EP3815222A1 - Fabrication d'un dispositif de distribution de puissance électrique multiphasée - Google Patents
Fabrication d'un dispositif de distribution de puissance électrique multiphaséeInfo
- Publication number
- EP3815222A1 EP3815222A1 EP19790614.2A EP19790614A EP3815222A1 EP 3815222 A1 EP3815222 A1 EP 3815222A1 EP 19790614 A EP19790614 A EP 19790614A EP 3815222 A1 EP3815222 A1 EP 3815222A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- independent conductive
- conductive elements
- distribution device
- power distribution
- manufacturing
- 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.)
- Pending
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
- H02K15/0056—Manufacturing winding connections
- H02K15/0062—Manufacturing the terminal arrangement per se; Connecting the terminals to an external circuit
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
- H01R43/24—Assembling by moulding on contact members
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/38—Windings characterised by the shape, form or construction of the insulation around winding heads, equalising connectors, or connections thereto
-
- 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
- H02K2203/09—Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
Definitions
- the invention relates to a current distribution device for a brushless electric machine.
- the brushless electric machines or self-controlled synchronous machine with permanent magnets, form a family of electric machines operating, seen from the outside, with a DC power supply, an electronic control system converting the continuous electric power into two-phase or three-phase alternating electric power.
- the electronic control system is integrated in the motor, while for higher powers, it constitutes an external inverter.
- Brushless motors are, for a given power, light and space-saving, and they allow high speeds of rotation. Their performance therefore justifies a growing interest in these engines in recent years.
- motors are used for portable tools, such as drills, screwdrivers, mowers, brushcutters or compactors, in robotics or in reduced models such as planes or radio-controlled cars, in computer disc players, or also in the automotive field: electric traction machines are often brushless machines. They are also used for electric bikes.
- the machine consists of permanent magnets distributed around the periphery of the rotor and of a multiphase winding on the stator, source of a rotating magnetic field.
- stator is at the periphery and the rotor is central.
- the inertia of the rotor in general low, and the speeds reached by this type of motor can reach 10000rpm.
- stator is central, while the bell-shaped rotor rotates around the stator.
- This latter configuration is advantageous in terms of engine torque, since the magnets are arranged over a large diameter, which creates a lever arm as a result.
- the rotor follows in synchronized fashion.
- the system is equipped with a rotor position sensor, in order to ensure its autopiloting.
- Brushless motors offer, compared to brushed motors, the advantages of less wear due to the absence of wear parts, low dust generation, and the absence of mechanical overheating associated with these. friction. There is also less noise pollution.
- Motors can be offered by range of engines from the same supplier, varying within the range by their dimensions and power. It is interesting to be able, with the same series of basic components, to equip different motors of the same range, or close in design.
- the method comprises a step of disposing of independent conductive elements each comprising a track forming an arc of a circle, seen from a distance, of the same radius, so as to define electrical contacts on different angular sectors for the machine to be equipped, then a step of overmolding the independent conductive elements arranged with a thermoplastic material forming a support for the brushless electric machine.
- connection bars or independent conductive elements improve assembly and the reliability of assembly and operation.
- the assembly is done with very few tools.
- the method comprises an assembly, to form an independent conductive element, of a semicircular track, of a terminal consisting of a plate arranged perpendicular to the plane of the track at the end thereof and of hooks for fixing the distribution device to the windings of the electric machine.
- the use of versatile means offers compatibility between models of similar dimensions, of different powers, for which it is nevertheless possible to keep certain parts, in particular hooks for fixing the distribution device to the motor windings and the terminals. connection, configured to interact with the user interface. These technologies (winding and interface) are typically constant at the same engine manufacturer.
- the surface covering is limited to only the parts in interface with external elements (customer interface, winding interface), which induces a reduction in the use of contaminating surface treatment processes.
- the final product can also be 5 to 7% lighter than equivalent products on the market.
- the disposal step is done by putting as many independent conductive elements as there are phase to the electric power to be distributed, as well as an additional independent conductive element for a neutral connector;
- the disposal step is done by putting independent conductive elements superimposed on each other so as to form a male plug comprising male connection terminals of the independent conductive elements next to each other;
- the disposal step is made by putting independent conductive elements superimposed so that their respective ends are accessible for the supply of the different coils of the brushless electric machine;
- the disposal step is done by putting several elements of independent conductors provided with a male connection terminal superimposed on a semicircle and an independent conductor element without male connection terminal on the other semicircle ;
- the disposal step is made by placing independent conductive elements on successive steps of a molding impression and by overmolding the independent conductive elements in the impression; - the independent conductive elements are made of copper, and are provided with conductive hooks turned to the side intended to receive the brushless electric machine;
- the independent conductive elements are made of copper, and the mounting of the semi-circular track, of the terminal consisting of a plate and of hooks is done by electrical welding, micro-TIG welding or laser welding;
- the semi-circular track is obtained by unwinding a copper wire to which a radius of curvature and a suitable cross-section shape are given.
- the means used are flexible, and there is a limited need for specific tools, and the methods of obtaining them are adaptable to all sizes of engines.
