EP2106632A2 - Générateur de courant alternatif comprenant un stator et un enroulement statorique, inclus dans des encoches statoriques, constitué d'éléments d'enroulement ainsi qu'un procédé pour la fabrication d'un stator selon la présente invention - Google Patents

Générateur de courant alternatif comprenant un stator et un enroulement statorique, inclus dans des encoches statoriques, constitué d'éléments d'enroulement ainsi qu'un procédé pour la fabrication d'un stator selon la présente invention

Info

Publication number
EP2106632A2
EP2106632A2 EP08701205A EP08701205A EP2106632A2 EP 2106632 A2 EP2106632 A2 EP 2106632A2 EP 08701205 A EP08701205 A EP 08701205A EP 08701205 A EP08701205 A EP 08701205A EP 2106632 A2 EP2106632 A2 EP 2106632A2
Authority
EP
European Patent Office
Prior art keywords
winding
stator
groove
grooves
section
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP08701205A
Other languages
German (de)
English (en)
Inventor
Gert Wolf
Thomas Berger
Eberhard Rau
Alexander Shendi
Helmut Kreuzer
Christoph Schwarzkopf
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SEG Automotive Germany GmbH
Original Assignee
Robert Bosch GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Robert Bosch GmbH filed Critical Robert Bosch GmbH
Publication of EP2106632A2 publication Critical patent/EP2106632A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H02K15/0435—Wound windings
    • H02K15/0442—Loop windings
    • H02K15/045—Form wound coils
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/02—Arrangements for cooling or ventilating by ambient air flowing through the machine
    • H02K9/04—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
    • H02K9/06—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49009—Dynamoelectric machine

Definitions

  • the invention relates to various forms of winding elements for producing a winding for an electric machine, in particular for a multi-strand vehicle generator with claw-pole rotor and fans lying in the housing.
  • Stator windings with disordered wire development in the winding heads are known from the prior art, which arise, for example, in that a plurality of individual, in particular single-layer, strand windings are individually added one after the other into a laminated core, eg. B. by Einziehtechnik in an annular laminated core or by inserting into a cuboid laminated core.
  • the wires are arranged touching each other and not spaced from each other, so that the cooling air does not flow through the winding heads, but can flow around only in their entirety and thus only the boundary layer of the winding head enveloping body is streaked.
  • These disordered windings cause large winding head dimensions on both sides.
  • stator windings with structured winding heads which are designed significantly compact.
  • Steckwickeltechnik substantially U-shaped conductor sections are inserted axially from a first package end face in grooves of a laminated core, in which case the free ends of the U-shaped conductor portion on the packet front side opposite the first packet end side initially substantially tangentially pivoted or bent in a desired shape or position and then each connected to one end of another conductor section, for example by welding.
  • a disadvantage here is a large number of connection points, which, especially in small designs of electrical machines high spatial demands on the connection technology in terms of pivoting and / or welding, extends the production time and increases costs.
  • an alternator in particular three-phase alternator is provided for a motor vehicle, with a north and south poles having runners, in particular with extending in the axial direction Klauenpolfingern located on the circumference of the rotor as the north and south poles alternately, a stator having a magnetic core, in particular laminated core, with grooves and a stator winding arranged in the slots of the magnetic core, wherein the stator winding has winding heads which are each cooled by an approximately radial air flow of at least one of the rotor mounted fan, wherein the stator facing the rotor and wherein the stator and the rotor are defined to each other positioned, wherein the multi-phase stator winding of
  • Winding elements consists, wherein at least one winding element has more than two sections inserted into grooves and wherein at least one winding element has more than one reversing section, which causes a change of the radial position.
  • FIG. 2 shows a perspective view of a basic form of a winding element
  • FIG. 3 shows a schematic illustration of the basic form of the winding element
  • FIG. 4 shows a schematic representation of a connection form of the winding element
  • FIG. 5 shows a schematic representation of a reversal shape of the winding element
  • FIG. 6 shows a schematic illustration of the course of a strand winding in the slots of a stator core
  • Figure 7 is a circuit diagram of an alternator with two independent three-phase systems, which are connected to two downstream rectifiers and
  • FIG. 8 to 13 show a second embodiment of a winding, its winding elements and a schematically illustrated stator with winding.
  • FIG. 8 is a schematic representation of a first basic form of the winding element for odd number of conductors, FIG.
  • Winding element for odd number of conductors
  • Figure 10 is a schematic representation of a first connection form of
  • Winding element for odd number of conductors
  • FIG. 11 shows a schematic representation of a reversal shape of the winding element
  • Figure 12 is a schematic representation of a second connection form of
  • Winding element for odd number of conductors
  • FIG. 13 shows a schematic representation of the course of a strand winding in the slots of a stator package for odd number of conductors
  • Figure 14 is a perspective view of a planar precursor of a
  • Figure 15 is a cylindrical device for producing the spatial
  • FIG. 16 shows a cuboid device for producing the spatial structure of winding elements
  • 17 shows a detail of a perspective view of a stator according to the invention
  • FIG. 18 is a detail of a perspective view of a stator according to the invention
  • Fig. 1 is a section through an alternator 10 for motor vehicles is shown. This has inter alia a two-part housing 13, which consists of a first bearing plate 13.1 and a second bearing plate 13.2.
  • End plate 13.1 and the bearing plate 13.2 take in itself a stand 16, with an annular laminated core 17 as a magnetic core, in which radially inwardly open and axially extending rectangular grooves 15, a stator winding 18 is inserted.
