Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
  • H02K1/12—Stationary parts of the magnetic circuit
  • H02K1/16—Stator cores with slots for windings
  • H02K1/165—Shape, form or location of the slots
• • 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
  • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
  • H02K15/024—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with slots
• • 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
  • H02K15/06—Embedding prefabricated windings in machines
  • H02K15/062—Windings in slots; salient pole 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
  • H02K15/14—Casings; Enclosures; Supports
• • 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
  • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• • 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
  • H02K3/48—Fastening of windings on the stator or rotor structure in slots
  • H02K3/487—Slot-closing devices
  • H02K3/493—Slot-closing devices magnetic
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
  • H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information

Definitions

• the present invention relates to rotating electrical machines and more particularly the stators of such machines.
• JP 2 875497 relates to an electric machine stator comprising a toothed crown whose portions between two consecutive teeth are thinned on the side of the air gap.
• JP 2011-097723 discloses individual teeth reported on a cylinder head.
• the breech household notches completely open or semi-open towards the gap, so as to allow the introduction of windings.
• the half-open notches receive electrical conductors of circular cross section arranged in bulk, while the open notches house electrical conductors of rectangular cross section, arranged in a row.
• the openings of the notches to the gap can produce significant electromagnetic disturbances, including an increase in the "magnetic" air gap due to flux fringes, higher iron losses on the rotor surface for the same reason, or else pulsating couples because the variations of permeance are relatively brutal.
• the patent application FR 3,019,947 describes a stator comprising a toothed crown comprising teeth interconnected by material bridges and defining between them notches for receiving the coils, the notches being open radially outwards. The openings of the notches are closed by a yoke attached to the toothed crown.
• the invention responds to this need with the aid of a stator comprising:
• a crown comprising:
• windings arranged in the notches of the ring at least a portion of these material bridges having at least one deformable zone that can deform during assembly of the cylinder head on the ring and / or the insertion of the windings in the notches.
• deformable zone includes a zone of the material bridge deforming preferentially during a relative movement of the teeth it connects.
• the deformation of the material bridge can result in an elongation or shortening of the circumferential dimension of the material bridge, resulting in an elongation or shortening of the circumferential dimension of the crown.
• the preferential deformation can result from a particular shape given to the bridge.
• the deformable zone makes it possible to respond to the mechanical stresses experienced by the crown during the assembly of the crown with the cylinder head. In addition, it allows if desired to have more open slots before mounting the cylinder head and therefore a greater clearance between the coils and the wall of the notches during the insertion of the coils, which facilitates it and reduces the risk of insulation damage.
• the cylinder head makes it possible to close the notches of the crown and to keep the coils in the notches after their insertion.
• the cylinder head can be assembled with the crown in various ways.
• the deformable areas of the material bridges facilitate this assembly by providing some flexibility to the crown, which allows it to adapt to the shape of the cylinder head during assembly of the latter, the cylinder head, more rigid, imposing its shape.
• the deformable zone preferably forms a clearance between the material bridge and the corresponding winding, which can facilitate the penetration of the varnish during the impregnation of the stator.
• the stator can be used as a closed impregnation chamber by sealing the ends of the stator only. The tooling is thus simplified. This also reduces the amount of varnish lost and cleaning operations.
• notches open radially outwardly allows the coils to be inserted into the notches by a radial inward movement of the notches.
• the installation of the coils is facilitated, firstly in that the access to the interior of the notches is easier, being open notches completely and towards the outside rather than the gap, and secondly in that the space available around the ring, for the necessary tools and even for a winding machine, is greater than the space available in the stator bore.
