DE102022113127A1 - Winding, electrical machine and manufacturing process - Google Patents

Abstract

The invention relates to a winding for an electrical machine, the winding comprising at least one first conductor, which is arranged in the form of a plurality of webs and a plurality of winding heads, wherein the webs and winding heads alternately follow one another along the first or respective conductor and a respective winding head forms a connection between two Forms webs, wherein a first winding head connects a first and a second web of the first conductor, wherein a second winding head of the first or a second conductor connects a third and a fourth web of the first or the second conductor, the first and the second winding head cross and the third web is arranged between the first and the second web, a first axis being parallel to at least the first web, a second axis being parallel to a direction of a relative movement of a rotor of the electrical machine to a stator of the electrical machine, wherein a third axis is perpendicular to the first and second axes, wherein the conductor in the area of the first winding head has a section in which the conductor runs at least substantially perpendicular to the third axis, wherein the first web runs in a first direction along the third axis has an end, the section having an end in the first direction along the third axis, the end of the section being offset from the end of the first web opposite the first direction, and the section being the third with respect to the second axis Bridge spans.

Description

The invention relates to a winding for an electrical machine, an electrical machine with a winding and the production of a winding or an electrical machine.

In particular, an object of the invention is a multi-phase wave winding with high packing density for electrical machines, in particular for electrical machines with high specific torque and high efficiency. A multi-phase wave winding with a high packing density enables electrical machines that, in addition to a low mass and a small volume, also have a high power density and a high energy efficiency, especially for applications in a wide speed range.

Preferred areas of application of the invention are in the field of drives for e-mobility, e.g. electric cars, electric aircraft, electric drones, electric motorcycles, electric bicycles, electric boats and other vehicles. Further preferred areas of application include the drive of electrical machines, e.g. in power tools, machine tools, toys, industrial drives. There are a variety of other areas of application.

In an electric machine, in particular an electric motor, in particular for one of the above-mentioned areas of application, it is advantageous if the highest possible torque and the highest possible efficiency are provided in relation to the lowest possible active masses and manufacturing costs used. For a winding of the machine, in particular a wave winding, it is desirable if it has a compact design, a good filling factor and enables largely automated production.

The document EP 2 124 317 A1 describes the basic structure of an electrical machine, in particular its stator with three-phase winding, which are each inserted into slots that are arranged in the circumferential direction of the stator. Each phase is arranged in one of three pairs of adjacent slots.

The portions of the winding that extend outside the slots of the stator core connect the portions in the slots.

The document EP 1 179 880 A2 refers to an electrical machine with a three-phase winding. In particular, the document describes engines for a high speed range of approximately 2000 to 5000 rpm.

The document US 2006/0226727 A1 describes a stator for an electrical machine having a generally cylindrical stator core with a plurality of teeth defining a plurality of grooves. The stator is designed for multi-phase winding. A protruding section of the winding, which connects two parts to be inserted into the slots, has a triangular two-dimensional shape.

The document EP 1 381 140 A2 relates to a multi-phase winding for a rotating electrical machine. A plurality of segments of the winding are connected via winding heads. There are two types of winding heads with small and large dimensions.

The DE10 321 956 A1 describes an electrical machine which contains a stator core which has circumferentially arranged grooves which alternate between odd and even grooves. Each groove has radial pin positions arranged in adjacent pairs to define radial layers. A hair pin winding includes a first path of interconnected hair pins arranged in the stator core such that for each of the radial layers, the first path is arranged in the odd and even slots the same number of times.

Important for high torque and low energy losses of the electrical machine are, among other parameters, a high value of the ratio Q=LACT/LPAS between the length LACT of the active part and the length LPAS of the passive part of the winding as well as a sufficiently large number of magnetic periods or Pole pairs, or magnetic poles NM.

Several possibilities for meeting this requirement for implementing the winding in electrical machines are known. The first option is in the documents WO 03/094328 A1 (PCT/ US03/09207 ) and WO 2005/117243 A1 (PCT/ SI05/000015 ) is a concentrated winding with a large number of individual coils.

Another possibility is a distributed winding in which all coils, or at least all coils of the same phase, are manufactured as a continuous piece that is inserted into the grooves of the ferromagnetic core.

The first type of distributed winding is loop winding, such as in the document WO 2005/050816 A2 ( PCT/CA2004/001978 ). Each conductor goes around a single magnetic pole several times before moving on to the next pole.

In the second, the most common type of distributed winding, the so-called wave winding, the conductor is shaped in particular as a meander and winds in particular between the magnetic poles, so that the same conductor returns to the same groove in the next position of the winding at the earliest.

Solutions for wave winding with a small number of electrical conductors in each slot exist. In the case of the document WO/2006/110498 A1 (PCT/ US2006/012914 ), these conductors can be cut out of copper sheets and can therefore have any shape. This document lists possible forms for both loop winding and wave winding as well as for the combination of both types of winding. The said document specifically mentions some processes for the production of such windings from continuous cuts of copper.

The document EP 2 695 284 B1 presents a compact multi-phase wave winding for an electric machine with high specific torque, which comprises winding layers stacked in the radial direction, the winding heads being curved in the radial direction at their beginning, middle and end, so that two adjacent, mutually parallel ones , straight sections of a conductor lie in approximately the same radial position. The winding heads of a layer lie alternately in a tangential direction on both sides of the stator. Furthermore, the proposal is made to create cavities through plastic deformation of the winding heads, which should enable the winding heads of different phases to be crossed easily.

The document US 2022/0021264 A1 presents a stator whose slots contain straight conductor pieces and whose winding heads are realized by end caps on both sides of the stator in order to reduce the manufacturing effort for the stator and winding.

The document DE 102011 111 352 B4 discloses an electric motor with an ironless air gap winding consisting of several tangentially arranged conductors in one phase, which are fixed directly on the ferromagnetic stator core, with an overlap of the winding heads occurring in such a way that in a 3-phase motor, three winding heads lie one above the other.

The document DE 10 2016 100 744 B3 discloses an electrical machine that combines a slot and an air gap winding in such a way that the winding webs of the air gap winding are arranged radially above the winding webs of the slot winding, so that the magnetic field of the permanent magnets is used by both windings at the same time.

The document DE 199 09 026 A1 describes a method and a device for producing coils in the form of a wave winding for electrical machines. First, an essentially round or polygonal coil is created on a winding template. It is stripped from the winding template using strippers, then formed into a wave winding by radial deformation using a molding tool and then transferred to a transfer or drawing-in tool.

With those in the documents EP 3 182 568 A1 and WO 2017/089455 A1 In the method described, a large number of winding wires are fed to the rotating mandrel of a winding device. The wire located on the mold core is gripped using grippers and moved in a transport direction to produce the winding heads of the wave winding, with the mold core being rotated. A wave winding is created on the mold core, which is then transferred to a transport device. The transport device rotates synchronously with the mold core so that the resulting wave winding can be generated continuously.

The solutions described have deficits in terms of high specific torque and high energy efficiency and, derived from this, also in terms of the specific power and other important properties of an electric machine. In addition, some of the existing machines have a high active mass and a high volume and are sometimes expensive to manufacture.

Manufacturing and assembling a large number of individual coils of a concentrated winding is a time-consuming process. Windings with discrete coils have unfavorable mechanical and geometric properties and require the connection of a large number of electrical contacts when building a phase. This design also has disadvantages from a geometric point of view, as the fill factors that can be achieved are limited, which in turn limits the efficiency.

A problem with distributed winding is the lack of space for the frequent crossings of the winding heads of adjacent coils for a larger number of turns around individual stator teeth or a group of teeth. An additional problem is the rapid and non-destructive insertion of the complexly arranged conductors into the slots.

In a number of electrical machines there are also problems with crossovers of the sequential winding heads, which belong to adjacent phases of the winding and cross over one another very closely.

Using a larger number of thin conductors in each groove, which must be deformed into the appropriate shape, is not optimal because the available space in the groove is not completely filled with conductive material.

Even with the existing wave winding solutions with a smaller number of conductors, there is a problem with adjacent winding heads crossing each other on both axial sides of the winding, i.e. outside the ferromagnetic core. In these two border zones the electrical conductors are not straight and parallel, but curved. The problem here is that in multi-phase machines where the conductors of several phases cross each other, there is little space for all winding heads, especially in cases where the number of winding layers is two or more.

With wave windings with a small number of electrical conductors, the individual wires are thicker and therefore not as easily deformable in the area of the winding heads. When the coil is inserted into the ferromagnetic core, the winding heads only deform into the correct shape with considerable pressure, which can cause damage to the insulation of the winding.

In the known compact wave windings, the winding head has a disadvantageous axial projection, which increases the winding head length and thus the electrical resistance. Proposals for reducing the installation space by radially deflecting the conductors in the winding head area can only be implemented with very small bending radii and are therefore problematic in terms of production technology and for reasons of operational safety. A curvature in the radial direction with a relatively small radius of curvature places high stress on the material during production. At the slot exit or slot entrance, a large bending radius leads to a large head projection and thus to an undesirably long winding head. A small bending radius is required in the middle of the head to limit the radial expansion of the winding head. The winding heads are stacked in the axial direction, which results in longer winding head packages, unfavorable efficiency and an increased axial installation space.

Any form of cross-sectional reduction when creating cavities to simplify the realization of crossing points of the winding heads leads to a higher phase resistance and is therefore not optimal.

Any deformation or processing that involves a narrowing of the cross-section of the conductors increases the electrical phase resistance and should therefore be avoided.

Upright formats (aspect ratio greater than 1:1) of the wire profiles, which can be used to increase the fill factor or to simplify production, make radial bending of the winding heads difficult or impossible.

Running a wire in several layers at the same time, as is required with some machines, makes the winding technique and insertion more difficult.

Large-volume end pieces on the stator sides, in order to avoid the effort involved in forming the winding heads, require a lot of installation space and require a very high number of contact points between the winding webs and the end pieces.

The pins of well-known hair-pin windings form very long winding heads for forming and welding reasons. This increases the axial installation space and increases the phase resistance of the machine. A large number of welds are required, the production of which requires a complex and complex quality-assured manufacturing process. Each individual weld increases the phase resistance and thus reduces the energy efficiency of the machine.

The known manufacturing processes for wave windings only support relatively simple round or polygonal geometries, which results in unfavorably large winding heads. This increases the required installation space, increases the phase resistance and reduces the energy efficiency of the machine.

With the known manufacturing processes for wave windings, winding mats of any length with small mold cores can be formed, but relatively large winding heads are created, no specific winding head shapes are possible and the transfer of the winding mat from the mold core to the stator is a complex and complex process.

The current state of the art therefore does not yet offer any satisfactory solutions in the area of electrical machines. The aims of the invention are to design the properties and the manufacturing process of a winding for an electrical machine in such a way that electrical machines have high performance and/or quality in terms of efficiency, torque, power and other properties at low small mass and volume can be easily constructed and manufactured inexpensively.

Specifically, an object of the invention is to provide a compact winding, the solution preferably having as little negative effect as possible on the performance data of the machine and the winding preferably being easy to manufacture.

