a laser beam 33 and direct it through a through hole 14 in the top wall 13 of the recording room 9 on the front end of the assigned hairpin conductor bars 6 such
    that metallic material of the top wall 13 as well as metallic material of the mutually assigned hairpin conductor bars 6 partially melts and a common melt 35 forms, causing the top wall 13 is welded to the hairpin conductor bars 6.
  • The fact that the connecting components 20th , 30th , 40 the hairpin ladder bars to be attached 6 in the respective, isolator-free recording room 9 Gripping tightly is a first mechanical and electrical connection between the hairpin conductor bars 6 and the connecting member 20th , 30th , 40 generated. By means of the subsequent welding using the laser beam 33 was a second mechanical and electrical connection between the hairpin conductor bars 6 and the connecting component 20th , 30th , 40 generated. This double electrical and mechanical connection ensures that the described hairpin winding 3 of an electric machine can be produced quickly, safely and also inexpensively.
  • In a further embodiment of the manufacturing method described, it can be provided that the laser beam 33 is aimed specifically at the area where the through hole 14 in the top wall 13 ends on the end face of the hairpin conductor rods 6 assigned to one another. This will create a 6 Radial welding of the two hairpin conductor bars 6 shown with the connecting component shown there 30th reached, the volume-related formation of the melt 35 can be comparatively small. Depending on that by the laser beam 33 Coupled energy can also be a comparatively large amount of melt 35 form, which completely covers the through hole-side areas of the two hairpin conductor bars 6 ( 7 ). As a result, the two hairpin conductor bars 6 are particularly well electrically connected to one another.
  • According to the method, it can further be provided that the laser beam 33 is oriented at such an angle that one of the laser beam 33 generated, possibly partially highly spraying metallic melt 36 the through hole 14 not leaves, but at most on the wall 34 of the through hole 14 arrested.
  • The connection components described 20th , 30th , 40 are particularly advantageous for generating a winding 3rd a stator of an electrical machine used in hairpin design. The electric machine can be designed as an electric motor and / or generator. Here is the winding 3rd of the stator is formed by a plurality of, for example, U-shaped hairpin conductor bars, the free ends of the hairpin conductor bars 6 using the described S-shaped or Z-shaped and C-shaped connecting components 30th , 40 are electrically connected to each other in phase. The J-shaped connecting components 20th serve as electrical connection elements which each have a winding with at least one hairpin conductor bar 6 3rd of the stator are electrically connected.
  • Claims (19)

