EP1905146A1

EP1905146A1 - Method for producing a winding of an electrical machine

Info

Publication number: EP1905146A1
Application number: EP06764000A
Authority: EP
Inventors: Uwe Knappenberger
Original assignee: Robert Bosch GmbH
Current assignee: Robert Bosch GmbH
Priority date: 2005-07-12
Filing date: 2006-06-30
Publication date: 2008-04-02
Also published as: JP5135217B2; US8230578B2; WO2007006668A1; JP2009501507A; DE102005032478A1; US20080072990A1

Abstract

The invention relates to a method for producing at least one winding of an electrical machine that has a plurality of poles, in particular of a motor generator, preferably for a hybrid drive of a motor vehicle, the winding being formed by winding parts connected in parallel and each pole being associated with at least one groove set that is associated with the winding parts and comprises a plurality of grooves which have different circumferential angle positions relative to the associated pole, grooves with the same circumferential angle position forming equivalent grooves and each winding part of the winding being wound with the same number of windings in equivalent grooves. The invention also relates to a corresponding winding.

Description

Method for producing a winding of an electrical machine

The invention relates to a method for producing at least one winding of a multi-pole electrical machine, in particular a motor-generator, preferably for a hybrid drive of a motor vehicle.

The winding of a winding of an electric machine by hand is time consuming and requires a high level of qualification. In the case of a machine winding, the winding wire can only be processed up to a diameter which is still manageable by machine, without causing damage, in particular insulation damage. Nevertheless, an electrical machine should be realized with the best technical data in an automated winding creation.

The method on which the invention is based for producing at least one winding of a multi-pole electrical machine has the advantage that, in the case of manual or mechanical production, good handling of the winding wire of the winding results, with excellent electrical and electromagnetic values being achieved. The winding is formed by parallel-connected winding parts, for example, three parallel winding parts can be provided per phase of the electric machine. In a three-phase electric machine, nine winding parts accordingly result. JE The pole is assigned at least one groove group assigned to the winding parts, each with a plurality of grooves having different circumferential angle positions with respect to the associated pole, wherein grooves having the same circumferential circumferential position form equal grooves. The fact that each winding part of the winding is wound with the same number of turns in equivalent grooves, resulting in the winding parts to be closed parallel or virtually no voltage differences, that is, the occurrence of circulating currents is prevented or substantially prevented, so that excellent electrical and electromagnetic values are achieved. Due to the parallel winding parts can be used a winding wire with a corresponding diameter, which can be handled very well manually and / or by machine. Considering, for example, a winding formed in the region of a pole from three winding strands connected in parallel, the winding wire of one of the winding parts lies in a PoI circumferential angle basic position, for example in a generator designed as a generator whose stator is to be wound. he is in a groove, which occupies a basic position in terms of Polausbildung. The winding wire of another winding part is located in an adjacent groove, which, however, is advanced with respect to the groove in the pole circumferential position with respect to the direction of rotation of the electric machine, that is, it is a "leading" groove A further, third winding part lies opposite the pole circumferential angle base position in a trailing peripheral angular position, that is to say in a groove that follows the first-mentioned groove, with the result that the electrical voltages forming in the winding parts have different phase positions The phase angle of the voltage induced in the middle winding wire will set a voltage with leading phase angle in the winding wire of the "leading groove" and a voltage with lagging phase angle in the "lagging" groove Phase position and the lagging phase position is, however, a repeal, so that overall in the three winding parts there is a balanced phase position, if -as already mentioned above-care is taken to ensure that in each winding part of these exemplified three winding parts, the winding with the same number Windings is wound in equivalent grooves. According to one winding part, four wires in leading grooves, four wires in neutral grooves, and four wires in lag grooves are provided with "equivalent grooves." As a result, a total of one turns into one winding part balanced ratio.

According to a development of the invention, it is provided that each winding part has the same number of turns at the same radial diameter. This means that within the grooves, the respective winding wires per winding part equally often have the same radial positions, so that there are no differences in the individual winding parts, since the induced voltage of each turn is influenced as a function of the radial position to the central axis of the electric machine. If-as preferably provided-the winding parts of the winding are of equal length, ie all three winding parts have the same number of turns, identical voltage values and phase positions are achieved within the winding parts of the winding, so that no equalization currents, circulating currents, etc. occur. The winding parts can accordingly be connected in parallel without problems since no voltage differences and the like occur.