  • the annular stator 16 surrounds with its radially inwardly directed surface an electromagnetically excited rotor 20, which is designed as a claw-pole rotor.
  • the rotor 20 consists, inter alia, of two claw-pole plates 22 and 23, on the outer circumference of which claw-pole fingers 24 and 25 extending in each case in the axial direction are arranged.
  • Both claw pole boards 22 and 23 are arranged in the rotor 20 such that their axially extending claw pole fingers 24, 25 alternate on the circumference of the rotor 20 as north and south poles.
  • This results in magnetically required Klauenpol thoroughlyshadow between the oppositely magnetized Klauenpolfingern 24 and 25, which extend slightly oblique to the machine axis because of tapering towards their free ends claw-pole fingers 24 and 25.
  • this course is simplified referred to as axial.
  • the rotor 20 is rotatably supported in the respective end shields 13.1 and 13.2, respectively, by means of a shaft 27 and one respective rolling bearing 28 located on each side. It has two axial end faces, on each of which a fan 30 is attached.
  • These fans 30 essentially consist of a plate-shaped or disk-shaped section, starting from the fan blades in a known manner. These fans 30 serve to allow an air exchange between the outside and the interior of the electric machine 10 via openings 40 in the end shields 13.1 and 13.2.
  • the openings 40 are provided at the axial ends of the end shields 13.1 and 13.2, via the means of the fan 30 cooling air is sucked into the interior of the electric machine 10. This cooling air is accelerated radially outward by the rotation of the fans 30, so that they can pass through the cool air-permeable winding heads 45 on the drive side and 46 on the electronics side. This effect cools the windings.
  • the cooling air takes after flowing through, or after the flow around the winding heads a path radially outward through openings, not shown, in the end shields 13.1 and 13.2.
  • the winding heads are lying outside the magnetic core winding parts.
  • a protective cap 47 which protects various components against environmental influences.
  • this protective cap 47 covers, for example, a slip ring assembly 49, which supplies a field winding 51 with exciting current.
  • the excitation current is adjusted by a voltage regulator so that a constant vehicle electrical system voltage is present.
  • Around this slip ring assembly 49 around a heat sink 53 is arranged, which acts here as a heat sink for the positive diodes of the rectifier.
  • As a heat sink for the negative diodes of the rectifier here acts the bearing plate 13.2.
  • connection plate 56 is arranged, which fixed in the bearing plate 13.2 minus diodes 58 and not shown in this illustration plus diodes of a rectifier 19 in the heat sink 53 in the form of a
  • FIG. 2 shows a possible basic form of a winding element 60 for an implementation of a winding with four conductors in each groove, the narrow sides of the conductor cross-sections are opposite to each other and the broad sides of the conductor cross sections opposite the groove walls, not shown here.
  • the conductors are arranged in the groove in four radial groove positions, wherein the radially outermost groove position is referred to as groove position one and the radially innermost groove position as groove position four.
  • Each winding element 60 consists of at least one essentially axially aligned first connecting section 60a, which serves for contacting two radially adjacent connecting sections 60a, 60z, 62a, 62z.
  • the broad side of the conductor cross-section is aligned parallel or substantially parallel to the circumferential direction in the region of the connecting sections, since this enlarges the contacting surface.
  • the contacting takes place cohesively, for example by Welding, soldering or other methods of electrical contacting done.
  • the first connection section 60a transitions into a first section 60b inclined to the axial and circumferential direction, which connects the first connection section 60a to a first axially aligned section 60c of the winding element 60 that is inserted in a groove 15.
  • the first section 60c which is inserted in a first slot, transitions into a second section 6Od inclined to the axial and circumferential direction, which further merges into a first reversing section 6Oe. From the first reversing section 6Oe, a third section 6Of inclined to the axial and circumferential direction is departed and connects the first reversing section 6Oe to a second section 60g inserted in a second groove 15.
  • This second groove 60-fitting portion 60g is connected to a fourth axis-and-circumferentially inclined portion 60h which merges into a second turnaround portion 6Oi which further has a fifth axis-and-circumferentially-inclined portion 6Oj with a third groove in the first groove inlying portion 60k of the winding element 60 is connected.
  • the third in-slot portion 60k is connected to a third reversing portion 60m via a sixth axial and circumferential inclined portion 601.
  • the third reversing section 60m is about a seventh to the axle and
  • Circumferentially inclined portion 6On connected to a fourth, in the second groove in-section 6Oo.
  • the fourth slot-in section 6Oo is further connected to the second connecting section 60z of the winding element via an eighth section 60p inclined to the axial and circumferential direction.
  • the basic form of the winding element shown here is constructed with three reversing sections 6Oe, 6Oi, 60m. Furthermore, it is also conceivable that the basic shape of the winding element 60 is carried out with two or more than three reversal sections, in which the number of loops of a winding element is reduced or increased.
  • winding element takes in this example, four different radial positions, wherein the position of the conductors in the end windings by a radial position and the position of the conductors in the grooves 15 by a radial groove position is marked and the radial positions of groove and radial position correspond to each other ,
  • the in-grooves in the sections form a radial row and are therefore easier to handle, since the sections are ordered.
  • the number of radial layers and that of the radial groove layers usually corresponds to the number of conductors in a groove, with a row arrangement of the conductors radially one above the other.
  • the first inclined portion 60b, the first groove-inserted portion 60c, and the second inclined portion 60d are disposed in the radially first position.
  • the winding element 60 occupies the first groove position in a first groove 15 and the third groove position in the second groove belonging to the winding element 60, which groove is spaced from the first one in the circumferential direction by substantially one pole pitch.