The task is solved by a winding according to claim 1.

The invention comprises a winding for an electrical machine, in particular a multi-phase wave winding, the winding comprising at least one first conductor, which is arranged in the form of a plurality of webs and a plurality of winding heads, the webs and winding heads alternating one after the other along the first or respective conductor and a respective one Winding head forms a connection between two webs, with a first winding head connecting a first and a second web of the first conductor, with a second winding head of the first or a second conductor connecting a third and a fourth web of the first or second conductor, wherein the first and the second winding head cross and the third web is arranged between the first and the second web, with a first axis being parallel to at least the first web, with a second axis being parallel to a direction of a relative movement of a rotor of the electrical machine to a stator of the electrical machine, wherein a third axis is perpendicular to the first and second axes, wherein the conductor in the area of the first winding head has a section in which the conductor runs at least substantially perpendicular to the third axis, the first web in a first Direction along the third axis has an end, the section having an end in the first direction along the third axis, the end of the section being offset from the end of the first web against the first direction, and wherein the section with respect to the second axis spans the third web.

Due to the offset of the section relative to the web against the first direction, the second winding head can be guided through the area of the offset and this results in a particularly compact overall height in relation to the third axis. This is further achieved by the offset without restricting the web width and/or the height at which the web is arranged in relation to the third axis. This means that a high power density can be achieved with a compact design. The offset represents a structurally simple solution so that production can be carried out easily and reliably.

The first, second and third axes ultimately form a coordinate system of the winding or the electrical machine. The electrical machine can basically be a rotary machine or a linear machine, with the coordinate system applying accordingly. In the linear machine, the relative movement of a rotor of the electrical machine to a stator of the electrical machine takes place on a straight or more complex path that deviates from a circular shape. In the case of a rotary machine, however, the relative movement of the rotor to the stand takes place on a circular path. Correspondingly, the second axis in a linear machine runs along the movement path, typically straight. In the rotary machine, the relative movement of the rotor to the stand runs on a circular path, and the second axis is therefore viewed as circular in the context of a rotary machine in the context of this application. To the extent that elements are stated to be parallel to the second axis, it is understood that in the context of a rotary machine they are concentric to the circular second axis. The axes can be referred to individually or each as a path.

The same applies to the third axis. In a rotary machine, this forms a radial axis and is correspondingly dependent on the angle at which the winding or the electrical machine is viewed.

The underlying coordinate system is explained in more detail below using the figures.

In preferred embodiments it is provided that the end of the section is arranged offset from the end of the first web against the first direction by an offset, the offset being at least 0.3, preferably at least 0.5, preferably at least 0.8, preferably at least 1.0, times a height of at least the first web in relation to the third axis. Installation space can be saved according to the offset.

A web is generally preferably cylindrical. i.e. a web generally comprises a cross section that is constant over its length. The cross section can basically be round or square or have another shape.

It is further advantageous with regard to the power density if at least the first and second webs are designed with the same cross section and/or are arranged at the same height and/or at the same position in a conductor stack with respect to the third axis.

The conductor can have an at least substantially square cross section in the area of at least the first web and/or in the section. This allows a high filling factor of the groove, which is also typically angular in cross section. In general, a square cross section, in particular of a conductor, can preferably be at least substantially rectangular, in particular with side edges of the cross section of different lengths.

In general, a conductor with a square cross-section can also have a rounding or a chamfer in the corner area.

According to an advantageous exemplary embodiment, a cross-sectional shape of the conductor in the section can be at least essentially the same as a cross-sectional shape of the conductor in the area of at least the first web.

A particularly compact design with a high filling factor of the groove can be achieved by a further embodiment in which the conductor in the area of at least the first web has a web width in relation to the third axis and a web width in relation to the second axis, the web width being in In relation to the third axis, it is in particular larger than the web width in relation to the second axis. In principle, the web width in relation to the third axis can also be smaller than the web width in relation to the second axis, for example in the case of radially stacked webs. It is preferably provided that the conductor in the section has a section width in relation to the third axis and a section width in relation to the first axis, wherein the section width in relation to the third axis is preferably smaller than the section width in relation to the first axis. It is further preferably provided that the section width in relation to the third axis is at least substantially equal to the web width in relation to the second axis and/or wherein the section width in relation to the first axis is at least substantially equal to the web width in relation to the third Axis is.

A further advantageous example includes that the conductor in the area of at least the first web has a rectangular cross section with a wider edge parallel to the third axis and a narrower edge parallel to the second axis, the conductor in the section having a rectangular cross section with a wider edge parallel to the first axis and a narrower edge parallel to the third axis.

Preferably, it can be provided that a cross-sectional area of the conductor in the section is at least substantially equal to or larger than a cross-sectional area of the conductor in the region of the first, second, third and/or fourth web. This ensures that the electrical resistance is no greater than in the area of the web and thus high efficiency is achieved. Cross-sectional area means an area dimension, for example in mm ² .

According to a further example, it is provided that the second web has an end in the first direction along the third axis, the end of the section being arranged offset from the end of the second web against the first direction, in particular by the same offset as between the end of the section and the end of the first bridge.

In principle, the embodiments described here, which relate to only the first web and, if applicable, its spatial relationship to the first winding head, can be transferred accordingly to the second web and/or to further webs and the winding heads connected to these webs.

A particularly compact embodiment is characterized in that the second web has an end in the first direction along the third axis, the ends of the first and second webs being arranged at the same height in the first direction with respect to the third axis. The overall height of the winding head in relation to the third axis is therefore limited in particular to the overall height of at least the first web.

The section preferably has a length with respect to the second axis of at least 0.2, more preferably at least 0.4, particularly preferably at least 0.6, preferably at least 0.8, preferably about 1.0, times a distance between the first and the second web in relation to the second axis.

A further example includes that the section of the first winding head with respect to the second axis is provided in the region of the second winding head and/or wherein the section of the first winding head is provided with respect to the second axis in an intersection region of the first and second winding heads.

The second winding head can extend in particular in an area starting from the section in the first direction.

In an advantageous embodiment, the conductor in the section has a section width with respect to the third axis that is smaller than a web width of the conductor in the web with respect to the third axis. This allows for even more construction save space in relation to the third axis. It is particularly advantageous if the section width is at most 1.0, preferably at most 0.8 times, preferably at most 0.6 times, particularly preferably at most or about 0.5 times, preferably at most 0.3 times, as large as the web width .

Furthermore, it is advantageous if at least the first web has a second end in a first opposite direction with respect to the third axis, the section having a second end in the first opposite direction, the second end of the web and the second end of the section is at least substantially at the same height with respect to the third axis. In other words, the first web and the section in the opposite direction end at the same height and are in particular aligned. This is particularly advantageous with regard to the installation space in relation to the third axis.

It can advantageously be provided that the conductor runs in the section at least substantially perpendicular to the first axis and/or parallel to the second axis. This saves additional installation space, especially with regard to the first axis.

In principle, a conductor can, for example, be designed either as a solid conductor or as a bundle of strands. A web is formed in particular by a conductor. In principle, for example, several webs, in particular of the same phase, can be arranged grouped and/or stacked. Several grouped conductors can be collectively referred to as a line. A line typically forms one phase of the electrical machine. One or more lines or phases can be provided.

In principle, it is not absolutely necessary, but in some embodiments it is quite advantageous, that all conductors of a web group or a web stack have the offset according to the invention between the web and winding head.

It is particularly advantageous if the webs are designed as hair pins. In this way, a high filling factor can be achieved and at the same time the offset according to the invention can be produced particularly easily with a hair pin winding.

According to a further embodiment, it is provided that the conductor in the area of the second winding head has a section in which the conductor runs at least substantially perpendicular to the third axis, in particular with the third and / or the fourth web in a second direction along the third axis has one end, in particular wherein the section of the second winding head has an end in the second direction along the third axis, in particular wherein the end of the section of the second winding head is arranged offset from the end of the third and / or fourth web against the second direction. This means that additional installation space can be saved. In particular, it can be provided that the section of the second winding head spans the first and/or second web with respect to the second axis.

The second direction can in particular be opposite to the first direction or correspond to the first opposite direction.

It can be advantageous for the section of the first winding head and the section of the second winding head to overlap. Alternatively or additionally, the section of the first winding head and the section of the second winding head can overlap with respect to the second axis.

In addition, the section of the first winding head and the section of the second winding head can run parallel to one another and/or to the second axis.

According to a further embodiment, the section of the first winding head is a first section, wherein the conductor in the area of the first winding head has a second section in which the conductor runs at least substantially perpendicular to the third axis. The second web can have an end along the third axis in a first opposite direction to the first direction. The second section may have an end in the first opposite direction with respect to the third axis. The end of the second section can be arranged offset from the end of the second web along the first opposite direction. This embodiment proves to be particularly advantageous in that a second winding head - corresponding to a viewing direction with respect to the third axis - is guided over the first winding head in the area of the first section and a third winding head is guided under the first winding head in the area of the second section can. This has particular advantages with regard to the production of the winding because there is increased flexibility in the order in which the conductors or winding heads are placed one on top of the other. In particular, it is possible for several lines or phases of a three-phase winding to simply be placed one on top of the other and for no complicated nesting to be necessary.

The conductor can preferably have the same cross section in the first and second sections sen, in particular wherein the cross sections of the conductor in the first and second sections are arranged parallel to the third axis and / or offset with respect to the third axis.

According to a further embodiment, the conductor comprises a step between the first and second sections, in particular with respect to the third axis.

For example, a step and/or an offset can be provided between the first web and the section of the first winding head. The same applies in particular between the or a section of the winding head and the second web.

The winding can preferably be designed as a multi-phase winding and/or as a wave winding. The offset according to the invention between the section of the winding head and the web proves to be particularly advantageous in these embodiments.

The webs can in particular be aligned parallel to one another and/or arranged evenly distributed over the circumference of a stator or rotor.

It goes without saying that the embodiments described here can in principle also be transferred to other webs and/or winding heads, especially since a winding often has a large number of webs and winding heads. Typically, all webs or at least sets of webs and/or all winding heads or at least sets of winding heads are designed at least essentially the same.

The invention also includes an electrical machine with a winding of the type described above.

The electric machine can be an electric motor and/or an electric generator, or the machine can be used as a motor and/or generator.

The electric machine can be a rotary machine or a linear machine.

In principle, the winding can be arranged on the stator or on the rotor of the electrical machine. The same may apply to one or more permanent magnets.

According to one embodiment, the electrical machine comprises a core. The winding can be a core winding. The core can comprise a plurality of grooves, in each of which, for example, at least one web can be arranged. For example, several webs, in particular one phase, can also be arranged in each groove. The plurality of webs in a groove can preferably be arranged stacked along the third axis.

The electrical machine can also be designed to be coreless and/or grooveless. The winding of this electrical machine can also be called air gap winding. Several webs, in particular of one phase, can, for example, be arranged next to one another along the second axis.

The electrical machine can preferably be designed as a synchronous machine and/or as a permanent magnet machine, particularly preferably as a permanent magnet synchronous machine, PMSM for short.

The winding and the electrical machine, as described herein, can be made particularly compact, although production is particularly simple.

