Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K5/00—Casings; Enclosures; Supports
  • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
  • H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
  • H02K5/225—Terminal boxes or connection arrangements
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
  • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
  • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
  • H02K11/0094—Structural association with other electrical or electronic devices
• • 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
  • H02K15/0056—Manufacturing winding connections
  • H02K15/0062—Manufacturing the terminal arrangement per se; Connecting the terminals to an external circuit
• • 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
  • H02K15/0056—Manufacturing winding connections
  • H02K15/0068—Connecting winding sections; Forming leads; Connecting leads to terminals
• • 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
• • 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
  • H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K3/00—Details of windings
  • H02K3/46—Fastening of windings on the stator or rotor structure
  • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
  • H02K2203/06—Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations
• • 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 present invention relates to electrical machines, in particular intended to be installed in road vehicles.
• the present invention relates in particular to electrical stator winding machines.
• This invention finds, for example, an example of application to permanent magnets in brushless electric machines.
• An electric machine is a machine for converting between electrical energy and mechanical energy. This conversion can be done in both directions, depending on whether the machine operates as a generator or motor. There are different types of machines, whether DC machines or AC machines, in which there are synchronous or asynchronous machines. To perform this conversion, an electrical machine generally comprises a fixed part, called stator, and a rotatable part, called rotor.
• Electrical machines can be installed in all kinds of systems, including a road vehicle, and more particularly in a wheel of a road vehicle.
• one of the challenges of installing an electrical machine is based on the connection of the machine to external connections, in this case an electrical harness of the vehicle.
• an electrical harness of the vehicle In the case of a permanent magnet machine without brushes, the connection on the side of the electrical machine takes place at the stator.
• This crimp is embedded in a coating resin, as close as possible to the cooled surfaces of the electric machine, to ensure good thermal behavior of the assembly.
• the present invention is therefore to provide an electric machine does not have these disadvantages.
• the present invention aims to provide an electric machine such that disassembly is relatively easy, and it can adapt to different applications without requiring special adaptations.
• the present invention relates to an electric machine with permanent magnets comprising a housing housing a stator winding at least two phase outputs, said electrical machine comprising
• each electrical connector fixed on each phase output of the winding, a cover comprising at least two contactors and connected to an electric harness, each electrical connector having a contact surface intended to cooperate with a contact element,
• each contactor of the cover is in contact with a contact surface of an electrical connector and the electrical machine is connected to the harness.
• contactor and connector designate separate elements but of the same nature, namely contacts, or contactors, electrical.
• a machine according to the invention has the advantage of requiring a single step of fixing electrical connectors on the phase outputs. Indeed, the second crimping step described in the state of the art is no longer necessary, since the electrical connection of the machine is performed by a simple contact of a bonnet contactor with a contacting surface an electrical connector installed on a phase output of the winding. Moreover, this connection by simple contact allows a better adaptability of the cover and the electric machine. Thus, it is possible to modify one of the elements without having to modify the other, as long as the geometry of the contact points remains the same. Such a solution therefore saves costs by not requiring specifically to manufacture machines for each application.
• a machine according to the invention allows disassembly and easy access to the various elements.
• Such a feature is particularly interesting in the case where an electric machine is installed on a wheel, because the wheel arch is a particularly difficult to access.
• the attachment of the electrical connector to a phase output of the winding is included in the group comprising: crimping, welding, pinching son by a screw.
• each electrical connector comprises:
• the lower and upper part forming an angle substantially equal to 90 °, and the lower part, the upper part, the fixing element and the contact surface forming a single mechanical part.
• the electrical connector is formed of a conductive metallic material, for example copper.
• the machine further comprises at least one insulating part cooperating with each electrical connector to prevent contact of the upper part of the electrical connector with the winding or the carcass of the machine.
• This piece is, for example, injected plastic.
• the invention also relates to a method of manufacturing an electric machine, comprising the following steps:
• an electrical connector is fixed, comprising a plane part extending in the axis of the electrical machine and supporting the fixing element to the winding,
• the flat portion of the connector is folded so as to form a lower part of the connector supporting the fixing element, and an upper part of the connector having a contact surface.
• the positioning of the electrical connector and its late folding can not interfere with the conformation of the chinions, necessary in the context of the manufacture of an electric machine.
• the lower portion and the upper portion of the connector form an angle substantially equal to 90 °.
• the method comprises the step, before or after the bending of the connector, to coat the coils and chinions with an impregnating resin.
• the lower part of the connector is also embedded in a coating resin.
• the method comprises the final step of installing a cover comprising three contact elements intended to be in contact respectively with each contact surface of an electrical connector.
• the step of fixing an electrical connector on a winding phase is comprised in the group comprising: a crimping step, a soldering step, a pinching step of the wires by a screw.
• the method comprises, prior to the folding step, the step of placing a conformation piece for isolating the upper part of the winding connector and the carcass of the electric machine.
• FIG. 1 represents a view of an electrical machine comprising three electrical connectors without the cover
• FIGS. 2a and 2b show two views of an electrical connector installed on a phase of a winding
• FIG. 3 represents an example of a hood
• FIG. 4 represents an external view of an electric machine comprising a cover shown in transparency
• FIG. 5 represents a sectional view of an electric machine and its cover
• Figure 6a shows an electrical connector before folding
• Figure 6b shows a folding step
• Figure 1 shows a brushless permanent magnet electric machine.
• This machine is represented without its hood.
• the machine comprises a casing 1, in which is installed a rotor 2 in the housing axis, surrounded by a stator winding 3.
• This winding is three-phase, that is to say that the windings define three phases.
• the machine has 3 identical connectors 4, each installed on an output of the winding.
• each connector is shaped around an insulating part 5.
• An electrical connector such as one of those shown in Figure 1 is, initially, a non-folded conductive metal part, as shown in Figure 6.
• an unfolded connector is fixed on a phase output of the stator winding.
• a fixing element 43 is crimped onto a phase output, for example comprising three wires, in order to establish a connection.
• This crimping action is performed after the winding of the stator windings.
• the connector is always in an unfolded state as shown in FIG. 6, and the flat portion 44 of the connector is situated in the axis of the casing 1, which appears in FIG. 1.
• the plane portion 44 is then folded so as to form, as shown in FIGS. 2a and 2b, an upper portion 41 having a contacting surface 42, and a lower portion 45 that is not very visible on 2a, supporting the fixing element 43.
• this folding is performed around an insulating part 5.
• This piece for example injected plastic, prevents the upper portion 41 from coming into contact windings upon bending of the connector and isolates the contact of the housing.
• the electrical machine comprises three connectors having three contacting surfaces on the surface of the stator winding. These three contacting surfaces are arranged so as to cooperate with three contactors 10 installed in a cover 11 as shown in FIG.
• Figures 4 and 5 show this contacting: in Figure 4, the cover is shown in transparency , in order to allow the visualization of the contactors 10 and the connectors 4.
• the cover 11 comprises sheaths 12, for passing electrical connections that will be connected on one side to the contactors 10, and the other to the system in which is installed the electric machine, for example a road vehicle.
• one of the sheaths is arranged to receive the three power wires connected to the three contactors, and the other sheath is arranged to receive links used to carry out measurements, in particular thermal measurements or measurements of the position. solver. It should be noted that in FIG. 3, the power wires connecting the contactors 10 to the electrical harness are not shown.
• the geometry of the electrical connectors allows their integration in a limited volume, thus ensuring good compactness to all.
• the present invention allows the removal of a flexible multi-strand wire, thus decreasing the volume required for the connection.
• only a crimping operation is necessary, which facilitates the connection and disconnection of the electric machine, and thus simplifies the maintenance of the electric machine.

Landscapes

• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Insulation, Fastening Of Motor, Generator Windings (AREA)
• Manufacture Of Motors, Generators (AREA)
• Motor Or Generator Frames (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

ID=47297283

Family Applications (1)

Country Status (6)

Families Citing this family (6)

Family Cites Families (6)

• 2011
  • 2011-12-09 FR FR1161417A patent/FR2984036B1/fr not_active Expired - Fee Related
• 2012
  • 2012-12-06 JP JP2014545254A patent/JP2015501125A/ja not_active Abandoned
  • 2012-12-06 US US14/363,863 patent/US20140354086A1/en not_active Abandoned
  • 2012-12-06 CN CN201280060595.9A patent/CN103975512B/zh not_active Expired - Fee Related
  • 2012-12-06 EP EP12797912.8A patent/EP2789077A1/fr not_active Withdrawn
  • 2012-12-06 WO PCT/EP2012/074631 patent/WO2013083688A1/fr active Application Filing

Non-Patent Citations (1)

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