    1. Electrically conductive connecting component (20, 30, 40) which, in the case of a stator of an electrical machine with at least one hairpin winding (3), electrically connects free ends (4) of mutually associated hairpin conductor bars (6), the connecting component (20, 30, 40) has a cap-shaped connecting area (8) with a receiving space (9), in which free ends (4) of at least two mutually assigned conductor bars (6) can be received, characterized in that the receiving space (9) of the at least one cap-shaped Connection area (8) of the connecting component (20, 30, 40) is delimited by three side walls (10, 11, 12) and a cover wall (13), and that the cover wall (13) has at least one through hole (14), which in the Recording room (9) opens out.
    2. Connection component after Claim 1 , characterized in that it is designed as a J-shaped electrical connection component (20), as an S-shaped or Z-shaped electrical connection component (30), or as a C-shaped electrical connection component (40).
    3. Connection component after Claim 2 , characterized in that the cap-shaped connecting area (8) of the J-shaped connecting component (20) is designed such that its side wall-free receiving space side in the installed state on the stator points radially inwards that the two cap-shaped connecting areas (8) of the C-shaped connecting components (40) such are designed such that their two side wall-free receiving space sides point radially inward when installed on the stator, and that the two cap-shaped connecting areas (8) of the S-shaped or Z-shaped connecting components (30) are designed such that their two side wallless receiving space sides in installed condition in opposite circumferential directions of the stator.
    4. Connection component after Claim 2 or 3rd , characterized in that the J-shaped connecting component (20) has a long leg (21) and a short leg (22) which are connected to one another via a connecting section, that on the short leg (22) a cap-shaped connecting region (8 ) is formed with a receiving space (9) for receiving free ends of hairpin conductor bars (6) to be electrically connected, and that on the long leg (21) a contact plate (23) with a through hole (24) for carrying out a connecting element is formed at the end is.
    5. Connecting component according to one of the Claims 2 to 4th , characterized in that the cap-shaped connecting area (8) of the J-shaped connecting component (20) has a receiving space (9), the wall-free receiving space side of which forms the free end of the short leg (22) and the opposite end of the cover to the top wall (13) Side is wallless.
    6. Connection component after Claim 2 or 3rd , characterized in that the S-shaped connecting component (30) has a cap-shaped connecting area (8) at its two ends, each with a receiving space (9) for receiving free ends of hairpin conductor bars (6) to be electrically connected.
    7. Connection component after Claim 6 , characterized in that the cap-shaped connection areas (8) of the S-shaped or Z-shaped connection component (30) each have a receiving space (9), the wall-free end faces of which are oriented in opposite directions, and that their cover-free opposite to the cover wall (13) Point sides in the same direction.
    8. Connection component after Claim 6 or 7 , characterized in that the cap-shaped connecting regions (8) of the S-shaped or Z-shaped connecting component (30) are connected to one another via a web section (31) whose cross-sectional area (QF) is at least as large as the cross-sectional area of the respective free end ( 4) the hairpin conductor bars (6) to be connected.
    9. Connection component after Claim 2 or 3rd , characterized in that the C-shaped connecting component (40) has a cap-shaped connecting area (8) at each of its two ends, each with a receiving space (9) for receiving free ends of hairpin conductor bars (6) to be electrically connected, and that a C-shaped leg (41) formed between the two connecting areas (8) has a cross-sectional area (QF) which is at least as large as the cross-sectional area of the respective free end (4) of the hairpin conductor bars (6) to be connected.
    10. Connection component after Claim 9 , characterized in that the cap-shaped connecting areas (8) of the C-shaped connecting component (40) each have a receiving space (9), the wall-less end faces of which do not point in opposite directions, and the sides of the lid remote from the lid wall are wall-less.
    11. Connection component after Claim 9 or 10th , characterized in that the C-shaped connecting component (40) has sections (42, 43) which are bent inwards from a central section, at the respective ends of which the two cap-shaped connecting areas (8) are formed.
    12. Connecting component according to one of the preceding claims, characterized in that the through hole (14) is designed and arranged in such a way that it covers that area in which the free ends of the hairpin conductor bars (6) to be connected within the receiving space (9) touch .
    13. Connecting component according to one of the preceding claims, characterized in that the thickness (D) of the cover wall (13) is selected such that the cover wall (13) is welded to the hairpin conductor bars (6) arranged in the receiving space (9) by means of a laser Beam (33) is possible.
    14. Connection component after Claim 13 , characterized in that the thickness (D) of the cover wall (13) is selected such that metal (36) spraying highly with a laser (32) comes into contact with the wall (34) of the through hole (14) during welding and there stiffens.
    15. Method for the electrical connection of the free ends of mutually assigned hairpin conductor bars (6) of a stator of an electrical machine, characterized by the following method steps: a) plugging on at least one cap-shaped connection area (8) of a connection component (20, 30, 40) with the features of at least one of the device claims for the free end of at least two mutually associated hairpin conductor bars (6) of the stator, the free ends being arranged in an associated receiving space (9) of the cap-shaped connecting area (8), b) pressing the cover wall (13) of the receiving space (9) onto the free ends of the assigned hairpin conductor bars (6), c) generating a laser beam (33) and directing the same through a through hole (14) in the top wall (13) of the receiving space (9) to the front end of the assigned hairpin conductor bars (6) such that metallic material of the top wall (13) and metallic material of the hairpin conductor bars (6) assigned to one another partially melt and form a common melt (35), as a result of which the top wall (13) with the hairpin conductor bars (6) is welded.
    16. Procedure according to Claim 15 , characterized in that the laser beam (33) is directed at the area at which the through hole (14) in the cover wall (13) ends at the end face of the hairpin conductor bars (6) assigned to one another.
    17. Procedure according to Claim 15 or 16 , characterized in that the laser beam (33) is directed at that end region of the hairpin conductor bars (6) which are assigned to one another and on which they lie side by side.
    18. Procedure according to one of the Claims 15 to 17th , characterized in that the laser beam (33) is oriented at such an angle that a metallic melt (35) generated by the laser beam (33), possibly partially highly spraying, does not leave the through hole (14), but at most the wall (34) of the through hole (14) comes to adhere.
    19. Use of connecting components (20, 30, 40) according to at least one of the preceding claims on a stator of an electric machine designed as an electric motor and / or generator, the windings (3) of the stator being formed by a plurality of hairpin conductor bars (6), and in which the free ends of the hairpin conductor bars (6) are electrically connected to one another in phase by means of S-shaped or Z-shaped and C-shaped connecting components (30, 40), and in the case of the J-shaped connecting components (20) as electrical Serving connection elements are each electrically connected to at least one hairpin conductor bar (6) of a winding of the stator.
    DE102018009206.3A 2018-11-23 2018-11-23 Connection component for connecting electrical conductors of a hairpin winding of a stator of an electrical machine and method for producing this connection Active DE102018009206B3 (en)