Accordingly, the invention also relates to a method for producing a winding of the type described above for an electrical machine, in particular an electrical machine of the type described above.

One embodiment of the manufacturing method includes that at least the first web and the section of the first winding head are manufactured from a component, in particular wherein the component is formed.

For example, an elongated conductor material can be provided, of which a longitudinal section is provided for the first web and a longitudinal section is provided for the section.

For example, a solid wire or a bundle of strands can be used as an elongated conductor material.

The conductor material between the longitudinal section for the first web and the longitudinal section for the section can, for example, be bent about a first bending axis, in particular starting from a substantially straight state of the conductor material. The bend can preferably be at least substantially 90°. The first bending axis can preferably be perpendicular to a longitudinal axis of the conductor material and/or parallel to the third axis in relation to a state installed in the electrical machine.

In principle, the same also applies to the procedures described Webs and winding heads as well as a respective transition between the web and winding head can be designed accordingly.

According to one embodiment, the conductor material is twisted between the longitudinal section for the first web and the longitudinal section for the section, preferably by at least substantially 90°.

In particular, a combination of bending and turning represents a simple possibility for flexible shaping and proves to be advantageous for the winding heads according to the invention. The bending and twisting can occur overlapping in time or one after the other.

In a further embodiment, a component, in particular the conductor material in the longitudinal section for the section, is massively formed, in particular extruded, to produce the section.

Generally and independently, an advantageous method is hereby disclosed, namely a method for producing a winding for an electrical machine or for producing an electrical machine with a winding, wherein at least one first conductor in the form of a plurality of webs and a plurality of winding heads is provided for the winding, wherein the webs and winding heads alternately follow one another along the conductor and a respective winding head forms a connection between two webs, with a shaping for at least a first winding head comprising solid forming. This method is particularly simple and, in particular, allows shaping essentially without changing the cross-sectional area. This is particularly advantageous because essentially no or at least only a small reduction in the conductivity of the winding head can be expected. At the same time, existing installation space can be used particularly efficiently. This method can of course be further developed in accordance with the other embodiments of methods and devices described herein.

During solid forming, a forming force can preferably be applied to the conductor section in a direction of force for the section, the direction of force being parallel to the third axis and/or opposite to the first direction in relation to a state installed in the electrical machine. The offset according to the invention can thus be produced in a particularly simple manner between the ends of the web and winding head.

If the production also includes bending, the massive forming to produce the section can take place, for example, before and/or after bending. In principle, solid forming during bending is also possible.

According to one embodiment, at least the first web and the first winding head are assembled from separate components, in particular by means of welding, soldering or a press connection.

The second web and the first winding head can be assembled from separate components, in particular by means of welding, soldering or a press connection.

The second web can be connected in one piece to the first winding head. The second web and the first winding head can be produced from one component, in particular by forming and/or as described above with respect to the first web.

The electric machine may include a ferromagnetic core with alternating teeth and grooves distributed, for example, circumferentially around the ferromagnetic core. The winding may include one or more layers stacked around the circumference of the ferromagnetic core with respect to the third axis and/or in the radial direction and inserted into the slots.

If NP represents the number of phases of the electrical machine, the winding can consist, for example, of NP or a multiple of NP conductors.

Each conductor can have parallel, straight segments inserted into the slots as webs and/or curved segments as winding heads, which connect the adjacent webs of a phase, in particular a direction parallel to the second axis and/or in a tangential direction. NP teeth and/or NP-1 grooves can preferably be arranged between two adjacent webs of the same phase.

The winding heads can be arranged in relation to the third axis and/or radially stacked in a hollow cylindrical winding head window. In particular, winding heads and/or a corresponding winding head window are provided at both ends of the webs with respect to the first axis. The winding heads can be arranged coaxially on both sides of the core with respect to the first axis. The winding heads can preferably be arranged with respect to the third axis and/or radially centered to the slots or by a maximum of twice the winding height above or below or inside or outside the circle formed by the slot centers.

The winding heads of three phases each, in particular at least one layer, can be radially stacked in two layers on both sides of the stator with respect to the first axis.

In the following, reference will only be made, by way of example, to a rotary machine and in particular to a radial direction, whereby the statements apply accordingly to the linear machine.

For example, the winding heads can be arranged in a tangential direction with alternating radial winding head positions, so that an internal winding head of one phase covers a part of the two right and left outer winding heads of the other two phases and an external winding head of a phase covers a part of the two right and left Left inner winding heads of the other two phases are covered, whereby in a phase in the direction of travel from the beginning of the phase to the end there are always two winding heads one after the other in one layer, aligned alternately inside and outside on different stator sides.

The winding heads can also be arranged in a tangential direction with a constant radial winding head position, so that all internal winding heads belong to one phase, all external winding heads belong to a further phase and the remaining phase exclusively winding heads with two radially offset sections and in particular an offset between the sections having. The sections lie in particular on the inner and outer winding heads. The winding heads can be stacked in multiples of three phases in the radial direction in one of the two defined arrangements and, for phase numbers that are not multiples of three, one or two phases can be placed in the remaining free positions in accordance with the division remainder. The height of the winding head package HH of a layer consisting of all inner and outer and cranked winding heads can preferably correspond to the winding web height HW or be in the range between 50% and 200% of the winding web height HW. The tangential course of the winding head can preferably run at a right angle or at an angle between 60° and 90° to the web direction.

The cross-sectional shape of the conductor can be circular, rectangular, or any shape. The conductor can, for example, comprise one thick or several thin wires, in particular strands, or profiles. The size and shape of the cross section can change along the conductor. The material may be or include copper and/or another material with good electrical conductivity. The conductor or layers can be manufactured partially or completely in or outside the ferromagnetic core.

Each phase may comprise a number NL of conductors arranged tangentially in series, where NL may preferably be greater than or equal to one.

A coil of each phase in one layer may include one or more conductors and the same conductor may be present in more than one layer.

A tangential conductor continuation direction at the radial transition of the conductor to the next layer can be made constant or can bend in the opposite direction.

The stator can, for example, have no grooves and/or teeth. The winding can be fixed on the stator in the air gap. Preferably, winding webs can be arranged on the stator at a magnetic pole angle of 2*NP.

Phase terminals can be formed by shortening and, if necessary, radially bending and/or deforming the winding head pieces at the beginning of the phase and can thereby be arranged axially behind the winding heads.

A star point rail can be formed, for example, by shortening and joining the winding head pieces at the phase ends and, if necessary, radially bending and deforming the winding head piece, in particular the third phase.

In the area of the phase terminals and the star point rail, an axial installation space with the depth of the winding head projection AH, with the height up to the magnets and/or with a width greater than a magnetic pool pair can be created, which can be used to accommodate a sensor.

The shape of a winding head can be semicircular, triangular, straight or U-shaped or have another geometric shape. The height of the conductor HW in the winding head can be reduced in order to be able to stack the winding heads in pairs in the radial direction without requiring additional radial installation space. The current-carrying cross section of the conductor can preferably not be reduced, but can be increased if necessary and/or shape changes can be carried out with continuous transitions in order to keep the phase resistance as small as possible.

The entire winding, including all phases, can be manufactured in one step, for example, or the phases are prefabricated individually, then woven or stacked to form a winding and then inserted into the grooves or the winding webs are inserted into the slots and then connected to the winding heads using joining technology.

The winding heads can be done, for example, by bending a solid wire or a stranded bundle with an aspect ratio greater than or equal to 2:1 in a torsion step with a 90° torsion angle about a torsion axis parallel to the web axis and/or a bending step about two radial axes by 90° each. The term “aspect ratio” refers to the ratio of the lengths of the side edges of a rectangular cross-section of the conductor.

The winding heads can be done, for example, by bending a radially stacked solid wire stack with an aspect ratio of the individual wire less than 2:1 in a torsion step with a 90° torsion angle about a torsion axis parallel to the web axis and/or a bending step about two radial axes by 90° each.

The winding heads and optionally the winding webs can be produced by massive forming, for example extrusion or forging, in particular of conductor profiles.

The winding heads and winding webs can be connected, for example, by joining, such as welding or clamping, either outside the stator or preferably after inserting the winding webs into the stator.

The sections of the winding heads can also be designed to be at least partially stepped or offset and/or two sections can be provided on the winding head, between which a step or offset is provided. The step or offset can be arranged approximately tangentially in the middle of the winding head. Thus, the part of the winding head can lie in front of the step or crimping point, as in a winding head lying on top, and the part of the winding head can lie after the step or crimping point, like in a winding head lying at the bottom. This order can also be swapped.

The winding heads can, for example, be manufactured additively and/or connected to non-additively manufactured winding webs inside or outside the stator. The winding heads and winding webs can be additively manufactured inside or outside the stator.

For example, the winding heads can be manufactured by bending a wire bundle from a number of profile wires arranged horizontally next to one another, e.g. by bending in two radial axes and a bend or two closely spaced bends of +90° and -90° around a tangential axis, which the curved part of the winding head is deformed upwards or downwards relative to the winding web by at least half of the winding web height HW.

The winding heads can, for example, also be bent radially in the direction of the stator core and, if necessary, be contacted mechanically and/or thermally with the stator.

The winding head packages can, for example, also be baked, cast and/or integrated into a carrier substance.

The winding heads can, for example, be stacked radially in at least one layer of a slot winding and/or at least one layer of an air gap winding.

The winding can be designed as a self-supporting air gap winding with either radially stacked or partially cranked winding heads. The winding heads can be baked, cast or embedded in a carrier substance and, if necessary, provided with radially or axially arranged support rings. The winding webs can be baked, cast or embedded in a carrier substance.

Numerous advantages can be achieved through the invention and, if applicable, its embodiments. The winding can be produced inexpensively. A high packing density, a large conductor cross section and short winding heads are achieved to reduce the phase resistance and the size. This is achieved, among other things, by an alternating arrangement of the winding heads in radial layers of a winding layer. The shaping and/or the connection of the winding heads to the winding webs are gentle on the material. The connection can optionally be designed with a reduction in the winding head height without reducing the current-carrying cross section. It is also possible to use profile wires or profiles, preferably in portrait format (aspect ratio greater than 1:1) in combination with a winding head and winding web that are geometrically, material- and production-technically adapted. The conductor or conductors can be produced, for example, as a continuous mat using a forming process, for example with a high dimensional stability to simplify handling, transport and positioning for inserting the winding webs into the stator slot. The conductor can also be inserted/inserted into the slot as discrete winding webs and connected to the winding heads using a joining process.

The invention provides a highly efficient, in particular multi-phase, winding structure high packing density and a cost-effective and precise manufacturing method for wave windings that can replace existing solutions and open up new fields of application. In existing manufacturing processes for electrical machines, only the manufacturing and feeding of the very easy-to-handle/transportable winding mat or an existing hair-pin manufacturing process needs to be replaced. The efficiency and specific torque of electrical machines are significantly increased and manufacturing costs are reduced.