It is advantageous if the formation of the same number of windings takes place in equivalent grooves per winding layer. In this respect, a corresponding compensation between the winding parts is brought about per winding layer. - A -

Preferably, a plurality of windings can be formed, in particular one winding per phase, which in turn consists of several winding parts.

According to a development of the invention it is provided that the winding and / or the winding parts prepared flat and then transferred into an arcuate shape or wound-up shape and then introduced radially into the grooves of the electric machine, preferably by machine, is / are. Due to the flat preparation of the winding or the winding parts, a mechanical production is possible, that is, the winding, that is, several winding parts to be switched in parallel or a winding part lies flat on a preparation surface, which may also be winding sections, which subsequently in series be switched to achieve the overall length. This winding, these winding parts or these winding sections are then converted into an arcuate shape or into a wound-up form, for example, wound onto a corresponding winding dome. This too happens automatically. Subsequently, the winding dome is inserted into the interior of the electric machine and subsequently the winding wires are inserted radially into the corresponding grooves, in the case of a stator accordingly moved radially outward. Again, this is done by machine, so that a low-cost and reproducible production is possible.

In order to be able to bring in the same number of turns in equivalent grooves in each winding part of the winding, it is necessary to make a change in the groove of a valency in a groove of another valence in the winding parts. This is done by appropriate wire guidance in the winding head. Accordingly, arise in the winding wires of the winding parts intersections or parallel courses in the winding head. The invention further relates to a winding of a multi-pole electric machine, in particular a generator, preferably for a hybrid drive of a motor vehicle, in particular produced by the aforementioned method, wherein the winding of parallel winding parts is formed and wherein each pole at least one Assigned to winding parts associated groove group, each with a plurality of, with respect to the associated pole different circumferential angle positions grooves, grooves with the same circumferential angular position form equivalent grooves and wherein each winding part of the winding has the same number of turns in equivalent grooves.

The drawing illustrates the invention, in which:

FIG. 1 is a winding diagram,

Figure 2 is a bending tool and

Figure 3a, b is a bending sequence diagram.

1 shows a winding diagram of a trained as a generator electric machine with six poles and three phases. In the winding diagram, the winding of a phase is shown, which is formed by three parallel winding parts to be switched. The arrangement is such that the winding section b, the winding section b, the winding section c, the winding section c, the winding section d are connected to the winding section d, the winding section e is connected to the winding section a, each winding section connecting all six poles 1 to 6 recorded. The winding sections a to e lead to five turns per pole, which is followed by another five turns, which are not shown in the winding diagram, but are wound according to the same principle. The winding of a phase 10 shown in the winding diagram is composed of three parallel winding parts 11, 12 and 13, wherein the winding wire of the winding part 11 by a solid line, the winding wire of the winding part 12 with a dashed line and the winding wire of the winding part 13 with dashed line Point line is shown. The winding parts 11, 12 and 13 are assigned in the region of the pole 1 to 6 in each case one pole zone 14 and beyond the corresponding pole 1 to 6 winding head zones 15 and 16. The individual circumferences according to the winding sections a to e are identified by Ui to U ₅ .

Hereinafter, the respective position of the winding wire 17 of the winding part 11, the winding wire 18 of the winding part 12 and the winding wire 19 of the winding part 13 will be discussed for the winding portion a, that is, the first circumference (Ui). The columns formed in the winding diagram respectively indicate the position of a groove, the poles 1 to 6 entered there being valid for phase 10. Since the electric machine is a three-phase machine, the other two phases 20 and 21 are indicated schematically only in the region of the pole 1 of the winding section a, but not registered according to the course of their parallel winding parts in order to keep the drawing clearly arranged , However, the following comments on Phase 10 apply mutatis mutandis to Phases 20 and 21.