- FIG. 1 shows an example of a brushless electric machine, seen from the outside
- FIGS. 2 and 3 show a basic element of a connection device according to the invention, before and after assembly of its parts;
- FIGS. 4 and 5 show the different basic elements of a dispensing device according to the invention, seen in exploded configuration, the elements being positioned relative to each other for assembly;
- a brushless electric motor 100 It comprises in a casing 101 cylindrical, of revolution, an input shaft 102 output coaxial with the housing.
- the casing 101 carries magnets by pair of poles around its internal periphery, and constitutes an external rotor connected to the input-output shaft 102.
- the casing 101 and the input-output shaft 102 rotate at the same speed.
- Inside the casing 101 are coils by multiples of three, supplied with three-phase current, so as to rotate the magnets carried inside the casing 101, which causes the latter to rotate and input output shaft 102.
- the supply of the brushless motor 100 is done using direct current, transformed by on-board power electronics into a three-phase current supplying the stator coils, which are in number multiple of three.
- connection support 103 Opposite the input-output shaft 102 on the opposite base of the cylinder constituting the casing, is located a connection support 103.
- connection support 103 allows the supply of the three coils or groups of coils, with the three-phase current supplied by a distribution device.
- FIG 2 there is shown a construction module of the distribution device according to the invention, which is used to bring the electric current to the coils.
- This distribution device is developed according to the typology of the motor, namely its size and its power, to distribute the current to the motor coils from the energy source.
- the distribution device consists of four inserts arranged in a particular way to manufacture the assembly.
- Figure 2 shows the structure of one of the inserts.
- the insert bears the reference 200 it consists of a semicircular track 201, a terminal 202 consisting of a plate arranged perpendicular to the plane of the track 201 at the end thereof, and two hooks 203 and 204.
- FIGS 2 and 3 show the detail of an assembled phase conductor (U-V-W).
- the conductor comprises a flat wire curved 201.
- the curve is dependent on the diameter of the motor.
- a terminal 202 is attached welded to the flat wire placed in a curve 201.
- the welding modes that can be used are in particular electric welding, laser welding or even micro TIG welding.
- Hooks 203 and 204 are also added welded to the flat wire placed in curve 201.
- the welding modes are again electric welding, laser welding or even micro TIG welding.
- the number of hooks per conductor 200 depends on the design of the motor, and more precisely on the number of coils per phase. Thus, if there are two coils on the phase, two hooks are placed on the conductor.
- FIG 3 there is shown the insert 200 after assembly of the four parts thus stated.
- the hooks 203 and 204 are oriented in the same half-space as the connector terminal 202 with respect to the plane of the track 201. It is specified that the connector terminal 202 and the winding hooks 203 and 204 are assembled by electric welding on runway 201.
- the insert 200 is essentially defined by the amplitude of the angular sector of the blade 201, the positioning of the winding hooks 203 and 204 and the number of winding hooks on the insert.
- the track 201 and the terminal 202 and the hooks are made of 99% pure copper.
- the terminals 202 and the winding hooks 203, 204 are covered with a protective layer against corrosion in various possible materials, such as lead-free tin, nickel, silver or gold.
- Figure 4 there is shown the four inserts for building an example, according to one embodiment of the dispensing device.
- the inserts are referenced 301, 302, 303 and 304.
- the inserts 301 to 303 correspond to the description which has been made with reference to FIG. 3, but the length of their track increases from the insert 301 towards the insert 302 and insert 303.
- a hook is always present, on each of these three inserts, at the end opposite to the terminal, and the second hook is placed at an intermediate position, closer to the terminal for insert 301, closer to the opposite hook for insert 303, and intermediate for insert 302.
- the insert 304 is devoid of terminal, is based on a track of just under half a turn and carries six hooks, distributed regularly from one end to the other of the track, and all turned towards the same half space.
- the conductor 304 is provided to perform the neutral function, the conductor 303 is provided to carry one of the phases and is united to the terminal 403 visible in FIG. 5, the conductor 302 is provided to carry a second of the phases and is united to terminal 402, and the conductor 301 is provided to carry the third phase and is connected to terminal 401.
- Each of these conductors is fitted with hooks.
- the function of these hooks is to connect the conductor to the associated coils by a suitable winding of wires on the hook and on the coils according to the rules of the art.
- the coil wire can be soldered to the hook.
- the hooks lead the voltage U (Volt) and the current I (Amp) to the stator coils.
- Figure 5 shows the exploded view of a distributor assembly or connection device according to the invention, based on the inserts of Figure 4 and therefore composed of four conductors as mentioned above. These conductors are arranged concentrically and are superimposed on each other. The space between each of these conductors is such that they ensure perfect electrical isolation between the phases. This distance is a function of the power P (W) of the motor and the nature of the insulating material which coats each of the conductors.
- the inserts 301 to 304 are placed coaxially around an axis XX by defining a cylinder of revolution around it, the inserts 301 to 303 on one side of the cylinder and the insert 304 on the other side of the cylinder, all the hooks directed towards the same half-space.