In particular, a) an increase in the efficiency of electrical machines can be achieved by reducing the phase resistance while simultaneously reducing the axial and radial installation space of electrical machines, in particular by minimizing the axial and tangential winding head length and the radial winding head height without reducing the current-carrying conductor cross section in combination with a very high filling factor in the groove or in the air gap, b) the reduction of the weight of electrical machines through maximum use of the copper content and the reduction of the iron content and c) the reduction of the costs for electrical machines through inexpensive winding and stator production.

The higher efficiency, the higher specific torque and the reduced installation space can open up new fields of application, especially in the areas of e-mobility, micro-mobility and lightweight drives as well as in all areas of application in which very high efficiency in combination with low weight is required is. The electrical machines with the winding according to the invention can cover a very wide speed range. Due to the low copper losses and the high torque, the machines are suitable as torque motors or wind power generators even in the very low speed range. Due to the low iron losses and high efficiency, the machines are also suitable for applications with very high speeds, for example in the field of micro drives or as generators, for example for gas turbines.

The invention is explained below by way of example using the schematic drawings.

The figures show examples of multi-phase wave windings with high packing density of an electrical machine or “e-machine” with a high specific torque and high efficiency. The machine is designed, for example, as an external rotor.

The embodiment shown is suitable, for example, for the direct drive of electric vehicles, electric drones and for the direct operation of generators in wind turbines, which are advantageous fields of application of the invention. In addition, the invention of course also relates to the other known embodiments, designs or types of electrical machines.

The illustrated embodiments of the machine have a radial orientation of the magnetic field. Constructions with a different orientation of the magnetic field are also possible.

The versions of the electrical machine shown include permanent magnets. In principle, the invention can also be implemented in an induction machine or another type of machine.

The illustrated versions of the electrical machine include alternating radially magnetized permanent magnets. However, other magnet topologies, such as a Halbach array, can also be used.

The illustrated versions of the electrical machine include a tangentially and axially uniform and axially aligned structure of the rotor and stator. Tangentially and axially inhomogeneous or axially inclined structures can also be used, e.g. the magnets or the stator slots, e.g. to reduce the cogging torque or for manufacturing reasons, can be used with an adapted winding. All grooves in the application example are drawn open for reasons of simplicity. It is obvious that they can be completely or partially closed, for example by a cover element or a specially shaped pole piece.

The designs of the electrical machine shown include a rotor and a stator iron yoke. However, sandwich structures with several rotor or stator iron connections can also be used, for example.

Constructive solutions according to the present invention can of course also be used for linear drives, in particular where the active part of the machine extends in a straight section over the length of the machine.

• 1 zeigt eine aufgeschnittene räumliche Ansicht der aktiven Teile einer permanenterregten E-Maschine mit genutetem Stator mit einer Wellenwicklung mit hoher Packungsdichte und mit radial alternierenden Wickelköpfen.
• 2 zeigt verschiedene Ansichten der aktiven Teile der E-Maschine: a) Frontansicht; b) Seitenansicht; c1) Schnitt durch die Seitenansicht; c2) vergrößerter Ausschnitt aus c1; d) Ausschnitt der Frontansicht mit Wickelköpfen; e) Schnitt durch die Frontansicht mit einem Wickelkopffenster; f) Ausschnitt der Frontansicht mit Phasenklemmen und Sternpunktschiene.
• 3 zeigt einen perspektivischen Ausschnitt der E-Maschine im Bereich von Phasenklemmen und Sternpunktschiene.
• 4 zeigt eine Phase einer Wellenwicklung in verschiedenen Ansichten: a) perspektivische Ansicht, Frontansicht, Seitenansicht und Draufsicht, b) Schnitt durch die Frontansicht mit axialer und radialer Ausdehnung eines Wickelkopffensters.
• 5 zeigt eine planare Matte einer Wellenwicklung mit einer Lage in verschiedenen Ausführungen: a) mit Phasenklemmen einseitig, b) mit Phasenklemmen zweiseitig.
• 6 zeigt einen Ausschnitt der Matte von 5 a).
• 7 zeigt einen Ausschnitt des Stators mit eingelegter Wicklung.
• 8 zeigt eine planare Matte einer Wellenwicklung mit drei Lagen in verschiedenen Ansichten: a) perspektivische Ansicht; b) Ausschnitt der perspektivischen Ansicht mit den Wickelköpfen.
• 9 zeigt eine planare Matte einer Wellenwicklung mit Wickelköpfen mit mittiger Kröpfung in verschiedenen Ansichten: a) perspektivische Ansicht mit Phasenklemmen einseitig, b) Ausschnitt aus 9 a) mit den Wickelköpfen.
• 10 zeigt Schemata verschiedener Stapelungen der Wellenwicklungen mit hoher Packungsdichte über den Umfang der Maschine: a) Keine Stapelung, einmal umlaufend; b) Stapelung fortlaufend; b1) zweilagig; b2) dreilagig; c) 2-Teilung, keine Stapelung; d) 2-Teilung, Stapelung rücklaufend; d1) zweilagig; d2) dreilagig; e) 3-Teilung, keine Stapelung; f) 3-Teilung, Stapelung dreilagig; f1) fortlaufend; f2) rücklaufend.
• 11 zeigt Schemata der Wickelkopfanordnung einer Wellenwicklung in verschiedenen Ausführungen: a) dreiphasig; b) vierphasig; c) fünfphasig.
• 12 zeigt Beispiele verschiedener Wickelkopfausführungen: a) räumlich gebogener Massivdraht oder Litzenbündel; b) vertikal gestapelter Doppeldraht gebogen; c) Profil aus Massivumformung; d) Profil für Schweißverbindung; e) Profil für Klemmverbindung mit Stegen; f) Wickelkopf gekröpft aus Massivumformung; g) Wickelkopf einer Luftspaltwicklung mit mehreren parallelen Drähten.
• 13 zeigt eine aufgeschnittene räumliche Ansicht der aktiven Teile einer permanenterregten E-Maschine mit nutenlosem Stator mit einer Ausführungsform der Wicklung als Luftspaltwicklung.
• 14 zeigt Schnitte durch die aktiven Teile der E-Maschine von 13: a) Fronansicht mit Wickelkopffenster; b) Schnitt quer zum Statorring; c) vergrößerter Ausschnitt des Schnitts b).

In addition, the described topological and design solutions for the winding can be implemented in both the stator and the rotor of the motor. For the sake of simplicity, the invention is presented for the stator winding.

• 1 shows a cut-away spatial view of the active parts of a permanently excited electric machine with a grooved stator with a Wave winding with high packing density and with radially alternating winding heads.
• 2 shows different views of the active parts of the electric machine: a) front view; b) side view; c1) Section through the side view; c2) enlarged section of c1; d) Detail of the front view with winding heads; e) Section through the front view with a winding head window; f) Detail of the front view with phase terminals and star point rail.
• 3 shows a perspective section of the electric machine in the area of the phase terminals and star point rail.
• 4 shows a phase of a wave winding in different views: a) perspective view, front view, side view and top view, b) section through the front view with axial and radial extent of a winding head window.
• 5 shows a planar mat of a wave winding with a layer in different designs: a) with phase clamps on one side, b) with phase clamps on two sides.
• 6 shows a section of the mat from 5 a) .
• 7 shows a section of the stator with the winding inserted.
• 8th shows a planar mat of a wave winding with three layers in different views: a) perspective view; b) Detail of the perspective view with the winding heads.
• 9 shows a planar mat of a wave winding with winding heads with a central offset in different views: a) perspective view with phase terminals on one side, b) detail 9 a) with the winding heads.
• 10 shows diagrams of various stackings of the wave windings with high packing density over the circumference of the machine: a) No stacking, one rotation; b) stacking continuously; b1) two-layer; b2) three-layer; c) 2-partition, no stacking; d) 2-partition, stacking backwards; d1) two-layer; d2) three-layer; e) 3-partition, no stacking; f) 3-partition, stacking in three layers; f1) continuous; f2) backwards.
• 11 shows diagrams of the winding head arrangement of a wave winding in different versions: a) three-phase; b) four-phase; c) five-phase.
• 12 shows examples of different winding head designs: a) spatially bent solid wire or stranded wire bundles; b) vertically stacked double wire bent; c) Profile from solid forming; d) Profile for welded joint; e) Profile for clamp connection with webs; f) Winding head cranked from solid forming; g) Winding head of an air gap winding with several parallel wires.
• 13 shows a cut-away spatial view of the active parts of a permanently excited electric machine with a slotless stator with an embodiment of the winding as an air gap winding.
• 14 shows sections through the active parts of the electric machine 13 : a) Front view with winding head window; b) Section across the stator ring; c) enlarged section of section b).

The first exemplary embodiment in 1 shows an electrical machine 1 designed as a rotary machine with an outer rotor or rotor 32 and an inner stand or stator 33, it being understood that a reverse design is also possible.

The stator 33 is designed as a grooved stator, into which a three-phase wave winding 2 with high packing density with radially alternating winding heads is inserted, together with the other active parts of a permanently excited electric synchronous motor. There is an even number NM of permanent magnets 4 on a rotor iron 3 of this machine. The magnets are magnetized in the radial direction and the magnetization takes place alternately in the tangential direction. Two alternatively polarized magnets next to each other form a pair of poles and define a magnetic period with the magnetic angle AM=4*π/NM.

The magnetic flux generated in the permanent magnet 4 passes through the air gap 5 and is then passed through the ferromagnetic stator core 6, which is made of magnetic steel or another material with high permeability. The number of teeth 7 and grooves 8 is usually the product of the number of phases NP and the number of magnets NM, but can also deviate from this. The groove width is at least as large as the width of the inserted conductor pieces 9.

In the slots 8 there is a winding 2, which consists of one or more layers 28. 1 shows a winding with a layer 28. The winding 2 consists of NP or a multiple of NP conductors 9, which fill the slots 8. 1 shows three phases 15, 16 and 17. NP is preferably three or a multiple of three. NP generally preferably has a value greater than or equal to two. Each conductor 9 consists of parallel straight segments, the winding webs 10, as well as angled connecting pieces, the winding heads 11. The straight ones Winding webs 10 are of the same length. There are preferably NP teeth 7 and NP-1 slots 8 between two adjacent straight winding webs 10 of the same phase.

The axially arranged straight winding webs 10 are tangentially connected by angled winding heads 11. The winding heads 11 are arranged geometrically in a hollow cylinder 12, which is in 2d) is indicated by dashed lines. Such a hollow cylinder 12 is provided coaxially on both sides of the stator core. In each of the two hollow cylinders 12, the winding heads of the three phases are radially stacked in a tangential direction, alternating in an outer and an inner layer in such a way that an internal winding head 13 covers a part of the two right and left external winding heads 14 and an external winding head 14 each covers part of the two winding heads 13 located on the right and left.

In 1 a coordinate system is drawn. A first axis A1 is parallel to at least one first web 11. In the rotary machine shown here as an example, in which the webs 11 are parallel to the axis of rotation, the first axis A1 is parallel to a rotation axis of the rotary machine. A second axis A2 runs parallel to a direction of a relative movement of a rotor or rotor of the electrical machine 1 to a stator or stator of the electrical machine 1. In this embodiment, the second axis A2 is perpendicular to the first axis A1. A third axis A3 is perpendicular to the first axis A1 and the second axis A2. The respective conductor of the phases 15, 16, 17 has a section 31 in the area of a respective winding head 11, in which the conductor runs at least essentially perpendicular to the third axis and, in the present embodiment, also parallel to the second axis A2.