  • the change in the groove position is effected by the first reversing section 6Oe.
  • the third inclined portion 6Of, the second groove-inserted portion 60g, and the fourth inclined portion 60h are arranged.
  • the second circumference portion 6Oi causes a groove position change from the third groove position of the second groove 15 to the second groove position of the first groove 15.
  • the fifth inclined portion 6Oj, the third groove-fitting portion 60k, and the sixth inclined one Section 601 arranged.
  • the third reversing section 60m causes a groove position change from the second groove position of the first groove to the fourth groove position of the second groove.
  • the seventh inclined portion 6On, the fourth groove-in portion 6Oo, and the eighth inclined portion 60p are disposed.
  • the first connecting portion 60a extends over the second and first radial positions.
  • the second connection portion 60z extends over the fourth and third radial layers.
  • the change of the radial positions in odd reversal sections is greater than in straight reversal sections.
  • the winding element has a zungsfit wire guide in the winding head, the wires are widely spaced in the winding head, the cooling is improved.
  • FIG. 3 shows a schematic representation of the winding element described under FIG.
  • FIG. 4 shows a schematic representation of the required for a complete stator winding terminal shape of a winding element 61.
  • This terminal shape is used to provide an electrical connection for interconnecting the string winding, or for contacting the rectifier available. This connection is preferably on the electronics winding side 46.
  • To form a complete strand winding at least two terminal forms of the winding element 61 are required, respectively for the strand winding start and the strand winding end.
  • connection form of the winding element corresponds for the most part to a shortened structure of the basic form.
  • the illustrated terminal form 61 of the winding element is intended for realization with four conductors in each groove, the narrow sides of the conductor cross-sections lying opposite each other and the broad sides of the conductor cross-sections facing the groove wall.
  • Each connection form of the winding element 61 consists of at least one substantially axially aligned first connecting portion 61a, which serves for contacting two radially adjacent connecting portions 61a, 60z.
  • the first connection section 61a merges into a first section 61b inclined to the axial and circumferential direction, which connects the first connection section 61a to a first axially aligned section 61c of the winding element 61 that is inserted in a groove 15.
  • Section 61c merges into a second axis-and-circumferentially inclined portion 61d, which further merges into a first turnaround portion 61e. From the first reversing portion 61e, a third portion 61f inclined to the axial and circumferential direction descends and connects the first reversing portion 61e to a second portion 61g inserted in a groove 15.
  • This second in the The groove 15-inserted portion 61g is connected to a fourth axis-and-circumference-inclined portion 61h which merges into a second turnaround portion 61i which further has a fifth axis-and-circumferentially inclined portion 61j with a third in the first one Nut eino portion 61k of the winding element 61 is connected.
  • the third in-slot portion 61k is connected to the terminal portion 61y via a sixth axial and circumferential inclined portion 611.
  • connection form of the winding element 61 shown here is constructed with two surrounding sections 61e, 61i. It is also conceivable here in principle that the connection form of the winding element 61 with one, two or more reversing sections 61e, 61i is performed.
  • the terminal shape of the winding element 61 is subdivided into three radial layers in this example.
  • the number of radial layers of the terminal shape of the winding member 61 is usually one less than the number of conductors in a groove 15.
  • the terminal form of the winding member 61 are in the radially first position of the first inclined portion 61 b, the first in-slot portion 61c and the second inclined portion 61d are arranged.
  • the terminal form of the winding element 61 occupies the first groove layer in a first groove 15 and the third groove layer in the second groove 15 associated with the winding element 61, which is spaced from the first one in the circumferential direction by substantially one pole pitch.
  • the change in the groove position is effected by the first turnaround portion 61e.
  • the third inclined portion 61f, the second groove-inserted portion 61g, and the fourth inclined slope portion 61h are arranged.
  • the second reversing portion 61i causes a groove position change from the third groove position of the second groove 15 to the second groove position of the first groove 15.
  • the fifth inclined portion 61j, the third groove-inserted portion 60k is the sixth inclined portion 611 and the terminal portion 61y arranged.
  • the first connection portion 61a extends over the second and first radial layers.
  • the connecting portion 61y extends substantially over the third radial position, but can for better Interconnection of the strand windings, change from the third groove position to another groove position.
  • FIG. 5 shows a schematic representation of the reversal shape of a winding element 62 required for a complete stator winding.
  • the reversal shape of a winding element 62 serves to connect basic shapes of the winding elements 60 in series with electric shapes 180 °. In this case, the strand winding course coming from a first circumferential direction is reversed and continued counter to the first circumferential direction. To form a complete strand winding at least one reversal of the
  • Winding element 62 required.
  • This reversal shape of a winding element 62 has at least one reversing section 62e which connects two groove-inserted sections 62c, 62g in the same groove position.
  • the illustrated reversal shape of the winding element 62 is provided for a realization with four conductors in each groove, the narrow sides of the conductor cross-sections facing each other and the broad sides of the conductor cross-sections of the groove wall opposite.
  • Each reversal shape of the winding element 62 consists of at least one substantially axially aligned first connecting portion 62a, which serves for contacting two radially adjacent connecting portions 62a, 60a.
  • the first connecting portion 62a merges into a first axis-and-circumferentially-inclined portion 62b connecting the first connecting portion 62a to a first axially-aligned portion 62c of the winding member 62 that is in a groove 15.
  • the first section 62c which is inserted in a first groove, transitions into a second section, which is inclined in the axial direction and in the circumferential direction, and which passes further into a first reversing section 62e. From the first reversing portion 62e, a third axis-and-circumferentially inclined portion 62f goes off and connects the first reversing portion 62e to a second portion 62g engaged in a groove 15.