• such a stator has many advantages from the electromagnetic point of view compared to a stator with notches open to the air gap. It makes it possible to greatly reduce the electromagnetic disturbances related to the presence of the openings of the notches giving onto the air gap in the prior art.
• the filling of the notches being facilitated, the filling rate can be improved, which can further increase the performance of the machine.
• the volume torque can be increased.
• the absence of opening of the notches to the air gap reduces the pulsations of notches.
• the electromagnetic performances of the machine are improved.
• At least one notch may have opposite edges parallel to each other, better all the notches.
• the width of the notches is preferably substantially constant over its entire height.
• At least one tooth may be generally trapezoidal when observed in section in a plane perpendicular to the axis of the stator.
• all the bridges of material each have at least one deformable zone. This makes it possible to vary the diameter of the crown over a larger value range and to have more homogeneous magnetic properties.
• the bridges of material are continuous with the teeth, extending from the base of the latter,
• the material bridges are integral with the teeth
• the teeth have a continuity of material between them at their base via the material bridges.
• each material bridge has a single deformable zone.
• the deformable zones may or may not be centered within the corresponding material bridge.
• each deformable zone has the shape of a fold defining at least one groove on one side of the material bridge, for example that facing the air gap, and a protruding projection on the opposite side.
• the grooves are open towards the gap and protruding reliefs extend into the bottom of the notch.
• the projecting reliefs extend into a recess in the bottom of the corresponding notch, the protruding reliefs being in particular of height less than or equal to the depth of said recess. This prevents the reliefs protrude into the bottom of the notch, which facilitates the filling of the notch by the coils.
• the height of the protruding reliefs remains less than or equal to the depth of said recess.
• the bridges of material having a deformable zone may have a median axis, when the stator is observed along the axis of rotation, curve or in the form of a broken line, in particular in the form of an arch or a V.
• the deformable zone is an area of the bridge of material that can stretch and deform by stretching, to form a necking when mounting the crown on the cylinder head and / or the insertion of the coils in the notches.
• the deformable areas are areas of the material bridge that are magnetically saturated during operation of the machine. This improves the passage of the electromagnetic flux between the notches and the air gap, which allows to minimize the harmonics, and to obtain more torque by desaturation of the teeth and the cylinder head.
• the bottom of the notches each has at least one flat portion against which a winding, preferably of substantially rectangular section, is supported.
• the flat portion or portions are substantially perpendicular to the radial axis of the notch.
• the bottom of the notch may be flat, with the exception of a recess.
• the bottom of the notch may be completely flat and the material bridge may be deformed by stretching to form a necking, as mentioned above.
• the deformable zone or the recess preferably forms a clearance between the material bridge and the corresponding winding, which can facilitate the penetration of the varnish during the impregnation of the stator.
• the crown has reliefs on its radially outer surface, cooperating with cooperating reliefs, in particular nested one inside the other of the cylinder head.
• Such reliefs allow by cooperation of forms to maintain the crown and the yoke fixed relative to each other.
• the cooperating reliefs are preferably of the dovetail and mortise type.
• the crown can be made by helically winding a sheet metal strip having teeth connected by the material bridges, the opposite edges of each notch preferably becoming substantially parallel to each other when the strip is wound on itself to form the ring.
• the strip may be formed of sectors each having a plurality of teeth, the sectors being connected by links, these sectors being cut in a sheet metal strip.
• the connections may be flexible bridges connecting the sectors to each other and / or parts of complementary shapes, for example of the dovetail and mortise type or complementary reliefs bearing against each other, especially when the crown is kept in compression by the cylinder head.
• the complementary shapes can be on the material bridges so that the different sectors are assembled at the bridges of material.
• the assembly of the complementary shapes of the different sectors is outside the deformable zones of the material bridges. This facilitates assembly, especially in the case of large machines.
• the sectors have recessed shapes cooperating with complementary projecting forms of an adjacent sector.