The position and alignment of the axes basically depend on the point of the machine that is being viewed. Since the machine 1 shown here as an example is a rotary machine, the third axis A3 in particular is aligned radially. This means that, for example, with a winding head 11 other than the coordinate system shown here, the axis A3 has a different angle to the viewer 1 has. The axis A2 is circular - corresponding to the relative movement between barrels 32 and stand 33. The coordinate system is therefore ultimately a cylindrical coordinate system. For a linear machine with a straight guideway, the coordinate system would be a Cartesian coordinate system.

2 shows at a) a front view and at b) a side view of the electric machine 1. The projection or the axial length of the winding heads AH over the stator core should be as short as possible in order to keep the axial length and the phase resistance as low as possible. This is achieved by a special course of the winding head 11. A section 31 of the conductor in the area of the winding head 11 runs perpendicular to the third axis A3 or tangentially. It is preferred if the section runs perpendicularly or at an angle greater than 60° to the web direction or to the first axis.

In the 2c1 ) and c2) a cross-sectional view is shown, where 2 c2 ) an increase in the in 2c1 ) shows winding heads 11, 13, 14 shown on the left. It can be seen how a web 10 extends across the width of the stator core. A winding head 11 is connected to the ends of the web 10 in relation to the first axis A1.

In 2 c2 ) two overlapping winding heads 11, namely an upper winding head 14 and a lower winding head 13, are visible. The winding head 14 connects to the web 10. The winding head 13 connects two other webs with each other and intersects with the winding head 14 of the web 10.

In 2 c2 ), the cutting plane lies in a section 31 of the winding head 13, namely a section 31 in which the conductor runs at least essentially perpendicular to the third axis A3.

A first direction 35 runs along the third axis A3. The web 10 has an end 36 in the first direction 35. The winding head 14 also has a section 31 which, with respect to the first direction 35, has an end 37 which is in 2 c2 ) is shown.

The end 37 of the section 31 of the winding head 14 is arranged offset from the end 36 of the (first) web 10 against the first direction 35, namely by an offset 38. The offset 38 in this embodiment is 0.5 times the height HW of the ( first) web in relation to the third axis A3.

A corresponding, mirror-inverted offset exists in the section 31 of the (second) winding head 13 with respect to the webs which this winding head 13 connects. Regarding the image level of 2 c2 ) this means that the upper end of the section 31 of the winding head 13, which is also located at position 37, is offset from the upper ends of the corresponding webs, again with an offset of 0.5 times the height HW of the webs in relation to the third axis A3.

The (first) web 10 has a second end 41 in a first opposite direction 39 with respect to the third axis A3 in a first opposite direction 35. The section 31 of the (first) winding head 14 has a second end 42 in the first opposite direction 39. The second end 41 of the web 10 and the second end 42 of the section 31 are at least essentially at the same height with respect to the third axis A3.

In section 31 of the winding head 13, the dimensions are referenced in the image plane, namely a section width AB1 in relation to the first axis A1 and a section width AB3 in relation to the third axis A3. In this example, the section width AB3 in relation to the third axis A3 is smaller than the section width AB1 in relation to the first axis A1. Specifically, in this particularly advantageous embodiment, the section width AB3 with respect to the third axis A3 is at least essentially equal to the web width WW, see 2e) , with respect to the second axis A2 and the section width AB1 with respect to the first axis A1 is at least substantially equal to the web width HW with respect to the third axis A3. This can be achieved, for example, in a particularly simple manner by massively forming the conductor material, in particular starting from the cross section present in the web. The introduction of a forming force could take place at least essentially parallel to the third axis A3.

How in particular 2 c2 ) and the above statements, the winding heads 11 are extremely compact. Firstly, the radial height HH of the winding head row is only as large as the web height HW. Secondly, the axial length AH of the winding heads 11 is also extremely short, and is simple to manufacture.

A width or tangential length of the winding head WH, see 2d) , is less than 75% of a magnetic period in this exemplary embodiment. For a height of the winding head package HH, see also 2d) , consisting of inner winding heads 13 and outer winding heads 14, advantageously corresponds to the winding web height HW, see for example 2c1 ) and c2), but can also be in the range between 50% and 200% of the winding web height HW. 2e) shows a section through the front view of the stator with an installation space 12 of the winding heads. The installation space 12 is ideally centered radially to the slots 8, but can also be located inside or outside the circle formed by the middle of the slots by a maximum of twice the winding web height HW.

In 2d) a length LA of a section 31.A of a first winding head 11.1 is marked. The conductor in the area of section 31.A runs perpendicular to the third axis A3 and parallel to the second axis A2. The length LA forms a length of the section 31.A with respect to the second axis A2 or in the tangential direction.

In 2d) is illustrated that the axis A2 is circular, since the electrical machine shown here as an example is a rotary machine and since the relative movement of the rotor 32 to the stator 33 is correspondingly circular.

In 2e) is a distance between two webs 10 of the same phase, which are connected via a winding head, not shown here, denoted by DS. The length LA of section 31.A, see 2d) , in particular of each section 31, is preferably at least 0.2, preferably at least 0.4, more preferably 0.6 times DS.

In 2d) a second winding head is designated 11.2. The second winding head 11.2 is one of a different phase than that of the winding head 11.1. The second winding head 11.2 also has a section 31.B in which the conductor runs at least essentially perpendicular to the third axis A3. However, the axis A3 in a rotary machine as shown here is radial. Depending on at what angle or at what position along axis A2 the winding is viewed, axis A3 has a different angle to the observer than that in 2d) is marked.

The section 31.A of the first winding head 11.1 and the section 31.B of the second winding head 11.2 are arranged to overlap and overlap with respect to the second axis A2. In addition, the section 31.A of the first winding head 11.1 and the section 31.B of the second winding head 11.2 run parallel to one another in the cylindrical coordinate system: The sections 31.A and 31.B are offset with respect to the third axis A3, in particular in this way that they do not overlap with respect to the third axis A3.

In 2f) a section is shown in which phase terminals 21, 22 and 23 are visible. These can be produced, for example, by shortening and, if necessary, radially bending and deforming the winding head pieces at the beginning of the phase. A star point rail is created by shortening the winding head pieces at the phase ends 24, 25 and 26, if necessary radially bending and deforming the winding head piece 26 and contacting the winding head pieces or phases.

The phase terminals 21, 22 and 23 are preferably arranged axially behind the winding heads, so that they do not require any additional axial installation space and are easy to contact. The star point rail, which is formed from the shortened last winding heads 24, 25 and 26 and is contacted using a usual joining process, for example welding, is located in the area of the winding heads and therefore also takes up little or no additional installation space. 2 f) shows a possible embodiment.

When the phase connections 21, 22 and 23 and the star point terminal 26 are bent radially, an axial installation space 27 is created, highlighted here with a tangential length L27 and a radial height H27, which can be used, for example, to accommodate a position sensor. The available installation space 27 extends with L27 in the tangential direction over more than one magnetic period AM and is therefore sufficiently large for magnetic field measurements to determine the rotor position. The axial depth corresponds to the winding head projection AH. The radial height H27 extends up to the magnet 4. A sensor, for example a position sensor, can thus be integrated without taking up additional installation space. If some of the terminals mentioned are not bent, the installation space is correspondingly reduced in the tangential and/or radial direction. A perspective cut through the active engine parts in 3 shows the area of the phase terminals and the star point rail.

The shape of a winding head 11 can basically be semicircular, triangular, straight or U-shaped or can have another geometric shape, in particular one that enables the shortest possible connection of two adjacent winding webs of the same phase. The height of the conductor HW in the winding head 11 is preferred, see 2c1 ) and c2), reduced in order to be able to stack the winding heads 11 in pairs in the radial direction without requiring additional radial installation space. The current-carrying cross section is preferably not reduced or, if necessary, increased in order to keep the phase resistance as small as possible. Changes in shape are carried out with constant transitions so as not to impede the flow of current.

The winding webs 10 preferably have at least a length which corresponds to the depth of the stator core along the first axis A1, usually the smallest possible excess length DH - see 4 b) - to ensure the insulation strength of the winding and/or to facilitate the production of the winding heads and assembly. Additional insulation of the stator sides, for example through a coating or a cover plate, enables very small excess lengths DH.

The sequential arrangement of the winding webs 10 and winding heads 11 together form one phase of a wave winding. 4 a) shows different views of a phase or a conductor with radially alternating winding heads. The side view (horizontal at the top) illustrates the radial positioning of the winding heads, according to which, viewed in the direction of travel from the beginning of the phase to the end of the phase, there are always two winding heads lying one after the other at the bottom (corresponds to winding head 13) or at the top (corresponding to winding head 14), aligned alternately on different stator sides. 4 b) shows a section through the front view of a phase, the radial position of the lower winding heads 13 and upper winding heads 14 as well as the axial and radial extent of the winding head window 12.

A phase can be made from one or more solid wires or profiles of any cross-section or from a bundle of strands of any cross-section.

All phases together form the wave winding 2. The entire winding can be manufactured either in one step inside or outside the stator, or the phases 15, 16 and 17 can be prefabricated individually, then woven into a winding and then inserted into the slots, or The winding webs 10 are inserted into the slots 8 and then connected to the winding heads 11 by joining. The winding webs 10 are located in the stator slots 8 and fill them as completely as possible. Each winding head 11 runs tangentially over part of the magnetic period.

5 shows two versions of a winding mat with radially alternating winding heads, namely in 5 a) a version with all phase terminals on one side of the mat and in 5b) with phase terminals on both sides of the mat. Arrangement a) has the advantage that the phase connections are easier to contact because they are spatially close to one another on the same side. Arrangement b) has the advantage that a gap-free mat is created that is easier to handle. 5 shows the dense structure of the winding head package, in which the winding heads of the three phases are arranged in two radially stacked layers without gaps.

6 shows a section of the winding mat consisting of three phases 15, 16 and 17 with winding heads alternating at the bottom 13 and at the top 14. Here the winding 2 is in a state before being inserted into the stator slots 8. Specifically, the mat is essentially spread out flat. In this state, axis A2 is straight. In the orientation shown, the winding 2 or mat could also be used in a linear motor, for example.

7 shows a winding 2 comprising the phases 15, 16 and 17 with winding heads alternating at the bottom 13 and at the top 14, which is inserted into the stator slots 8.

The compact multi-phase wave winding 2 can consist of more than one layer 28. 8th shows an exemplary embodiment of the structure of a winding mat consisting of three layers 28.1, 28.2 and 28.3. The height of the winding heads is ideally matched to the height of the winding layer, so that any number of layers can be stacked radially without collision, without taking up additional radial installation space. However, it is also possible to use higher or lower winding heads, which increases the height of the winding head package. 8th shows three stacked individual mats with radially alternating winding heads. A longer winding mat can also be made and then stacked and inserted onto the stator. The wrapping mat 8th For example, a stack of three winding mats can easily be created according to 5 a) or b).