  • This second groove portion 15 intervening portion 62g is connected to a fourth axis-and-circumferentially inclined portion 62h which is connected to the second connecting portion 62z.
  • the reversal shape of the winding element 62 shown here is constructed with a reversing section 62e. It is also conceivable here in principle that the reversal shape of the winding element 61 can be executed not only with one, but with another odd number of reversing sections, wherein all connecting sections are arranged on a winding side. It is in principle also possible to carry out the reversal shape of the winding element with an even number of reversing sections, in which case connecting sections are arranged on both end winding sides.
  • the reversal shape of the winding element 62 is arranged in a radial position in this example.
  • the number of radial layers of the reversal shape of the winding member 62 is usually one.
  • the reversal form occupies the radially innermost layer, since such a simple assembly can be ensured.
  • the first inclined portion 62b, the first groove-in portion 62c, the second inclined portion 62d, the first turnaround portion 62e, the third inclined portion 62f, the second are in a groove inset portion 62g and fourth inclined portion 62h.
  • the first connecting portion 62a extends over the third and fourth radial positions.
  • the second connecting portion 62z extends substantially across the fourth and third radial layers.
  • FIG. 6 shows a schematic representation of the course of a strand winding in the stator core. Shown here is a package with ninety-six slots, in which six string windings are arranged. The runner has sixteen poles in this case. Because of the schematic nature of the representation in FIG. 6, the other five strand windings are not shown for the sake of clarity. It is possible to adapt the invention presented here to any strand winding number and number of poles, for example a stator pack with sixty slots and five line windings and a rotor with twelve poles. Continuous connections are arranged on the electronics side winding head. Dashed connections are arranged on the drive-side winding head.
  • the strand winding 70 is composed of a terminal shape of the winding element 61, seven basic shapes of the winding element 60, a reversal shape of the winding element 62, seven other basic shapes of the winding element and a further connection form of the winding element, all of which are connected in series according to the order listed.
  • the stator core is passed through by this strand winding 70 once and once counter to a first circumferential direction, all groove positions of all of these strand winding associated grooves are occupied.
  • the strand windings 71, 72, 73, 74, 75, not shown in FIG. 6, are constructed identically to the illustrated strand winding 70 and are offset relative to the illustrated strand winding 70 by a predetermined number of slots in the circumferential direction.
  • This groove offset results in this example, a phase angle of electrically 30 °, or a multiple of electrically 30 ° between the strand windings 70, 71, 72, 73, 74, 75th
  • an alternator in particular an alternator, is provided for a motor vehicle, with a rotor 20 having north and south poles, in particular with claw-pole members 24, 25 extending in the axial direction, which are arranged on the circumference of the rotor 20 as a north pole. and south pole, a stator 16, the magnetic core, in particular
  • the multi-phase stator winding 18 consists of winding elements 60, 61, 62, 63, 64, 65, 66, 67, wherein at least a winding element has more than two in-slot portions and wherein at least one winding element 60, 61, 62, 63, 64, 65, 66, 67 has more than one reversing section causing the radial position to change.
  • FIG. 7 shows an AC generator 10 with six strand windings 70, 71, 72, 73, 74, 75 on the basis of a circuit diagram.
  • the six string windings 70, 71, 72, 73, 74, 75 are connected to two independent three-phase systems, wherein each of the independent three-phase systems has a star connection whose phase windings 70, 71, 72 - 73, 74, 75 at the neutral point a phase difference of 120 electrically ° have.
  • the star circuits are represented by the strand windings Ul, Vl, Wl (70, 71, 72), or U2, V2, W2 (73, 74,
  • the two independent three-phase systems have a phase difference of 30 ° electrically.
  • Each of the two three-phase systems is connected to a separate B6 bridge rectifier 19.1, 19.2, which are connected in parallel on the DC voltage side.
  • the rectifier 19 is thus composed of two parallel-connected bridge rectifiers 19.1, 19.2.
  • a voltage regulator 21 is connected in parallel to the rectifier 19.
  • the voltage regulator controls by influencing the current flowing through the field winding 51, the voltage of the generator and thus the electrical system.
  • the electrical system is shown schematically by the vehicle battery 31 and by vehicle consumers 32.
  • the three-phase systems are independent in such a way that the windings are connected to each other only after the two B6 bridge rectifiers 19.1 and 19.2.
  • FIGS. 8 to 13 show a further embodiment for realizing odd numbers of conductors in the slots.
  • FIG. 8 shows a schematic illustration of a first basic form of a winding element 63 for a realization of a winding with three conductors in each groove, wherein the narrow sides of the conductor cross sections lie opposite one another and the broad sides of the conductor cross sections are opposite to the groove walls not shown here.
  • the conductors are arranged in the groove in three radial groove positions, wherein the radially outermost groove position is referred to as groove position one and the radially innermost groove position as groove position three.
  • the first basic form of a winding element for odd number of conductors 63 consists of at least one substantially axially aligned first connecting portion 63 a, the for contacting two radially adjacent connecting portions 63a, 63z, 66z is used.
  • the broad side of the conductor cross-section is aligned parallel to the circumferential direction in the region of the connecting sections, since this increases the contacting area.
  • the contacting takes place cohesively, for example by welding, soldering or other methods for electrical contacting.