With regard to the pole 1, the winding wire 17 of the winding part 11 in the winding section a has a neutral position in the pole zone 14 lying on the left side of the pole 1. This is a pole circumferential angle home position. In contrast, the winding wire 18 assumes a (electrically) leading position and the winding wire 19 has a corresponding (electrically) trailing position in the pole zone 14. The winding wires 17 to 19 extend in the winding head zone 15 without crossing, so that the right side of the pole 1 in the pole zone 14 results in the following situation: the with shown through solid line winding wire 17 continues to take due to its central position a neutral position, so again a pole circumferential angle basic position. In contrast, the winding wire 18 trailing and the winding wire 19 is leading. In the adjoining end winding zone 16 there is an intersection between the winding wires 17 and 19, with the result that on the left side of the pole 2 the winding wire 19 has a neutral position with respect to the phase position, the winding wire 18 has a leading position and the winding wire 17 has a trailing position. In the winding head zone 15 of the pole 2 there is no crossing of the winding wires 17 to 19, so that the right side of the pole 2 in the pole zone 14 of the winding wire 19 retains its neutral position, the winding wire 17 assumes a leading and the winding wire 18 a trailing position. In the end winding 16, which is located between the poles 2 and 3, there is an intersection of the winding wires 18 and 19. In the left side of the pole 3 lying Polzone 14, the winding wire 18 has a neutral position, the winding wire 19 a leading position and the winding wire 17th due to the respective Nutenlage a lagging position. In the winding head zone 15 of the pole 3, the winding wires 17 to 19 do not intersect. On the right side of the pole 3, the winding wire 18 has a neutral position, the winding wire 17 a leading position and the winding wire 19 a trailing position. In the winding head zone 16 lying between the poles 3 and 4, an intersection of the winding wires 17 and 18 takes place. On the left side of the pole 4, the winding wire 17 has a neutral position, the winding wire 19 a leading position and the winding wire 18 a trailing position. In the subsequent winding head zone 15 of the pole 4, there is no crossing of the winding wires 17 to 19. On the right side of the pole 4, the winding wire 17 has a neutral position, the winding wire 18 a leading position and the winding wire 19 a trailing position. In the winding head zone 16 lying between the poles 4 and 5, the winding wires 17 and 19 intersect at the left-hand side of the pole 5 The winding wires in the pole zone 14 have the following positions: the winding wire 19 is in the neutral position, while the winding wire 17 assumes a leading position and the winding wire 18 assumes a trailing position. In the winding head zone 15 associated with the pole 5 there is no crossing of the winding wires 17 to 19. On the right side of the pole 5, the winding wire 19 has a neutral position, the winding wire 18 a leading position and the winding wire 17 a trailing position. In the winding-over zone 16, which lies between the poles 5 and 6, a crossing of the winding wires 18 and 19 takes place. On the left-hand side of the pole 6, the winding wires 17 to 19 have the following positions in the pole zone 14: The winding wire 18 is in the neutral position, that is, in the pole peripheral angle basic position. In contrast, due to the groove position, the winding wire 17 assumes a leading position and the winding wire 19 assumes a trailing position. In the winding head zone 15 assigned to the pole 6, there is no crossing of the winding wires 17 to 19. The right side of the pole 6, the winding wire 18, the neutral position, the winding wire 19, the leading position and the winding wire 17, the trailing position. In the subsequent to the pole 6 winding core 16 a crossing of the winding wires 17 and 18 takes place. This description could be continued now, namely for the winding sections b, c, d and e, but the respective situation and the respective crossing situation can also be taken from the figure. This is explicitly stated.

Considering the overall situation in the winding section a with respect to the winding parts 11, 12 and 13 having the winding wires 17, 18 and 19, it should be noted that in the area of the first circumference Ui at each of the winding parts 11, 12 and 13, that is at each the winding wires 17, 18 and 19 are four times a leading position, four times a neutral position and four times a trailing position. Since this is the case with each of the winding parts 11 to 13 due to the insertion of the winding wires 17 to 19 Also always the same number of turns are on radially equal diameter and the winding parts 11 to 13 with respect to the considered winding section a are the same, there are balanced ratios, that is, in each section of the winding parts 11 to 13 results in the operation of the generator of the same size Voltage with the same phase position, so that in a parallel connection of the winding parts 11 to 13 no leakage currents flow.