9 a) shows another version of a winding mat with one layer consisting of three phases. The first phase 15 only has lower winding heads 13 here. All winding heads of the third phase 17 are upper winding heads 14. The second phase 16 has cranked winding heads 30, which proportionately occupy the lower and upper part of the winding head window or the lower and upper layers. This form of wave winding with cranked winding heads 30 also enables the three phases to be stacked in an optimal space. 9 b) shows a section with the winding heads 13, 30, 14. The advantage of this arrangement is that the three phases only have to be stacked radially one after the other in order to create a winding mat. The position of the webs and the winding head window corresponds to the wave winding with radially alternating winding heads, as described above, so that winding mats of both designs can be used equally and even mixed.

The layers 28 can be stacked one above the other on the stator, basically over the entire circumference of the machine in the radial direction or only on individual segments of the stator or in a combination, as in 10 shown as an example. The radial transition between the individual layers 28 can take place in such a way that the sequence of winding webs 10 and winding heads 11 runs in the same or in the opposite tangential direction. The layers 28 can also be intertwined. The split configurations allow the voltage level to be lowered by connecting the split segments in parallel. If there is an even number of segments, rotating the even or odd segments by 180° can ensure that the phase terminals and star point are in pairs, which greatly simplifies contacting, especially in the case of two segments, whereby all phase terminals and the two star points can be placed together .

The figures show a solution for the three-phase motor case. Analog solutions are generally also suitable for all other multi-phase motors. The phase number NP is preferably equal to three or a multiple of three, since in this case a particularly high packing density of the winding heads can be achieved. 11 shows examples of an arrangement scheme with radially alternating winding heads for a) three phases, b) four phases and c) five phases. The winding head arrangements at the beginning of a phase can be chosen arbitrarily as long as the alternating order is maintained. With three phases, there is a very compact winding head arrangement in two layers, each in one level of lower level E1 and upper level E2 without gaps. By radially stacking the winding heads of three-phase arrangements, compact six-, nine-, etc.-phase arrangements can be created. The winding head height of the three-phase arrangement used must be halved, divided into thirds, etc. if the radial installation space is to be maintained. Phase numbers NP that are not a multiple of three can be represented as in 11 b) using the example of four phases and 11c) shown using the example of five phases. A four-phase winding is created, for example, from a tightly packed three-phase winding and an additional fourth phase inserted into the remaining free space. Thus, a total of three layers are occupied by the winding heads, each in a level of lower level E1, middle level E2 and upper level E3. A five-phase winding is created, for example, from a tightly packed three-phase winding and two additional fourth and fifth phases inserted sequentially into the two free spaces. Thus, a total of four layers are occupied by the winding heads, each in one level of the lowest level E1, second level E2, third level E3 and top level E4. Due to the individual phases, the winding head package has gaps in the tangential direction and therefore requires additional installation space compared to a three-, six- or nine-phase arrangement.

The winding 2 consists of conductors 9, the cross section of which can be circular, rectangular, trapezoidal or another cross section, whereby a conductor 9 can consist of many thin wires or a solid wire or profile. The size and shape of the cross section can change along the conductor. Copper or another material with good electrical conductivity can be used become. Adapting the conductor cross section to the slot geometry enables a high fill factor. The high fill factor enables good thermal contacts and lower electrical resistance. The height HW and width WW of the conductor 9 (see e.g 2e) ) represent the conductor dimensions in radial and tangential dimensions. For a circular or square cross section, the width and height are identical. Each phase can consist of any number NL of conductors in a tangential order, with one preferred choice for NL for slot windings.

1. a) Biegen und/oder Verdrehen, jeweils insbesondere in mehreren Achsen
2. b) Fügen
3. c) Massivumformen
4. d) Additive Fertigung

A winding described herein can be produced by different methods and from different semi-finished products, which in turn have an impact on the possible winding head and winding web designs. Examples of these manufacturing processes are:

1. a) Bending and/or twisting, in particular in several axes
2. b) Joining
3. c) massive forming
4. d) Additive manufacturing

• Beispielsweise kann die Herstellung der Wicklung ein Biegen eines Massivdrahts oder eines Litzenbündels in mehreren Achsen, z.B. gemäß 12 a), umfassen. Das Biegen eines Massivdrahts bzw. eines Litzenbündels erfolgt vorzugsweise in zwei Umformungsschritten, um die Materialbeanspruchung zu begrenzen. In einem Torsionsschritt mit 90° Torsionswinkel um eine Torsionsachse, Pos. 34 in 12 a), parallel zur Stegachse, wird der tangentiale Abschnitt 31 des Wickelkopfes 11 gebildet. In einem Biegeschritt um zwei radiale Achsen, Pos. 44 in 12 a), werden zwei Biegungen um 90° ausgeführt, um eine gebogene Form des Wickelkopfes 11 darzustellen. Der Wickelkopf 11 hat dann die Höhe der Stegbreite. Ein Aspektverhältnis des Stegs von 2:1 liefert nach Stapelung von zwei Wickelkopfstücken ein Wickelkopfpaket in Höhe des Wicklungstegs HW und damit eine sehr kompakte Anordnung. Der minimale Biegeradius ist vorzugsweise auf das 3- bis 4-fache der Drahtbreite WW begrenzt, wodurch sich eine axiale Wickelkopflänge von z.B. 4*WW+HW+DH ergibt. Bei einem Aspektverhältnis von 2:1 ergibt das 6*WW+DH. Der Querschnitt des Wicklungsstegs ist durch den Querschnitt des verwendeten Massivdrahts bzw. Litzenbündels festgelegt. 12 a) zeigt ein Ausführungsbeispiel eines Wickelkopfes aus räumlich gebogenem Massivdraht. Ein Litzenbündel zeichnet sich z.B. dadurch aus, dass es nicht aus ausschließlich vertikal gestapelten Drähten besteht.

In the following, the possibilities will be clarified using a few exemplary embodiments:

• For example, the production of the winding can involve bending a solid wire or a stranded bundle in several axes, for example according to 12a) , include. The bending of a solid wire or a stranded bundle is preferably carried out in two forming steps in order to limit the stress on the material. In a torsion step with a 90° torsion angle around a torsion axis, position 34 in 12a) , parallel to the web axis, the tangential section 31 of the winding head 11 is formed. In one bending step around two radial axes, pos. 44 in 12a) , two bends of 90 ° are carried out in order to represent a curved shape of the winding head 11. The winding head 11 then has the height of the web width. After stacking two winding head pieces, an aspect ratio of the web of 2:1 provides a winding head package at the height of the winding web HW and thus a very compact arrangement. The minimum bending radius is preferably limited to 3 to 4 times the wire width WW, which results in an axial winding head length of, for example, 4*WW+HW+DH. With an aspect ratio of 2:1 this results in 6*WW+DH. The cross section of the winding web is determined by the cross section of the solid wire or stranded bundle used. 12a) shows an exemplary embodiment of a winding head made of spatially bent solid wire. A bundle of strands is characterized, for example, by the fact that it does not consist exclusively of vertically stacked wires.

A phase is created when several alternating winding heads and winding webs made of solid wire or a stranded bundle are bent sequentially. Three phases can then be woven into a winding mat. The winding heads of all three phases are preferably made from three solid wires or stranded bundles in one step and the winding mat is built up directly during bending. The shape and order of the winding heads result from the arrangement in 12a) and or 11 .

The production can also include bending a solid wire in several axes, in particular a conductor with a radially offset section 31 and a conductor without a radial offset can be combined, as in 12 b) is shown. In order to avoid the combined bending of a solid wire with a high aspect ratio or the fill factor deterioration of the stranded bundle, for example two or more radially stacked solid wires, preferably with a square cross section, can be used. The bends remain in the same manner and order as with a solid wire/stranded bundle, but are simplified due to the significantly lower resistance moments of the thinner solid wires. When using two identical square wires, you automatically have an effective aspect ratio of 2:1 when you look at the two conductors together, and therefore a very compact winding head package. The axial combined winding head length is, for example, 5*WW+DH. The cross section of the winding web is determined by the cross section of the wire used. 12 b) shows an embodiment with two conductors with radially stacked and bent square solid wires. More than two wires can also be stacked with adjusted wire heights to further reduce the section modulus of the wires. When several alternating winding heads are bent sequentially, a phase is created. Three phases can then be woven into a winding mat. The winding heads of all three phases are preferably made from three stacked solid wire pairs in one step and the winding mat is built up during bending. The shape and order of the winding heads result from the arrangement in 12 b) and or 11 .

A wide range of freedom in shaping the winding head and/or winding web is achieved by massive forming, for example extrusion or forging, of the winding heads. For example, the favorable flow properties of copper are used to create an ideal winding head geometry, without being limited by bending radii. Through the high flexibility during forming, axially very short winding heads can be produced and the cross-sectional changes can be continuously shaped. With a selected distance of WW between the stator and winding head, the axial winding head length can be shortened, for example, to 3*WW+DH, for example with an aspect ratio of 2:1. If necessary, the winding web can also be adapted, for example, to a trapezoidal shape or another desired geometry, for example by massively forming the winding web or by selecting a semi-finished product with a suitable geometry, whereby the fill factor can be significantly increased, especially with a smaller stator diameter. The cross sections used in the winding web and winding head can be selected independently. The starting material is, for example, bare copper or another material with high electrical conductivity such as wire, profile or other semi-finished product. The insulation is applied after the phase/winding has been completed, for example by painting.

12c) shows an exemplary embodiment of a massively formed winding head. When several alternating winding heads and possibly winding webs made of profile wire are sequentially formed, a phase is created. Three phases can then be woven into a winding mat. The winding heads of all three phases are preferably manufactured from three profiles in one step and the winding mat is built up during massive forming. The shape and order of the winding heads result from the arrangement in 12c) and 11 .

In particular, the in 12c) shown winding head 11 are formed from a solid wire with a substantially rectangular cross section by first bending the wire into a U-shape so that webs 10 are aligned parallel. Mass forming can then take place in such a way that the area between the parallel webs 10 is essentially pressed flat. This creates a cross section with essentially the same cross-sectional area as in the area of the webs 10, the height in this exemplary embodiment being essentially halved and the width being essentially doubled. The cross-sectional shape essentially corresponds to that of the webs 10, but is rotated by 90°.

In 12c) a first direction 35, an end 36 of the web 10 in the first direction 35 and an end 37 of the section 31 in the first direction 35 are also indicated. There is an offset 38 between the end 36 and the end 37.