  • the first connecting portion 63 a is transitioned to a first axis and circumferential inclined portion 63 b, the first connecting portion 63 a with a first axially aligned and in a groove 15 eino portion
  • the first section 63c inserted in a first groove merges into a second section 63d inclined to the axial and circumferential direction, which further merges into a first reversing section 63e. From the first reversing portion 63e, a third portion 63f inclined to the axial and circumferential direction goes off and connects the first reversing portion
  • This second groove 63 inserted in the portion 63g is connected to a fourth to the axial and circumferential direction inclined portion 63h, which merges into a second reversing portion 63i, which further via a fifth axis to the circumferential and circumferential direction inclined portion 63j with a third, in the first groove eino portion 63k of the winding element 63 is connected.
  • the third groove-inserted portion 63k is connected to a third turn-around portion 63m via a sixth axis-and-circumferentially-inclined portion 631.
  • the third reversing portion 63m is connected to a fourth groove 63o in the second groove via a seventh axis-and-circumferential direction inclined portion 63n.
  • the fourth groove-inserted portion 63o is further connected to the second connecting portion 63z of the winding member via an eighth circumferential-direction-inclined portion 63p.
  • the first basic form of the winding element for odd number of conductors 63 shown here is constructed with three reversing sections 63e, 63i, 63m. Furthermore, it is also conceivable that the basic shape of the winding element 63 is executed with two or more than three reversal sections in order to adapt the winding elements to different odd number of conductors in the groove. This will achieved in that the number of loops of a winding element is lowered or increased. However, in the case of two or for example four reversal sections, mutually adjacent winding elements are then to be contacted with one another on both sides of the laminated core 17, which is associated with a higher level of mechanical and labor expenditure.
  • the winding element in this example occupies three different radial positions, wherein the position of the conductors in the winding heads is characterized by a radial position and the position of the conductors in the grooves 15 by a radial groove position and the radial positions of groove and radial position correspond to each other ,
  • the number of radial layers and the radial groove layers usually corresponds to the number of conductors in a groove, with a row arrangement of the conductors radially one above the other.
  • the first inclined portion 63b, the first groove-inserted portion 63c, and the second inclined portion 63d are disposed in the radially first position.
  • the winding element 63 occupies the first groove position in a first groove 15 and the second groove position in the second groove associated with the winding element 63, which groove is spaced from the first one in the circumferential direction by substantially one pole pitch.
  • the change in the groove position is effected by the first reversing portion 63e.
  • the second reversing section 63i does not cause a groove position change in this case.
  • the third reversing portion 63m causes a groove position change from the second groove position of the first groove to the third groove position of the second groove.
  • the seventh inclined portion 63n, the fourth groove-in portion 63o, and the eighth inclined portion 63p are disposed.
  • FIG. 9 shows a schematic representation of a second basic form of a winding element 64 for a realization form of a winding with three conductors in each groove.
  • the second basic form of a winding element 64 for odd number of conductors consists of at least one substantially axially aligned first connecting portion 64a, which serves for contacting two radially adjacent connecting portions 64a, 64z, 66a.
  • the broad side of the conductor cross-section is aligned parallel to the circumferential direction in the region of the connecting sections, since this increases the contact-making area.
  • the contacting takes place cohesively, for example by welding, soldering or other methods for electrical contacting.
  • the first connection portion 64a transitions into a first axis-and-circumferentially-inclined portion 64b that defines the first connection portion 64a with a first axially-aligned portion that is inserted in a groove 15
  • the 64c of the winding element 64 connects.
  • the first section 64c inserted in a first groove merges into a second section 64d inclined to the axial and circumferential direction, which further merges into a first reversing section 64e.
  • a third portion 64f inclined to the axial and circumferential direction goes off and connects the first reversing portion
  • This second groove 64-inserted portion 64g is connected to a fourth axis-and-circumferential direction inclined portion 64h, which is further connected to the second connecting portion 63z of the winding member.
  • the illustrated here second basic form of the winding element for odd numbers of conductors 64 is constructed with a reversing portion 64e. Furthermore, it is also conceivable that the basic shape of the winding element 64 is executed with two or more than two reversal sections in order to adapt the winding elements to different odd number of conductors in the groove.
  • the winding element in this example occupies three different radial positions, wherein the position of the conductors in the winding heads is defined by a radial position and the position of the conductors in the packet slots by a radial slot position. is marked and the radial positions of groove and radial position correspond to each other.
  • the first inclined section 64b, the first slot-inserted section 64c and the second inclined section 64d are arranged in the radially first position.
  • the winding element 64 occupies the first groove position in a first groove 15 and, in the second groove associated with the winding element 64, which is spaced from the first one in the circumferential direction by substantially one pole pitch, the third groove position.
  • the change in the groove position is effected by the first reversing section 64e.
  • substantially the third inclined portion 64f, the second in-slot portion 64g, and the fourth inclined portion 64h are substantially the third inclined portion 64f, the second in-slot portion 64g, and the fourth inclined portion 64h.
  • the first connection portion 64a initially overlaps portions of the second and first radial layers, and then fully extends in the first radial position.
  • the second connection portion 64z initially extends completely over the third radial layer and then covers portions of the second and third radial layers.
  • FIG. 10 shows a schematic representation of the first connection form of a winding element for odd number of conductors 65 required for a complete stator winding.
  • This connection form serves to provide an electrical connection for interconnecting the phase winding or for contacting the rectifier.
  • This connection is preferably arranged on the electronics side winding head 46.
  • To form a complete strand winding at least two terminal forms of the winding element 65, 67 are required, in each case for the strand winding beginning and the strand winding end.
  • the first connection form of the winding element 65 corresponds for the most part to a shortened structure of the first basic shape of the winding element 63.