- the terminals of the inserts 301 to 303 are placed close to each other, with a slight angular offset around the axis XX so that they are not superimposed, in the terminal order of the insert 301, terminal of the insert 302 and terminal of the insert 303.
- the four inserts are positioned in an overmolding of thermoplastic material 400, having a generally annular shape and placed around the axis X-X.
- the overmoulding 400 comprises seven legs turned towards the half-space opposite to the half-space towards which the hooks of the inserts are turned.
- Figure 6 shows in an overview the assembled connection device 500. It includes overmolding 400 within which the four inserts are present. The seven legs of the overmold are facing half a space, and the hooks and terminals 401 to 403 are facing the other half space.
- Terminals 401 to 403 are terminals or terminals that interface with the inverter. This actively drives the motor by varying the potential difference U (Volt) and the intensity I (Amp) at the terminals to adapt the power P (W) of the motor through these two components: the torque C (N / m) and speed of rotation w (R / s).
- the neutral or ground function is provided through the casing of the stator of the motor. This envelope is metallic and therefore allows this function.
- FIGs 7 and 8 is shown the overmolding process, and more specifically the establishment of all the conductors in the imprint of the thermoplastic or thermosetting injection mold.
- the four inserts 301 to 304 are finely positioned in mold cavities, lower 450 and upper 451.
- FIG 9 there is shown a sectional view of the conductors in place in the mold cavity.
- the zone 600 is intended to be filled with thermoplastic material, different channels, for example the channel 700 bringing the material in fluid form so as to proceed with the molding, by filling then cooling. Once the thermoplastic material has cooled, the lower and upper indentations are separated and the dispensing device 800 is released.
- FIG. 10 represents the BusBar product (called phase connector or inverter interface or intermediate connector) after the overmolding step.
- the thermoplastic or thermosetting overmolding step consists in coating each of the conductors with an insulating material. It has several objectives: to provide electrical isolation between each conductor, to structure the power distribution device by providing it with the necessary geometry in relation to the design of the engine, to keep each of the conductors united. The construction of the inserts, prior to overmolding, will be presented below.
- Figure 1 1 shows the first phase of construction. It consists in the unwinding of wire 700 to transform it into a conductor with radius R and length of cord corresponding to its angle a depending on the target motor.
- Figure 12 shows the second phase of construction. It includes the welding of the hooks 200, using a welding coordinate machine 800 the number and position of which depend on the definition of the motor, then the welding of a terminal or terminal 401, 402 or 403 in the phase conductor case.
- Figure 13 shows a conductor 301 assembled. In the case of a phase conductor, it consists of the conductor, hooks and a terminal, in the case of the neutral conductor, it consists of the conductor and hooks.
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Manufacture Of Motors, Generators (AREA)
- Brushless Motors (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR1855799A FR3083387B1 (fr) | 2018-06-27 | 2018-06-27 | Fabrication d'un dispositif de distribution de puissance electrique multiphasee |
PCT/FR2019/051596 WO2020002847A1 (fr) | 2018-06-27 | 2019-06-27 | Fabrication d'un dispositif de distribution de puissance électrique multiphasée |
Publications (1)
Publication Number | Publication Date |
---|---|
EP3815222A1 true EP3815222A1 (fr) | 2021-05-05 |
Family
ID=63579402
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19790614.2A Pending EP3815222A1 (fr) | 2018-06-27 | 2019-06-27 | Fabrication d'un dispositif de distribution de puissance électrique multiphasée |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP3815222A1 (fr) |
FR (1) | FR3083387B1 (fr) |
WO (1) | WO2020002847A1 (fr) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN113139235B (zh) * | 2021-04-22 | 2022-10-28 | 贵州天义电器有限责任公司 | 一种飞机曲面配电装置的设计方法 |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP3733312B2 (ja) * | 2001-10-26 | 2006-01-11 | 住友電装株式会社 | 車両用薄型ブラシレスモータの集中配電部材に用いるバスバーの製造方法 |
JP2010200400A (ja) * | 2009-02-23 | 2010-09-09 | Nippon Densan Corp | ステータ、バスバーユニット、モータ、及びパワーステアリング装置 |
EP2562915B1 (fr) * | 2011-08-24 | 2015-05-20 | Sumitomo Wiring Systems, Ltd. | Élément d'alimentation central et son procédé d'assemblage |
JP6053001B2 (ja) * | 2013-03-08 | 2016-12-27 | Kyb株式会社 | バスバーユニット |
-
2018
- 2018-06-27 FR FR1855799A patent/FR3083387B1/fr active Active
-
2019
- 2019-06-27 WO PCT/FR2019/051596 patent/WO2020002847A1/fr unknown
- 2019-06-27 EP EP19790614.2A patent/EP3815222A1/fr active Pending
Also Published As
Publication number | Publication date |
---|---|
WO2020002847A1 (fr) | 2020-01-02 |
FR3083387B1 (fr) | 2021-11-05 |
FR3083387A1 (fr) | 2020-01-03 |
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