It is also possible to add winding heads and bars, as exemplified in 12e) is illustrated. When joining the winding heads, it is possible to insert winding webs with a geometrically adapted cross-section and insulated, for example painted, into the slots, which in this case can also be partially or completely closed. The winding heads can be prefabricated using forming technology, for example by punching or by a cutting process, for example by laser cutting, or other manufacturing processes. The joining process between winding web 10 and winding head 11 is carried out, for example, by welding, clamping, riveting, extrusion, another joining method or a combination of these methods. The joint must be subsequently insulated. The cross sections used in the winding web and winding head can be selected independently. The compact joint makes it possible to produce axially very short winding heads. The axial winding head length can be shortened to 3*WW+DH with a selected distance of WW between stator and winding head, especially with an aspect ratio of 2:1. Depending on the joining method chosen, a slight increase in the contact resistance between the winding web and the winding head can be expected. 12d) shows an exemplary embodiment of a winding head for a welded connection, in which the winding web is butt-joined to the winding head, for example by plasma welding. 12e) shows an exemplary embodiment of a winding head and a suitable winding web for a clamp connection. The shape of the joint can, for example, be slightly conical, as in 12e) , executed or take on another geometric shape. Alternating concave and convex elevations or depressions on the surface of both joining partners improve the mechanical and electrical connection. The order of the winding heads results, for example, from the arrangement in 11 .

In 12f) an embodiment of a winding head 11 is shown, which has a first section 31.1 with an offset 38.1, such as in relation to 12c) described, opposite a first web 10.1. In the area of the winding head 11, a second section 31.2 is also provided, in which the conductor runs at least essentially perpendicular to the third axis A3.

The second web 10.2 has an end 36.2 in a first opposite direction 39 along the third axis A3, opposite the first direction 35. The second section 31.2 has an end 37.2 in the first opposite direction 39 in relation to the third axis A3. The end 37.2 of the second section 31.2 is offset from the end 36.2 of the second web 10.2 along the first opposite direction 39, namely by an offset 38.2. The first section 31.1 and the second section 31.2 are thus ultimately designed to be mirror-inverted. A step or offset 40 is provided between the first section 31.1 and the second section 31.2.

For example, in order to avoid the effort involved in interweaving phases with radially alternating winding heads, such cranked winding heads can be used. The offset 40 lies approximately in the middle of the tangentially extending section of the winding head, so that the part of the winding head lies in front of the offset point, as in the case of an overhead winding head 14, and the part of the winding head lies after the offset point, as in the case of an underlying winding head 13. This order can also be swapped.

The winding head 30 from 9 b) can advantageously accordingly 12f) be carried out. Alone 12 The winding head designs shown can basically be designed in a cranked form.

The exemplary embodiment according to 12 f) can, for example, be similar to that of 12c) are produced, in particular by massive forming and preferably with prior bending of an elongated starting material. The cross section of the elongated starting material is preferably rectangular, in particular with different aspect ratios and/or an aspect ratio of 2: 1. It is also advantageous if the cross section remains in the area of the webs 10, that is, the cross section of the webs 10 corresponds to that of the starting material. It is therefore only necessary to deform the cross section in the area of the winding head 11.

As well as 12c) as well as 12 f) It is preferably the case that during massive forming, a forming force is applied to the conductor section for section 31 in a direction of force, the direction of force being parallel to the third axis A3 in relation to a state installed in the electrical machine.

Furthermore, additive manufacturing of the winding heads and/or winding webs is also possible. Additive manufacturing processes offer a very high level of flexibility in both the shape and design of the winding. Similar to joining, insulated winding webs 10 can be inserted or inserted into the open or closed slots, after which the winding heads 11 are additively manufactured as a connection between two adjacent winding webs 10 of a phase and, in particular, contacted at the same time. In this case, only the winding heads 10 need to be re-insulated. Similar to massive forming, the individual phases 15, 16 and 17 or the entire winding 2, consisting of winding webs 10 and winding heads 11, can be manufactured additively, either outside the stator 6 as a prefabricated winding mat or directly in the slots 8 of the stator as an integrated winding . With prefabricated winding mats, insulation can be carried out in a separate step. For integrated windings, insulation is part of additive manufacturing. With a selected distance of WW between the stator and winding head, the axial winding head length can be shortened, for example, to 3*WW+DH, especially with an aspect ratio of 2:1. Alone 12 The winding head geometries listed can be achieved using additive manufacturing. The order of the winding heads results, for example, from the arrangement in 11 .

The next exemplary embodiment in 13 shows an electrical machine 29 with a slotless stator, on which a three-phase wave winding with high packing density 2 is applied as an air gap winding with radially alternating winding heads, together with the other active parts of a permanently excited electric synchronous motor. This machine 29 has an even number NM of permanent magnets 4 on the rotor iron 3. The magnets 4 are magnetized in the radial direction and the magnetization takes place alternately in the tangential direction. Two alternatively polarized magnets next to each other form a pair of poles and define a magnetic period AM=4*π/NM.

After passing through the air gap 5 and the wave winding 2 lying in the air gap, the magnetic flux is guided through the ferromagnetic stator core 6, which consists of magnetic steel or another material with high permeability. The stator has no grooves or teeth, which means it is very low and easy to implement and, due to its design, avoids cogging torque.

On the iron yoke in the air gap 5 there is a winding 2, which can consist of one or more layers 28, for example with stacking similar to 8th . 13 shows the winding with a layer 28. The winding 2 can comprise NP or a multiple of NP conductors 9, which lie directly in the air gap, where NP represents the number of phases. NP is preferably three or a multiple of three or any value greater than or equal to two. Each phase here comprises several adjacent, parallel, straight segments, the winding webs 10, as well as angled connecting pieces, the winding heads 11. The straight winding webs 10 are of the same length. To reduce eddy currents, each phase is divided into NL individual wires. The number NL of individual wires results from the speed range in which the machine is operated and the cross section of the individual wires. The individual wires can have a round, preferably a rectangular, generally any cross-section.

The axially arranged, straight winding webs 10 are tangentially connected by angled winding heads 11, which are in particular geo are arranged metrically in a hollow cylinder or winding head window, which lie coaxially on both sides of the stator core. In each of the two hollow cylinders or winding head windows, the winding heads of the three phases lie radially stacked in a tangential direction, alternating on an outer and an inner layer in such a way that an internal winding head 13 covers and covers a part of the two winding heads 14 on the right and left External winding head 14 covers part of the two winding heads 13 on the right and left. 14 a) shows a detail from the front view of the electric machine 29 with the winding head window 12.

14 b) shows a section through the active parts of the slotless electric machine 29. The projection of the winding heads AH over the stator core should be as small as possible in order to keep the axial length and the phase resistance as low as possible. This is achieved by a tangential course of the winding head at right angles or at an angle greater than 60° to the web direction. The width of the winding head WH, see 14 a) , is preferably less than 75% of a magnetic period. The height of the winding head package HH, see 14c) , is preferably in the range between 50% and 200% of the winding web height HW. The radial position of the winding head package can be as in 13 b) be aligned centrally to the winding web or, for example, be shifted radially downwards or upwards by a maximum of two winding web heights HW.

A respective conductor in the area of the (first) winding head 13 has a section 31 in which the conductor runs at least essentially perpendicular to the third axis A3 and here also perpendicular to the first axis A1. The (first) web 10 has an end 36 in a first direction 35 along the third axis A3. The section 31 of the winding head 13 has an end 37 in the first direction 35 along the third axis A3. The end 37 of the section 31 of the winding head 13 is arranged offset from the end 36 of the first web 10 against the first direction 35.

An end 42 of the section 31 of the first winding head 13 in a first opposite direction 39 opposite the first direction 35 is offset from an end 41 of the web 10 in the opposite direction 39. There is an offset 43 between the end 42 and the end 41. This results in an added height HH of the winding heads 13 and 14, which - unlike at 2 c2 ) - is greater than the web height HW.

To increase the mechanical stability and reduce the axial installation space, the winding heads can, for example, be bent radially in the direction of the stator core 6 and, for example, be fixed to it. By making thermal contact with the stator core 6, for example, an improvement in heat dissipation and thereby a significant reduction in the winding head temperature is achieved. Another possibility for increasing the mechanical rigidity is to bake, cast, glue or otherwise embed the winding heads 11 in a carrier substance.

A further embodiment of the electrical machine is characterized in that the stator core 6 is replaced by a second rotor equipped with permanent magnets and the winding 2 is positioned freely in the air gap. The winding heads 11 are baked, glued, cast or embedded in a carrier substance in order to be able to transmit torque and forces to the stationary parts of the machine. To increase the mechanical strength, additional fastening rings can be attached inside, outside or on both sides of the winding heads 11. The winding webs are preferably also baked, glued, cast or embedded in a carrier substance in order to increase the mechanical stability. In this application example, the winding 2 forms a completely iron-free stator of the machine. To increase stability, completely or multiple wrapping layers are preferably used.

With regard to the structure of the winding layers 28, the phase connections 21, 22 and 23, the star point rail 24, 25 and 26 as well as the available sensor installation space, the statements regarding the winding of the grooved motor apply accordingly.

The shape of the winding head can be semicircular, triangular, straight, U-shaped or have another geometric shape, in particular one that enables the shortest possible connection of two adjacent winding webs of the same phase. The height of the winding HW is preferably retained in the winding head of the air gap winding, but it can also be reduced in order to reduce the radial height of the winding head package.

The winding webs at least preferably have a length which corresponds to the depth of the stator core along the axis A1, and usually the smallest possible excess length in order to ensure the insulation strength of the winding and/or to facilitate the production of the winding heads and assembly. The winding webs 10 are tightly packed on the stator core 6 in a tangential direction in order to achieve a high filling factor. Two NP winding webs 10 preferably cover one magnetic period.

Analogous to the grooved motor, the sequential arrangement of the winding webs and winding heads together forms a phase of a wave winding with a radially alternating positioning of the winding heads 11, in that, viewed in the running direction from the beginning of the phase to the end, there are always two winding heads 11 lying one after the other, alternately aligned at the bottom 13 and at the top 14 on both sides of the stator.

14 b) shows the axial and radial extent AH and HH of the winding head window 12. 12g) shows an exemplary embodiment with seven individual wires or conductors 9. The stator protrusion of a respective conductor 9 forms a winding head 11. All in 12g) The winding heads shown have a section 31 with an offset from the respectively assigned web 10.

The production takes place, for example, from a wire bundle of NL profile wires arranged horizontally next to one another by bending in two radial axes 44 in order to achieve the curved shape, and a subsequent bending around a tangential axis 45, which adjusts the curved part by at least half of the winding web height HW outside (outer winding head 14) or inside (inner winding head 13) deformed relative to the respective winding web.

In 12g) a step 46 is provided by the offset, with the respective section 31 being offset upwards in relation to the image plane compared to the corresponding web 10.

Alternatively, the cranks on the inner 13 and on the outer winding head can also be divided asymmetrically, but preferably in such a way that there is always a distance of one winding web height between the outer 14 and inner 13 winding head.

All phases together form the wave winding in the air gap. The entire winding can either be manufactured in one step or the phases can be prefabricated individually and then woven into a winding mat (winding heads with radially alternating positioning) or laid (offset winding heads). The winding mat can be completely prefabricated outside the stator and then applied to the stator by gluing or another joining method, or it can be manufactured directly on the stator.