If one considers the winding sections b, c, d and e, then corresponding conditions can be established there. As already mentioned, phases 20 and 21 are wound in a similar manner. Furthermore, it has already been mentioned that the fifth five turns, according to the winding sections a to e, are followed by another five turns (not shown), which, however, are likewise designed as described above. Overall, accordingly, each phase 10, 20 and 21 associated windings, each consisting of three parallel winding parts, resulting within the windings no circulating currents or equalizing currents flow. The illustrated and explained winding scheme therefore leads to an optimal electromagnetic training, in particular, as few intersections of the winding wires take place in the winding head zones.

In particular, in an automatic winding production of the stator of a generator, the procedure is such that the winding is prepared flat, its length may be a multiple of the circumference. The arrangement is preferably made such that the respective groove is completely filled in the width by the thickness of the winding wire, that is, the wire width or the wire diameter corresponds to the groove width. The prepared by means of a mounting device flat winding is then wound onto a mandrel and axially retracted with this tool in the stator of the electric machine. Subsequently, by radial expansion, the individual winding wires this radially inserted externally into the grooves. Overall, therefore, the stator winding can be created in mass production by simple means with simple means. The parallel connection of the individual winding parts can already take place in the flat state of the winding or after the winding is inserted into the slots of the electrical machines.

Particularly preferred is a winding with nine winding wires, wherein three winding wires are connected in parallel for three phases. It is a stator with one hundred and eight grooves, twelve poles and sixty turns.

As already described, no voltage differences should occur in the individual winding parts which are closed in parallel. Each winding part must have the same wire length equal to many Win- fertilize in equivalent grooves and lie within a groove radially on the same diameter. In particular, it is provided that in a layer winding in each layer of each winding wire changes the groove, wherein in the example with twelve poles twelve grooves of the same phase present, ie the groove 1, 10, 19, 28, 37, 46, 55, 64, 73rd , 82, 91, 100, so that, for example, three winding wires to be closed in parallel within each winding layer are equally frequent in each equivalent groove.

There are a large number of variations of the principle according to the invention, with different patterns resulting from different numbers of intersections in the winding head zones, which is of particular importance for manufacturability.

Of particular importance is that each winding path is the same number of times in each groove, wherein the valency of the groove, so their respective peripheral angular position is observed in accordance with the foregoing. Further, the arrangement is made such that not too frequent intersections in the winding head areas occur to keep the winding head dimensions small. Of special Significance is that, according to Figure 1, only six winding wire intersections occur within each winding part of a phase of a winding layer. This leads from the manufacturing point of view to a high degree of symmetry. Variants with more or fewer intersections are possible. Preferably, the winding wires are produced individually and can be placed one after the other on a winding support. For the (few) intersections, the wires can be specially shaped.

The winding process is preferably as follows: A single winding wire consists of coils / waves of different widths in a fixed order. The different widths are due to the corresponding groove changes (see Figure 1). For the production, it is advantageous to make at least two opposing bends on the wire at the same time, in order to not have to rotate either the wire feeders or the winding tray. This is a suitability for flat wire with a large cross section.

FIG. 2 shows a bending tool 33 in order to be able to bend the winding wire, with circles having bending dome and rectangles having counterholds. The bending tool 33 has a fixed part 30 and a carriage 31 which can be moved away in the x and y directions. The movable part 31 does not rotate. On the fixed part 30 is a bending axis A and an associated counter-holder GH. Furthermore, a bending dome B can approach the various positions shown there or be implemented accordingly. This also applies to the bending dome F. The bending dome E is in turn associated with an anvil GH. Furthermore, by means of projections 32, a guiding and positioning device is provided in order to be able to deposit already curved waves of corresponding width. The device according to FIG. 2 is the flat device which is used to create the flat winding, which is wound up later and then radially displaces the groove. th the electric machine is supplied. According to FIG. 2, the movable part 31 of the bending tool 33 has bending dome C, D, G and H, wherein the bending dome C and G can approach or enter the different positions entered there. The bending terms D and H are assigned counterholds GH. Furthermore, a wire feed DR is provided. The winding wire is indicated in Figure 2 with dotted line.