  • connection form of the winding element 65 is provided for realizing a winding with three conductors in each groove, the narrow sides of the conductor cross-sections facing each other and the broad sides of the conductor cross-sections of the groove wall opposite.
  • Each first connection form of the Winding element 65 consists of at least one substantially axially aligned first connecting portion 65a, which serves for contacting two radially adjacent connecting portions 63z, 65a.
  • the first connection section 65a transitions into a first section 65b inclined to the axial and circumferential direction, which connects the first connection section 65a to a first axially aligned section 65c of the winding element 65 which is inserted in a groove 15.
  • the first section 65c inserted in a first slot merges into a second section 65d inclined to the axial and circumferential direction, which passes further into a first reversing section 65e.
  • a third portion 65f inclined to the axial and circumferential direction goes off and connects the first reversing portion 65e to a second portion 65g inserted in a groove 15.
  • This second groove portion 15 inserted portion 65g is connected to a fourth to the axis and circumferential direction inclined portion 65h, which merges into a second turnaround portion 65i, which further via a fifth to the axial and circumferential direction inclined portion 65j with a third in the first groove eino portion 65k of the winding element 65 is connected.
  • the third groove-inserted portion 65k is connected to the terminal portion 65y via a sixth portion 651 inclined to the axial and circumferential directions.
  • connection form of the winding element 65 shown here is constructed with two reversing sections 65e, 65i.
  • terminal form of the winding element 65 is designed with one or more than two surrounding sections 65e, 65i in order to adapt the winding to a higher, odd number of conductors in the groove.
  • the terminal shape of the winding element 65 is divided into two radial layers in this example.
  • the number of radial layers of the terminal form of the winding member 65 is usually one less than the number of conductors in a groove 15. From the terminal form of the winding member 65 in the radially first position of the first inclined portion 65 b, the first in-slot portion 65c and the second inclined portion 65d are arranged. The connection form of the wick The guiding element 65 occupies the first groove position in a first groove 15 and the second groove position in the second groove 15 associated with the winding element 65, which is spaced from the first circumferential direction by substantially one pole pitch. The change in the groove position is effected by the first reversing portion 65e.
  • substantially the third inclined portion 65f, the second groove-inserted portion 65g, the fourth slope portion 65h, the second turn-back portion 65i, the fifth slope portion 65j, the third groove-inserted portion 65k are the sixth inclined portion 651 and the terminal portion 65y arranged.
  • the second reversing section 65i causes in this case no change of the radial layers.
  • connection portion 65a initially overlaps portions of the second and first radial layers and then extends completely in the first radial position.
  • the connection section 65y extends essentially over the second radial position, but can change from the second radial position into another radial position for better interconnection of the strand windings.
  • FIG. 11 shows a schematic representation of the reversal shape of a winding element 66 required for a complete stator winding.
  • the reversal shape of a winding element 66 serves to connect first basic shapes of the winding elements 63 in series with second basic shapes 64 offset by 180 °. In this case, the strand winding course coming from a first circumferential direction is reversed and continued counter to the first circumferential direction.
  • at least one reversal shape of the winding element 66 is required.
  • This reversal shape of a winding element 66 has at least one reversing section 66e, which connects two groove-inserted sections 66c, 66g in the same groove position.
  • the illustrated reversal shape of the winding element 66 is intended for a realization with three conductors in each groove, the narrow sides of the conductor cross-sections facing each other and the broad sides of the conductor cross-sections of the groove wall opposite.
  • Each reversal shape of the winding element 66 consists of at least one substantially axially aligned first connecting portion 66a, which serves for contacting two radially adjacent connecting portions 66a, 64a.
  • the first connection section 66a merges into a first section 66b inclined to the axial and circumferential direction, which connects the first connection section 66a to a first axially aligned section 66c of the winding element 66 which is inserted in a groove 15.
  • Section 66c merges into a second axis and circumferential inclined portion 66d which further merges into a first turnaround portion 66e.
  • a third section 66f inclined to the axial and circumferential direction branches off and connects the first reversing section 66e to a second section 66g inserted in a groove 15. This second in the
  • Groove 15-inserted portion 66g is connected to a fourth to the axial and circumferential direction inclined portion 66h, which is connected to the second connecting portion 66z.
  • the reversal shape of the winding element 66 shown here is constructed with a reversing section 66e. It is also conceivable here in principle that the reversal of the winding element 66 can be performed not only with one, but with three or any other odd number of turnarounds, all connecting portions are arranged on a winding head page. It is in principle also possible to carry out the reversal shape of the winding element with an even number of reversing sections, in which case connecting sections are arranged on both end winding sides.
  • the reversal shape of the winding element 66 is arranged in a radial position in this example.
  • the number of radial layers of the reversal shape of the winding element 66 is usually one.
  • the reversal form occupies the radially innermost layer, since such a simple assembly can be ensured.
  • the first inclined portion 66b, the first in-slot portion 66c, the second inclined portion 66d, the first turn-up portion 66e, the third inclined portion 66f, the second in FIG a groove inserting portion 66g and the fourth inclined portion 66h arranged.
  • the first connecting portion 66a initially overlaps portions of the second and third radial layers and then extends completely in the third radial position.
  • the second connecting portion 66z initially fully extends in the third radial position and then overlaps portions of the third and second radial positions.
  • FIG. 12 shows a schematic representation of the required for a complete stator winding second terminal form of a winding element for odd numbers of conductors 67.
  • This terminal shape is used to provide an electrical connection for interconnecting the string winding, or for contacting the rectifier available.
  • This connection is preferably arranged on the electronics side winding head page 46.