    Priority Applications (1)

    Application Number Priority Date Filing Date Title
    DE102018009206.3A DE102018009206B3 (en) 2018-11-23 2018-11-23 Connection component for connecting electrical conductors of a hairpin winding of a stator of an electrical machine and method for producing this connection

    Applications Claiming Priority (2)

    Application Number Priority Date Filing Date Title
    DE102018009206.3A DE102018009206B3 (en) 2018-11-23 2018-11-23 Connection component for connecting electrical conductors of a hairpin winding of a stator of an electrical machine and method for producing this connection
    PCT/EP2019/082457 WO2020104701A1 (en) 2018-11-23 2019-11-25 Connection component for connecting electrical conductors of a hairpin winding of a stator of an electric machine, and method for producing said connection

    Publications (1)

    Publication Number Publication Date
    DE102018009206B3 true DE102018009206B3 (en) 2020-03-19

    Family

    ID=68655556

    Family Applications (1)

    Application Number Title Priority Date Filing Date
    DE102018009206.3A Active DE102018009206B3 (en) 2018-11-23 2018-11-23 Connection component for connecting electrical conductors of a hairpin winding of a stator of an electrical machine and method for producing this connection

    Country Status (2)

    Country Link
    DE (1) DE102018009206B3 (en)
    WO (1) WO2020104701A1 (en)

    Citations (8)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    US20030159269A1 (en) * 2001-02-28 2003-08-28 Romaric Lenoir Method for assembling conductive segments of a rotor winding or stator winding in a rotary electric machine
    DE10321702A1 (en) * 2002-05-15 2004-01-08 Delco Remy America, Inc., Anderson Hairpin wound electric machine connection device, has slots that are positioned in plate, which is made up of insulative material, receiving coil end of conductors, and jumpers providing connection between slots
    DE60129902T2 (en) * 2000-09-12 2008-05-08 Mitsubishi Denki K.K. Stand of a dynamoelectric machine and method for producing the same
    DE102011016115A1 (en) * 2010-04-13 2011-11-17 GM Global Technology Operations LLC Electric motor assemblies and systems associated with joining wires of electric motor assemblies
    DE102012219668A1 (en) * 2012-05-14 2013-11-14 Hyundai Mobis Co., Ltd. Method for binding stator coils of a motor
    US9847683B2 (en) * 2012-09-20 2017-12-19 Hyundai Mobis Co., Ltd. Hairpin connecting device and hairpin winding motor including the same
    US20180040392A1 (en) * 2016-08-03 2018-02-08 Honda Motor Co., Ltd Bus bar unit
    EP3088124B1 (en) * 2015-04-16 2018-03-14 Magneti Marelli S.p.A. Method of laser welding two adjacent metal elements of a stator winding with rigid bars for an electric machine