• the ring comprises a stack of pre-cut magnetic sheets.
• the ring is manufactured by additive manufacturing, for example by sintering powder.
• the cylinder head can be made by directly winding a sheet metal strip if its width allows it, forming or not in said sheet metal strip adapted slots during its cutting, so as to facilitate this winding, by stacking pre-cut magnetic sheets or by additive manufacturing, for example by powder sintering.
• the cylinder head is attached to the crown after the installation of the windings in the notches.
• the coils can be arranged in the notches in a concentrated or distributed manner.
• distributed is meant that at least one of the windings passes successively in two not adjacent notches.
• the coils are arranged in the notches in a distributed manner, in particular when the number of rotor poles is less than or equal to 8.
• the windings each comprise at least one electrical conductor which may be in cross section of circular shape, or of polygonal shape with rounded edges, preferably of rectangular shape, this list not being limiting.
• the conductors When the conductors are of circular cross section, they can be arranged in the notch according to a hexagonal stack. When the conductors are of polygonal cross section, they can be arranged in the notch in one or more rows oriented radially. The optimization of the stack can allow to have in the notches a larger amount of electrical conductors and thus to obtain a stator of greater power at constant volume.
• the electrical conductors can be arranged randomly in the notches or rows.
• the electrical conductors are stored in the notches.
• rows is meant that the conductors are not arranged in the notches in bulk but in an orderly manner. They are stacked in the slots in a non-random manner, being for example arranged in one or more rows of aligned electrical conductors, in particular in one or two rows, preferably in a single row.
• the electrical conductors are preferably electrically isolated from the outside by an insulating coating, in particular an enamel.
• the coils are separated from the walls of the notch by an insulator, in particular by at least one insulating sheet.
• an insulator in particular by at least one insulating sheet.
• Such a sheet insulator allows better electrical insulation of the windings relative to the notch.
• each notch receives at least two coils, in particular at least two coils of different phases. These two windings can be superimposed radially.
• the two coils can be separated from each other by at least one insulating sheet, preferably by at least two sheets of insulation.
• Each winding can be formed of several turns.
• the windings are said to be in pins, in particular U-shaped ("U-pin” in English) or straight, I-shaped ("I-pin” in English) pins, and in this case comprise an I-shaped or U-shaped portion whose ends are welded to conductors out of the corresponding notch.
• the stator can be twisted ("skewing" in English). Such twisting may help to clamp the coils into the notches and reduce the harmonic notches.
• the invention also relates to a rotating electrical machine comprising a stator as defined above.
• the machine can be synchronous or not.
• the machine can be reluctant. It can constitute a synchronous motor.
• the rotating electrical machine may comprise a wound rotor or permanent magnets.
• the subject of the invention is also a process for manufacturing a stator as defined above, in which the step of inserting the coils into the notches of the stator ring is implemented.
• the method comprises a step of deformation of the deformable zone or zones when mounting the cylinder head on the ring and / or the insertion of the windings in the notches.
• Such deformation can change the diameter of the crown and the width of the notches.
• the step of inserting the coils into the notches can be implemented so as to widen the notches by extension of the material bridges. This also causes an increase in the outer diameter of the crown. This facilitates the insertion of the windings.
• the coils are preferably inserted into the slots by a radial inward movement.
• the stage of mounting the cylinder head on the ring may cause a decrease in the inner diameter of the ring by tightening the material bridges.
• the method may comprise a step of cutting the crown and the yoke simultaneously in the same sheet with one or more common cuts, including a single cut.
• the mounting of the cylinder head on the ring may cause a decrease in the outer diameter of the ring by tightening the material bridge or bridges.
• the method may comprise a step of deforming the deformable zones to increase the diameter of the ring so as to reduce the possible clearance between the ring and the cylinder head after the step of mounting the cylinder head on the ring.
• FIG. 1 is a diagrammatic and partial cross-section of a machine comprising a stator produced in accordance with the invention