  • To form a complete strand winding at least two terminal forms of the winding elements 65, 67 are required, each for strand winding start and strand winding end.
  • the first connection form of the winding element 67 corresponds for the most part to a shortened construction of the first basic shape of the winding element 64.
  • connection form of the winding element 67 is for realizing a winding with three conductors in each groove, the narrow sides of the conductor cross-sections facing each other and the broad sides of the conductor cross-sections of the groove wall opposite.
  • Each connection form of the winding element 67 consists of at least one essentially axially aligned first connecting section 67a, which serves to make contact with two radially adjacent connecting sections 64z, 67a.
  • the first connection section 67a merges into a first section 67b inclined to the axial and circumferential direction, which connects the first connection section 67a to a first axially aligned section 67c of the winding element 67 that is inserted in a groove 15.
  • Portion 67c transitions to a second axially and circumferentially inclined portion 67d, which further passes into a terminal portion 67y.
  • the second connection form of the winding element 67 shown here is constructed with no reversing section. It is also conceivable here in principle that the Terminal shape of the winding element 67 is performed with two or with each other even number of turnarounds to adapt the winding to a higher odd number of conductors in the groove.
  • the terminal shape of the winding element 67 is housed in this example in only one radial position.
  • the number of radial layers of the second connection form of the winding element 67 is usually one.
  • the first inclined portion 67b, the first in-slot portion 67c, the second inclined portion 67d, and the terminal portion 67y are disposed in the radially first position.
  • the first connection portion 67a initially overlaps portions of the second and first radial layers and then extends completely in the first radial position.
  • connection section 67y extends essentially over the first radial position, but can change from the first radial position into another radial position for better interconnection of the strand windings
  • FIG. 13 shows a schematic representation of the course of a strand winding in the stator core. Shown here is a package with ninety-six slots, in which six string windings are arranged. The runner has sixteen poles in this case. Because of the schematic nature of the representation in FIG. 6, the other five strand windings are not shown for the sake of clarity. It is possible to adapt the invention presented herein to any strand winding number and number of poles, e.g. a stand package with sixty grooves and five strand windings and a runner with twelve poles.
  • Continuous connections are arranged on the electronics side winding head. Dashed connections are arranged on the drive-side winding head.
  • the strand winding 70 is composed of a first terminal form of the winding element 65, seven first basic shapes of the winding element 63, a reversal shape of the winding element 66, seven further second Basic forms of the winding element 64 and a second terminal form of the winding element 67, which are all connected in series according to the order listed.
  • the stator core is passed through by this strand winding 70 once in and once against a first circumferential direction, all groove positions being assigned to all of these strand windings
  • the strand windings 71, 72, 73, 74, 75 are constructed identically to the illustrated strand winding 70 and are offset from the illustrated strand winding 70 by a predetermined number of slots in the circumferential direction.
  • the slot offset results in this example in a phase difference of electrically 30 °, or a multiple of electrically 30 ° between the strand windings 70, 71, 72, 73, 74, 75th
  • FIG. 14 shows a preliminary layer of the basic shape of a winding element 60 wound essentially in one plane.
  • the connecting sections 60a, 60z are arranged as precursors 60 ' a, 60 ' z in the same plane.
  • the portions located in the first groove position, namely, the first inclined portion 60b, the first groove-engaging portion 60c, and the second inclined portion 60d together form a first straight portion 60 ' b, 60 ' c, 60 ' d in this preliminary stage.
  • the portions located in the third groove position namely, the third inclined portion 6Of, the second groove-inserted portion 60g, and the fourth inclined portion 60h together form a second straight line in this preliminary stage
  • the portions located in the second groove position namely, the fifth inclined portion 6Oj, the third groove-engaging portion 60k, and the sixth inclined portion 601 together form a third straight line in this preliminary stage
  • the portions located in the fourth groove position namely, the seventh inclined portion 6On, the fourth groove-fitting portion 6Oo, and the eighth inclined portions 60p together in this preliminary stage form a fourth straight section 60 ' n, 60 ' o, 60 ' p.
  • the inversion sections 6Oe, 6Oi, 60m each form in this precursor a curved section 60 ' e, 60 ' i, 60 ' m, the curved sections
  • the precursor of the winding element 60 ' is brought in a further manufacturing step in a first spatial form in which the later first and third in-grooves section 60 ' c, 60 ' k opposite the later second and fourth in-slot section 60 ' g, 60 ' o is pulled apart perpendicular to the winding plane by substantially one pole pitch, wherein the later in-slots portions 60 ' c, 60 ' k, 60 ' g, 60 ' o remain straight.
  • FIG. 15 shows a device 80, 81 for the inventive manufacturing method for a winding element for joining into an annular laminated core.
  • the device is composed of two nested and circumferentially against each other rotatable cylinder or cylinder segments 80,81.
  • the inner cylinder or the inner cylinder segment 80 has grooves in the outer region, in which the precursors of the later inner groove sections 60 ' o, 60 ' g are inserted.
  • the outer cylinder or the outer cylinder segment 81 has grooves in the interior, into which the precursors of the later outer groove sections 60 ' c, 60 ' k are inserted.
  • the resulting winding elements 60 are suitable to be inserted into a round stator core with radially inwardly open grooves, since the sections of the winding elements inserted in the grooves are aligned in the radial direction.
  • the first basic shape of the winding element for three conductors in the groove 63 can be produced, in which by an additional manufacturing step, the intervening in different grooves sections of the winding to each other a groove position are radially offset.