    Family Cites Families (5)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    US4321497A (en) * 1980-04-10 1982-03-23 Westinghouse Electric Corp. Peripheral connector ring stator end winding for dynamoelectric machines
    US10186925B2 (en) * 2015-04-16 2019-01-22 MAGNETI MARELLI S.p.A. Electric machine having a stator winding with rigid bars
    US10505423B2 (en) * 2016-09-30 2019-12-10 Faraday & Future Inc. Nested three phase bus bar unit
    DE102016219221A1 (en) * 2016-10-04 2018-04-05 Bayerische Motoren Werke Aktiengesellschaft Formstabstator and method for the production of the electrical switching
    DE102016225503A1 (en) * 2016-12-19 2018-06-21 Bayerische Motoren Werke Aktiengesellschaft Stator for a rotary electric machine

    Patent Citations (8)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    DE60129902T2 (en) * 2000-09-12 2008-05-08 Mitsubishi Denki K.K. Stand of a dynamoelectric machine and method for producing the same
    US20030159269A1 (en) * 2001-02-28 2003-08-28 Romaric Lenoir Method for assembling conductive segments of a rotor winding or stator winding in a rotary electric machine
    DE10321702A1 (en) * 2002-05-15 2004-01-08 Delco Remy America, Inc., Anderson Hairpin wound electric machine connection device, has slots that are positioned in plate, which is made up of insulative material, receiving coil end of conductors, and jumpers providing connection between slots
    DE102011016115A1 (en) * 2010-04-13 2011-11-17 GM Global Technology Operations LLC Electric motor assemblies and systems associated with joining wires of electric motor assemblies
    DE102012219668A1 (en) * 2012-05-14 2013-11-14 Hyundai Mobis Co., Ltd. Method for binding stator coils of a motor
    US9847683B2 (en) * 2012-09-20 2017-12-19 Hyundai Mobis Co., Ltd. Hairpin connecting device and hairpin winding motor including the same
    EP3088124B1 (en) * 2015-04-16 2018-03-14 Magneti Marelli S.p.A. Method of laser welding two adjacent metal elements of a stator winding with rigid bars for an electric machine
    US20180040392A1 (en) * 2016-08-03 2018-02-08 Honda Motor Co., Ltd Bus bar unit

    Also Published As

    Publication number Publication date
    WO2020104701A1 (en) 2020-05-28

    Similar Documents

    Publication Publication Date Title
    US4952829A (en) Rectifier arrangement
    US8183728B2 (en) Stator for an electric machine
    US9006961B2 (en) Endshield
    EP0106444B1 (en) Termination for electrical armature winding
    DE10152006B4 (en) Stator for an electric machine
    US9475440B2 (en) Electrical connection console for motor vehicle on-board electrical system conductor
    JP3668661B2 (en) Vehicle alternator
    US6949848B2 (en) Terminal for armature
    US9444154B2 (en) Terminal fitting-equipped conductor
    EP2013961B1 (en) Method for producing a bar winding for the stator of an electric machine
    CA1312113C (en) Motor field winding with intermediate tap
    KR100541334B1 (en) Rotary electric machine
    US4673834A (en) Enamelled wire connection for circuit boards
    JP4494457B2 (en) Centralized power distribution member for rotating electrical machines
    US7598637B2 (en) Stator for an electrical machine
    US9035523B2 (en) Coil for an electric machine and method for producing a coil
    KR101832984B1 (en) Device for establishing electrical contact between a shield of an electrical cable and a housing, and a pre-assembled cable
    JP2004056873A (en) Rotary electric machine
    EP2082472B1 (en) Electric motor
    US8294328B2 (en) Brush gear of a motor
    JP4703125B2 (en) Neutral point terminal device for rotating electrical machines
    EP2053706A2 (en) Electric motor commutator
    JP4816017B2 (en) Bus bar coupling unit for stator of rotating electrical machine
    US20140306561A1 (en) Motor connecting member and motor device
    JP6066609B2 (en) Aluminum wire with crimp terminal

    Legal Events

    Date Code Title Description
    R012 Request for examination validly filed
    R138 Derivation of utility model

    Ref document number: 202018006090

    Country of ref document: DE

    R082 Change of representative

    Representative=s name: DREISS PATENTANWAELTE PARTG MBB, DE

    R082 Change of representative

    Representative=s name: DREISS PATENTANWAELTE PARTG MBB, DE

    R016 Response to examination communication
    R018 Grant decision by examination section/examining division