Reference symbol list

1

electric machine

2

wave winding

3

Rotor iron inference

4

Permanent magnet

5

air gap

6

Stator iron inference

7

stator tooth

8th

stator slot

9

Director

10

winding web

11

winding head

12

Hollow cylinder/winding head installation space

13

Winding head below

14

Winding head above

15

Phase 1

16

Phase 2

17

Phase 3

18

Phase 4

19

Phase 5

20

Phase 6

21

Phase terminal 1

22

Phase terminal 2

23

Phase clamp 3

24

Star point terminal 1

25

Star point terminal 2

26

Star point terminal 3

27

Installation space position sensor

28

winding position

29

Electric machine with slotless stator

30

Winding head cranked

31

Section

32

Stand/Stator

33

Runner/rotor

34

Torsion axis

35

first direction

36

End

37

End

38

offset

39

first opposite direction

40

Step/offset

41

End

42

End

43

offset

44

bending axis

45

tangential axis

46

Level

AB1

Section width

FROM 3

Section width

UH

Projection/axial length of winding head

AT THE

Angle magnetic period

DH

Distance winding head to stator

D.S

Distance between two bars of the same phase

H27

Radial height installation space position sensor

HH

Height of winding head

HW

Height of winding web

L27

Tangential length installation space position sensor

LA

Length of the section relative to the second axis/tangential

NM

Number of magnets

NP

Number of phases

WH

Width/tangential length of winding head

WW

Thick winding web

QUOTES INCLUDED IN THE DESCRIPTION

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

Cited patent literature

• EP 2124317 A1 [0005]
• EP 1179880 A2 [0007]
• US 20060226727 A1 [0008]
• DE 10321956 A1 [0010]
• WO 03094328 A1 [0012]
• US 0309207 [0012]
• WO 2005117243 A1 [0012]
• SI 05000015 [0012]
• WO 2005050816 A2 [0014]
• CA 2004/001978 PCT [0014]
• WO/2006110498 A1 [0016]
• US 2006012914 [0016]
• EP 2695284 B1 [0017]
• US 20220021264 A1 [0018]
• DE 102011111352 B4 [0019]
• DE 102016100744 B3 [0020]
• DE 19909026 A1 [0021]
• EP 3182568 A1 [0022]
• WO 2017089455 A1 [0022]

Claims (15)

Winding (2) for an electrical machine (1, 29), especially multi-phase wave winding, comprising the winding (2). at least one first conductor (9), which is arranged in the form of several webs (10) and several winding heads (11, 13, 14, 30), wherein the webs (10) and winding heads (11, 13, 14, 30) alternately follow one another along the first or respective conductor (9) and a respective winding head (11, 13, 14, 30) forms a connection between two webs (10). , wherein a first winding head (11, 13, 14, 30) connects a first and a second web (10) of the first conductor (9), wherein a second winding head (11, 13, 14, 30) of the first or a second conductor (9) connects a third and a fourth web (10) of the first or second conductor (9), wherein the first and second winding heads (11, 13, 14, 30) cross each other and the third web (10) is arranged between the first and second webs (10), wherein a first axis (A1) is parallel to at least the first web (10), wherein a second axis (A2) is parallel to a direction of a relative movement of a rotor (33) of the electrical machine (1) to a stator (32) of the electrical machine (1), where a third axis (A3) is perpendicular to the first and second axes (A1, A2), wherein the conductor (9) in the area of the first winding head (11, 13, 14, 30) has a section (31) in which the conductor (9) runs at least substantially perpendicular to the third axis (A3), wherein the first web (10) has an end (36) in a first direction (35) along the third axis (A3), wherein the section (31) has an end (37) in the first direction (35) along the third axis (A3), wherein the end (37) of the section (31) is arranged offset from the end (36) of the first web (36) against the first direction (35), and wherein the section (31) spans the third web (10) with respect to the second axis (A2). winding (2). Claim 1 , wherein the end (37) of the section (31) is arranged offset by an offset (38) relative to the end (36) of the first web (10) against the first direction (35), the offset (38) being at least 0, 3, preferably at least 0.5, preferably at least 0.8, preferably at least 1.0, times a height (HW) of at least the first web (10) in relation to the third axis (A3). Winding (2) according to at least one of the preceding claims, wherein at least the first and second webs (10) are designed with the same cross section and/or are arranged at the same height and/or at the same position in a conductor stack with respect to the third axis (A3), and or wherein the conductor (9) has an at least substantially square cross section in the area of at least the first web (10) and/or in the section (31) and/or wherein a cross-sectional shape of the conductor in the section (31) is at least essentially the same as a cross-sectional shape of the conductor (9) in the area of at least the first web (10). Winding (2) according to at least one of the preceding claims, wherein the conductor (9) in the area of at least the first web (10) has a web width (HW) in relation to the third axis (A3) and a web width (WW) in relation to the second axis (A2), where the web width (HW) with respect to the third axis (A3) is greater than the web width (WW) with respect to the second axis (A2), wherein the conductor (9) in section (31) has a section width (AB3) in relation to the third axis (A3) and a section width (AB1) in relation to the first axis (A1), wherein the section width (AB3) with respect to the third axis (A3) is smaller than the section width (AB1) with respect to the first axis (A1), in particular wherein the section width (AB3) with respect to the third axis (A3) is at least is substantially equal to the web width (WW) with respect to the second axis (A2) and/or wherein the section width (AB1) with respect to the first axis (A1) is at least substantially equal to the web width (A3) with respect to the third Axis (A3). Winding (2) according to at least one of the preceding claims, wherein a cross-sectional area of the conductor (9) in the section (31) is at least substantially equal to or greater than a cross-sectional area of the conductor (9) in the region of the first, second, third and/or or fourth web (10). Winding (2) according to at least one of the preceding claims, wherein the second web (10) has an end (36) in the first direction (35) along the third axis (A3), the end (37) of the section (31) is arranged offset relative to the end (36) of the second web (10) against the first direction (35), in particular by the same offset (38) as between the end (37) of the section (31) and the end (36) of the first web (10) and/or wherein the second web (10) has an end (36) in the first direction (35) along the third axis (A3), the ends (36) of the first and second webs (10) in the first direction (35) are arranged at the same height with respect to the third axis (A3). Winding (2) according to at least one of the preceding claims, wherein the section (31) has a length (LA) with respect to the second axis (A2) of at least 0.2, preferably at least 0.4, preferably at least 0.6 at least 0.8, preferably approximately 1.0, times a distance (DS) between the first and second webs (10) with respect to the second axis (A2) and/or wherein the conductor (9) in the section (31) has a section width (AB3) with respect to the third axis (A3) which is smaller than a web width (HW) of the conductor (9) in the web (10) with respect to the third axis (A3), in particular wherein the section width (AB3) in relation to the third axis (A3) is at most 1.0, preferably at most 0.8 times, preferably at most 0.6 times, particularly preferably at most or about 0.5 times , preferably at most 0.3 times, is as large as the web width (HW) in relation to the third axis (A3). Winding (2) according to at least one of the preceding claims, wherein at least the first web (10) has a second end (41) in a first opposite direction (39) with respect to the third axis (A3), the section (31) in the first opposite direction (39) has a second end (42), wherein the second end (41) of the web (10) and the second end (42) of the section (31) are at least substantially at the same height with respect to the third axis (A3) and/or wherein the conductor (9) in the section (31) runs at least substantially perpendicular to the first axis (A1) and/or parallel to the second axis (A2) and/or wherein the webs (10) are designed as hair pins. Winding (2) according to at least one of the preceding claims, wherein the conductor (9) in the area of the second winding head (11) has a section (31) in which the conductor (9) runs at least substantially perpendicular to the third axis (A3), wherein the third and/or the fourth web (10) has an end in a second direction along the third axis (A3), wherein the section (31) of the second winding head (11) has an end in the second direction along the third axis (A3), wherein the end of the section (31) of the second winding head (11) is arranged offset against the second direction relative to the end of the third and/or fourth web, in particular, the section (31) of the second winding head (11) spanning the first and/or second web (10) with respect to the second axis (A2), and/or in particular wherein the section (31) of the first winding head (11) and the section (31) of the second winding head (11) overlap and/or in particular wherein the section (31) of the first winding head (11) and the section (31) of the second winding head (11) run parallel to one another and/or to the second axis (A2). Winding (2) according to at least one of the preceding claims, wherein the section (31) of the first winding head (11) is a first section (31.A) and wherein the conductor (9) in the area of the first winding head (11) has a second section (31.B) in which the conductor (9) runs at least substantially perpendicular to the third axis (A3), wherein the second web (10.2) has an end (36.2) along the third axis (A3) in a first opposite direction (39) along the third axis (A3), wherein the second section (31.B) has an end (37.2) in the first opposite direction (39) with respect to the third axis (A3), wherein the end (37.2) of the second section (31.B) is arranged offset relative to the end (37.2) of the second web (10.2) along the first opposite direction (39), in particular, a step (40) being provided in the conductor (9) between the first and second sections (31.A, 31.B). Electrical machine (1, 29) comprising a winding (2) according to one of the preceding claims, in particular, the electrical machine (1) having a core and the winding (2) forming a core winding, the core comprising a plurality of slots (8), in each of which at least one web (10) is arranged, in particular, a plurality of webs (10), in particular a phase (15, 16, 17), being provided in each groove (8), or wherein the electrical machine (29) is designed to be coreless and/or grooveless, in particular, a plurality of webs (10), in particular of a phase (15, 16, 17), being arranged next to one another along the second axis (A2). Method for producing a winding (2) according to one of Claims 1 until 10 for an electrical machine (1, 29), in particular one like this Claim 11 , in particular wherein at least the first web (10) and the section (31) of the first winding head (11) are made from one component, the component being formed. Procedure according to Claim 12 , wherein an elongated conductor material is provided, of which a longitudinal section is provided for the first web (10) and a longitudinal section for the section (31), in particular wherein the conductor material is between the longitudinal section for the first web (10) and the longitudinal section for Section (31), in particular starting from a substantially straight state of the conductor material, is bent about a first bending axis (44), preferably by at least substantially 90 °, and / or in particular wherein the first bending axis (44) to a longitudinal axis of the conductor material is perpendicular and/or parallel to the third axis (A3) with respect to a state installed in the electrical machine (1, 29), and/or in particular wherein the conductor material is between the longitudinal section for the first web (10) and the longitudinal section for the Section (31) is rotated, preferably by at least substantially 90 ° and / or the bending and twisting occur overlapping in time or one after the other. Procedure according to Claim 12 or 13 , wherein a component for producing the section (31) is massively formed, in particular extrusion-pressed, in particular wherein during massive forming a forming force is applied in a direction of force to the conductor section for the section (31), the direction of force in relation to one in the electrical machine (1, 29) installed state is parallel to the third axis (A3) and / or opposite to the first direction (35) and / or in particular wherein the massive forming to produce the section (31) takes place after bending. Method according to at least one of the Claims 12 until 14 , wherein at least the first web (10) and the first winding head (11) are assembled from separate components, in particular by means of welding, soldering or a press connection, in particular wherein the second web (10) and the first winding head (11) are assembled from separate components are, in particular by means of welding, soldering or a press connection, or in particular wherein the second web (10) is connected in one piece to the first winding head (11) and/or wherein the second web (10) and the first winding head (11) consist of one component , especially by forming.

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