In order to be able to bend a wave of a winding wire, reference is made to the various steps Si to Sβ of FIG. 3a, b. 3a and 3b correspond to the bending mandrels and counter-holders of FIG. 2 marked with the same letters. It can be seen in step 1 of FIG. 3a, b that a winding wire WD shown by a solid line is shown in FIG 34 is fed and held (clamped) between bending dome A and an associated counter-holder GH. Furthermore, there is a holding between the bending dome D and the associated counter-holder GH. Subsequently, in accordance with step S ₂ , the bending dome D with anvil GH is moved along a spiraling movement with arrow 35 about the bending dome A and corresponding movement of the bending mandrel C with corresponding counter-holders GH and a cranked shape of the winding wire WD is created, that is, he is bent in the region of the bending dome A and in the area of the bending dome D. In accordance with step S ₃ , a bent bend is then again made around the bending mandrels B and C, the bending dome C (and also the bending dome D) being displaced along a helical path according to arrow 36 for this purpose. The displacements according to the arrows 35 and 36, which are also indicated by dashed lines, carried out by corresponding displacement of the part 31 relative to the part 30 of the bending tool 33. The bends around the bending mandrels A and D and about the bending mandrels B and C take place simultaneously and in opposite directions. In step 4, the bending moments H and G are now displaced with corresponding counterholds GH along an ner spiral-shaped path, which is indicated by the arrow 37. Subsequently, in step 5, a displacement of the bending mandrels G and H is performed with corresponding counter-holders GH to form the entire shaft, wherein the last movement also takes place on a spiral path and is indicated by the arrow 38. The turns around the bending dome E and H as well as F and G take place simultaneously and in opposite directions. Now, a first wave of the winding wire WD is generated. In step 6, a re-tensioning and a repetition of the steps, starting at step Si, to form the subsequent wave. By appropriate displacement possibilities of the bending mandrels B, C, G and F, the corresponding mesh sizes can be adjusted in order to achieve the corresponding neutral position, leading or trailing position of the wires in the region of the poles.

As already mentioned, the waves of the winding wire WD can be produced in five working steps (Si to S ₅ ). The winding wire can be embossed in further steps, so that the winding heads of the phases with each other and the first layer insert into the second layer. The points of intersection within a phase can be specially shaped so that they do not over-apply dimensionally. Preferably, round or flat wire is used for the winding wire. It is also possible to proceed in such a way that several winding wires are bent simultaneously in parallel.

Claims

claims

1. A method for producing at least one winding of a multi-pole electrical machine, in particular a motor-generator, preferably for a hybrid drive of a motor vehicle, wherein the winding of parallel winding parts is formed and wherein each pole at least one winding elements associated with the groove group each groove is assigned to a plurality of grooves having different circumferential angular positions with respect to the associated pole, wherein grooves having the same circumferential circumferential position form equivalent grooves and wherein each winding part of the winding is wound with equal numbers of turns in equivalent grooves.

2. The method according to claim 1, characterized in that each winding part has the same number of turns on radially equal diameter.

3. The method according to any one of the preceding claims, characterized in that the winding parts of the winding are formed of equal length.

4. The method according to any one of the preceding claims, characterized in that the formation of the same number of turns takes place in equivalent grooves per winding layer.

5. The method according to any one of the preceding claims, characterized in that a plurality of windings are formed.

6. The method according to any one of the preceding claims, characterized in that each winding forms a phase.

7. The method according to any one of the preceding claims, characterized in that the winding and / or the winding parts prepared flat and then transferred into an arcuate or wound shape and then introduced radially into the grooves of the electric machine, preferably machined, is / are.

8. The method according to any one of the preceding claims, characterized in that the winding is formed as a stator winding.

9. The method according to any one of the preceding claims, characterized in that in the winding parts, a change of the groove of a valence in a groove of another valence in the respective associated winding head is made.

10. winding of a multi-pole electrical machine, in particular a generator, preferably for a hybrid drive of a motor vehicle, in particular produced by a method according to one or more of the preceding claims, wherein the winding of parallel winding parts is formed and wherein each pole at least a groove group assigned to the winding parts is associated in each case with a plurality of grooves having different circumferential angle positions with respect to the associated pole, wherein grooves with the same circumferential circumferential position form equivalent grooves and wherein each winding part of the winding has the same number of turns in equivalent grooves.