• FIG. 2 schematically represents a portion of the stator ring of the machine of FIG. 1,
• FIG. 3 illustrates the portion of the stator ring of FIG. 2, the deformable zones being widened
• FIG. 4 represents the portion of the stator ring of FIG. 3, the deformable zones being tightened
• FIGS. 5 to 7 illustrate variants of the shape of the material bridges and the notches
• FIG. 8 illustrates a variant of the portion of the stator ring, the deformable zones being widened
• FIG. 9 represents the portion of the stator ring of FIG. 8, the deformable zones being constricted
• FIGS. 10 to 13 illustrate variant portions of the stator ring.
• FIG. 1 illustrates a rotary electrical machine 10 comprising a rotor 1 and a stator 2.
• the stator makes it possible to generate a rotating magnetic field driving the rotor 1, in the context of a synchronous motor, and in the case of an alternator, the rotation of the rotor induces an electromotive force in the stator windings.
• the stator 2 comprises windings 22, which are arranged in notches 21 formed between teeth 23 of a toothed crown 25.
• the notches are closed on the air gap side by material bridges 27, each connecting two consecutive teeth of the crown 25.
• the stator 2 comprises a yoke 29 attached to the ring 25.
• the notches 21 are, in the example described, with radial edges 33 parallel to each other, and are, in section in a plane perpendicular to the axis of rotation X of the machine, of substantially rectangular shape.
• the bottom of the notches 35 is of a shape substantially complementary to that of the windings 22, with the exception of a recess 40.
• the bottom of the notches 35 has two planar portions 30 on each side. other of the recess 40, against which the rectangular windings 22 are supported.
• the bottom of the notches 35 is connected to the radial edges 33 by rounded edges 36.
• the recess 40 is in the form of a longitudinal groove extending along the axis of rotation X of the machine, centered on the bottom of the notch 21.
• the recess 40 preferably has a depth p between 0.4 mm and 1 mm, for example equal to 0.6 mm.
• the bridges of material 27 preferably each have a deformable zone 32 making it possible to vary their circumferential dimension e, corresponding to the width of the notches 21, and in this way to vary the average internal diameter 2R of the ring 25.
• the deformable zones 32 are in the form of folds.
• the material bridges 27 have a variable width, the deformable areas 32 being the areas of smaller width.
• the smallest width of the material bridges 27 is preferably between 0.3 mm and 0.6 mm, for example equal to 0.4 mm.
• each fold defines on the bottom side of the notches 35 a protruding relief 42 extending into the recess 40 and, on the side of the air gap 46, a groove 48.
• Each projecting relief 42 is in the form of a rounded rib at its apex. It has a height h less than the depth p of the recess 40, so as not to exceed it.
• the grooves 48 are in the form of grooves of rounded section in a plane perpendicular to the X axis.
• the grooves 48 and projecting reliefs 42 bend.
• the projecting reliefs 42 have a height h, mlx greater than the height h without deformation and the recesses 40 have a depth p mxX greater than depth of the recess p without deformation, the height h, mlx remaining lower than the depth p müX of the recess 40 correspondent.
• the ring 25 and / or the yoke 29 are each formed of a stack of magnetic sheets stacked along the X axis, the sheets being for example identical and superimposed exactly. They can be held together by clipping, rivets, tie rods, welds and / or any other technique.
• the magnetic sheets are preferably magnetic steel.
• the teeth 23 of the ring 25 have complementary reliefs 56 on the surface for clipping the various sheets forming the ring 25 between them.
• the complementary reliefs 56 may be on all the teeth 23 or on a portion of the teeth 23 only, for example on a tooth 23 out of two.
• the sheets are glued together or assembled otherwise.
• the yoke 29 may have complementary surface reliefs for clipping the different plates forming the yoke 29 between them.
• the crown and / or the cylinder head can still be formed of a cut sheet metal strip wound on itself.
• the yoke 29 is mounted on the ring 25 by cooperation of shapes.
• the ring 25 and the yoke 29 have complementary reliefs 49 on the outer surface of the ring and the inner surface of the cylinder head, to maintain them in position relative to each other.
• the coils 22 may be arranged in the notches 21 in a concentrated or distributed manner, preferably distributed.
• the electrical conductors 34 of the windings 22 are arranged in the notches in a row.
• the electrical conductors 34 are preferably of flattened rectangular cross section and are superimposed radially for example in a single row.
• the electrical conductors 34 are enamelled or coated with any other suitable insulating coating.
• Each notch 21 can receive two coils 22 stacked of different phases.