  • FIG. 16 shows a device 82, 83 for the manufacturing method according to the invention for a winding element for joining into a cuboid laminated core.
  • the device is called from two superimposed, cuboid device parts in the following upper and lower part 82,83.
  • the top 82 has on the
  • the lower part 83 has grooves on the upper side.
  • the device parts 82,83 are mutually displaceable three-dimensionally.
  • the later inner groove portions 60 O, 60 ' g are inserted and inserted into the grooves of the lower part 83, the later outer groove portions 60 ' c, 60 ' k.
  • the upper part is displaced against the lower part in the direction of the arrows by approximately one pole pitch.
  • the resulting winding elements 60 are suitable to be inserted into a cuboid laminated core with open to one side grooves, wherein the groove openings after bending the cuboid
  • the first basic shape of the winding element for three conductors in the groove 63 can be made in which by an additional manufacturing step, the in different grooves portions of the winding element to each other by a groove position be offset in the groove depth direction.
  • the winding elements 60 provided for joining in a cuboid laminated core are aligned parallel with their slots in the grooves in the groove depth direction.
  • a cuboid laminated core loaded with all winding elements is bent into a round shape, so that the two
  • the connecting sections of the winding elements are materially connected to one another, for example by welding, and thus the strand windings are produced.
  • a protective layer applied to the welded connection sections protects against corrosion and serves as an electrical insulator.
  • Sections of a winding element are insulated together.
  • An overlapping region of the insulation can be arranged along the groove walls or between the sections of two winding elements which are inserted in the grooves. It is advantageous if the insulation adheres to the sections of the winding elements that are inserted in the slots.
  • FIG. 17 and FIG. 18 show a detail of a perspective view of a stator 16 according to the invention.
  • the orientation of the broad side of the conductor cross-section in the region of the sections 60c, 60g, 60k, 60o lying in the slots is parallel to the slot depth direction and in the region of the connecting sections 60a, 60z in FIG circumferential direction.
  • the turnaround portions 6Oi effect a change of the radial groove position of the groove-engaging portions 60c, 60g, 60k, 60O from a first groove 15 to a second associated groove 15.
  • the portions arranged outside the laminated core 17 and the winding heads 45, 46 thus forming portions 60a , 60b, 6Od, 6Oe, 6Of, 60h, 6Oi, 6Oj, 601, 60m, 6On,
  • 60p, 60z are spaced apart from one another and form defined passage openings through the winding head 45, 46, which guide the radial flow of cooling air.
  • a winding element of the stator winding has at least one slot-in section with a groove-dependent position the groove shape adapted cross-section has, for example, applies to sections that are based on original round wire and embossed ..
  • the groove shape should be rectangular. This leads to a high slot fill factor with a rectangular wire cross section, so that the ohmic strand winding resistance is reduced.
  • the total number of winding elements contained in a stand at least equal to the number of slots of the stator.
  • the number of slots in slots 15 is an even or odd number.
  • Each strand winding contains, based on the types of winding elements used, at least one basic shape and one terminal shape of the winding element. This applies, for example, when the strand winding is oriented only in a circumferential direction.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Windings For Motors And Generators (AREA)
  • Synchronous Machinery (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

L'invention concerne un générateur de courant alternatif, en particulier un générateur de courant triphasé pour une automobile, comprenant un rotor (20) présentant un pôle nord et un pôle sud, comprenant en particulier des doigts de pôles à griffes (24, 25) s'étendant dans une direction axiale, qui alternent en tant que pôle nord et pôle sud autour du rotor (20), un stator (16), qui présente un noyau magnétique, en particulier un empilage de tôles (17), comprenant des rainures (15) et un enroulement statorique (18) agencé dans les rainures (15) du noyau magnétique, l'enroulement statorique (18) présentant des têtes de bobines (45, 46), qui peuvent être refroidies grâce à respectivement un courant d'air approximativement radial qui est provoqué par au moins un ventilateur (30) fixé au niveau du rotor (20), le stator (16) faisant face au rotor (20) et le stator (16) et le rotor (20) étant positionné l'un par rapport à l'autre de manière définie, l'enroulement statorique polyphasé (18) étant constitué d'éléments d'enroulement (60, 61, 62, 63, 64, 65, 66, 67), au moins un élément d'enroulement présentant plus de deux sections incluses dans des rainures et au moins un élément d'enroulement (60, 61, 62, 63, 64, 65, 66, 67) présentant plus d'une section d'inversion, qui provoque un changement de la position radiale.
EP08701205A 2006-12-29 2008-01-02 Générateur de courant alternatif comprenant un stator et un enroulement statorique, inclus dans des encoches statoriques, constitué d'éléments d'enroulement ainsi qu'un procédé pour la fabrication d'un stator selon la présente invention Withdrawn EP2106632A2 (fr)

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DE102006062594 2006-12-29
PCT/EP2008/050018 WO2008081020A2 (fr) 2006-12-29 2008-01-02 Générateur de courant alternatif comprenant un stator et un enroulement statorique, inclus dans des encoches statoriques, constitué d'éléments d'enroulement ainsi qu'un procédé pour la fabrication d'un stator selon la présente invention

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EP2106632A2 true EP2106632A2 (fr) 2009-10-07

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US (1) US8878413B2 (fr)
EP (1) EP2106632A2 (fr)
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WO2008081020A3 (fr) 2009-07-23
JP2010531127A (ja) 2010-09-16
WO2008081020A2 (fr) 2008-07-10
US20110043059A1 (en) 2011-02-24
JP5537952B2 (ja) 2014-07-02
US8878413B2 (en) 2014-11-04

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