• Each coil 22 may, in cross section, be of substantially rectangular shape.
• Each coil 22 is surrounded by a sheet of insulation 37 for isolating the windings of the walls 33 and 36 of the notch and the coils 22 of different phases.
• the electrical conductors 22 are assembled in coils 22 out of the notches 21 and surrounded by an insulating sheet 27 and the coils 22 with the insulating sheets 37 are inserted into the notches 21. This operation is facilitated by the fact that the notches are open completely radially outwards, and by the fact that the material bridges are deformable.
• the rotor 1 shown in FIG. 1 comprises a central opening 5 for mounting on a shaft and comprises a rotor magnetic mass 3 extending axially along the axis of rotation X of the rotor, this rotor mass being for example formed by a package of magnetic sheets stacked along the X axis, the sheets being for example identical and superimposed exactly.
• the rotor 1 comprises for example a plurality of permanent magnets 7 arranged in housings 8 of the rotor magnetic mass 3. In a variant, the rotor is wound.
• the stator can be obtained by means of the manufacturing method which will now be described.
• the coils 22 are inserted into the notches 21 of the ring 25 by a radial displacement of the coils 21 towards the inside of the notches 21.
• the notches 21 can expand by deformation of the deformable areas of the coils 21. material bridges 27.
• the outer diameter of the ring 25 can thus be larger than before winding.
• the yoke 29 is force-applied on the ring 27.
• This assembly can cause a decrease in the enlarged outer diameter of the ring 25 by deformation of the deformable areas 32.
• the clearance between the crown and the yoke is then minimal.
• the embodiment of Figure 5 differs from that of Figures 1 and 2 in that the bottom of the notch 21 does not have a recess.
• the protruding reliefs are of rounded sectional shape in a plane perpendicular to the X axis.
• FIG. 6 differs from that of FIGS. 1 and 2 in that the bottom of the notch 21 does not have a recess and in that the folds are each formed of a groove 50 facing towards this bottom. the notch 21 and a protruding relief 52 extending in the gap 46.
• FIG. 7 differs from that of FIG. 5 in that the protruding grooves 48 and reliefs 42 have a V-shaped broken line profile and that the bottom of the notch 21 is of decreasing width towards the relief projecting from the radial edges 33 of the notch 21.
• FIGS. 8 and 9 differs from that of FIGS. 1 and 2 in that the deformable zone is an area that can stretch and deform by stretching to form a necking 60. When stretched, like this is shown in Figure 8, the deformable zone 32 may thin locally. Before mounting the yoke, the material bridge 27 may have a constant thickness, as illustrated in FIG. 9.
• the embodiment of FIG. 10 differs from that of FIGS. 1 and 2 in that the bottom of the hole has two deformable zones 32 as previously described.
• FIGS. 11 to 13 differ from that of FIGS. 1 and 2 in that at least a portion of the material bridges 27 have complementary reliefs 62 and 64. These complementary reliefs 62 and 64 may be in an area of material bridge 27 different from the deformable zone 32.
• the ring 25 is manufactured by assembling sectors of sheets which are assembled together circumferentially via the complementary reliefs 62 and 64.
• the complementary reliefs 62 and 64 may be complementary reliefs which are fixed to one another, for example tails donde and mortise, as shown in Figure 11. They allow to fix two sectors between them whether in extension or compression of the crown. As a variant, as illustrated in FIGS.
• the complementary reliefs 62 and 64 are respectively projecting and recessed reliefs of complementary shapes which bear against one another without being fastened thereon. reliefs 62 and 64 between them, by compression of the ring 25, in particular by the cylinder head 29. They make it possible to maintain two adjacent sectors by interlocking the reliefs 62 and 64 and by supporting the reliefs 62 and 64 between them while maintaining the crown in compression.
• the invention is not limited to the exemplary bridges of material illustrated and these can be made with other forms still, multiple corrugations for example.

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

Applications Claiming Priority (2)

Publications (1)

Family

ID=63557614

Family Applications (1)

Country Status (7)

Families Citing this family (4)

Family Cites Families (41)

• 2018
  • 2018-06-07 FR FR1854959A patent/FR3082374B1/fr active Active
• 2019
  • 2019-06-04 US US17/057,969 patent/US11949284B2/en active Active
  • 2019-06-04 JP JP2020567140A patent/JP2021526001A/ja active Pending
  • 2019-06-04 WO PCT/EP2019/064504 patent/WO2019234031A1/fr unknown
  • 2019-06-04 KR KR1020207035060A patent/KR20210042261A/ko unknown
  • 2019-06-04 CN CN201980037305.0A patent/CN112219340B/zh active Active
  • 2019-06-04 EP EP19727431.9A patent/EP3804089A1/de active Pending

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