EP4222842A1 - Moteur électrique comprenant une unité de câblage et un stator, et procédé de fabrication dudit moteur électrique - Google Patents

Moteur électrique comprenant une unité de câblage et un stator, et procédé de fabrication dudit moteur électrique

Info

Publication number
EP4222842A1
EP4222842A1 EP21820116.8A EP21820116A EP4222842A1 EP 4222842 A1 EP4222842 A1 EP 4222842A1 EP 21820116 A EP21820116 A EP 21820116A EP 4222842 A1 EP4222842 A1 EP 4222842A1
Authority
EP
European Patent Office
Prior art keywords
contacting
stator
connection
section
ring
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
Application number
EP21820116.8A
Other languages
German (de)
English (en)
Inventor
Jan Mildenberger
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.)
SEW Eurodrive GmbH and Co KG
Original Assignee
SEW Eurodrive GmbH and Co KG
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 SEW Eurodrive GmbH and Co KG filed Critical SEW Eurodrive GmbH and Co KG
Publication of EP4222842A1 publication Critical patent/EP4222842A1/fr
Pending legal-status Critical Current

Links

Classifications

    • 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
    • H02K3/52—Fastening salient pole windings or connections thereto
    • H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
    • H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
    • 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

  • Electric motor with an interconnection unit and a stator, and method for producing such an electric motor
  • the invention relates to an interconnection unit for an electric motor, a stator of an electric motor, an electric motor with this interconnection unit and this stator, and a method for producing this electric motor.
  • an electric motor has a stator on which a multi-phase winding is arranged.
  • the winding consists, for example, of the three phases II, V and W, it being possible for each phase to consist of a plurality of coils connected to one another.
  • the coils usually consist of winding wires that have to be connected to one another.
  • Various types of such interconnections using interconnection devices are known from the prior art:
  • DE 10 2012 023477 A1 discloses a switching element for an electric motor, a stator with such a switching element and an electric motor.
  • a stator of a three-phase electronically commutated direct current motor is known from DE 10 2017 223 519 B3.
  • DE 10 2016 211 230 A1 discloses a connection device for a stator, an electrical machine containing such a connection device and a method for producing such a device.
  • DE 10 2016206 657 A1 discloses an interconnection ring and a method for interconnecting winding wires of a stator.
  • DE 10 2015 200 093 A1 discloses a wiring board for a stator of an electrical machine, the wiring board having conductor elements which can be connected to the electrical winding.
  • the invention is therefore based on the object of further developing an electric motor with an interconnection unit and a stator and a method for its production, with the production effort being reduced during production and the electric motor being simpler, more cost-effective and more stable to produce.
  • the object is achieved with the interconnection unit according to the features specified in claim 1, with the stator according to the features specified in claim 5, with the electric motor according to the features specified in claim 9 and with the method for producing the electric motor.
  • connection unit for a stator of an electric motor, by means of which individual phases of a multi-phase electrical winding of the stator can be connected to one another, in particular in a star connection, and to phase connections for the power supply, are that the connection unit has a carrier ring surrounding a ring axis, in particular concentrically and has a plurality of, in particular exactly four or at least four, metallic conductor elements spaced apart from one another, which in particular are shaped essentially in the shape of a circular arc, the support ring at least partially enclosing the conductor elements, in particular completely and materially at least partially enclosing the conductor element cross-section, with each conductor element having at least one contacting section has for electrical contacting with a portion of the electrical winding, each conductor element, in particular relative to the ring axis , covers a circumferential angle range, wherein the circumferential angle area covered by each conductor element overlaps with at least one circumferential angle area covered by another conductor element, in
  • carrier ring is to be understood in such a way that this part is essentially ring-shaped.
  • This means that the carrier ring has approximately the shape of a ring with a central opening.
  • a ring plane and a ring axis are defined by this ring, which is intended to be clarified by the expression “a ring axis, in particular concentrically, surrounding the carrier ring”.
  • the carrier ring thus has a ring axis, by means of which specific directions in space can be defined.
  • the ring cross-section of the carrier ring ie a section perpendicular to the plane of the ring and through the ring axis, can be of any shape and can also be variable in the circumferential direction.
  • the cross section of the carrier ring ie a section parallel to the plane of the ring, can deviate from the perfect circular ring shape, for example due to introduced grooves, depressions, projections or the like.
  • a direction parallel to the ring axis is also referred to as the "axial direction".
  • the directions “circumferential direction” and “radial direction” are to be understood correspondingly in relation to the ring axis.
  • “Circumferential direction” is therefore to be understood as a direction parallel to the plane of the ring and concentrically around the ring axis, i.e. following the circumference of a circle around the ring axis.
  • “Radial direction” is therefore to be understood as a direction parallel to the ring plane and perpendicular to the ring axis, i.e. following a radius of a circle, with the circle lying in the ring plane and having the intersection point between the ring axis and the ring plane as its center.
  • the carrier ring is preferably made of plastic in order to electrically insulate the spaced metallic conductor elements contained in it from one another.
  • another electrically insulating material is also conceivable.
  • the expression "at least partially enclose” is intended to express that the conductor elements are not completely surrounded by the material of the carrier ring, but that certain sections, in particular the contacting sections, protrude from the carrier ring.
  • the carrier ring accommodates the conductor elements and thus ensures the spatial arrangement of the conductor elements in relation to one another. The conductor elements are therefore spaced apart from one another, ie they do not touch one another, ie are not in direct contact with one another.
  • the conductor elements are made of an electrically conductive material, preferably metal or metal sheet and in particular copper sheet.
  • the conductor elements are preferably designed in one piece and/or preferably as stamped and bent parts. The production can advantageously be carried out by means of water jet cutting or laser cutting.
  • each conductor element has at least one contacting section
  • the wording “wherein each conductor element has at least one contacting section” is to be understood in such a way that the contacting section is part of the conductor element.
  • the at least one contacting section is advantageously connected in one piece to the rest of the respective conductor element.
  • each conductor element covers, in particular relative to the ring axis, a specific circumferential angular range, i.e. an angular range in the circumferential direction. If the circumferential angular range covered by a first conductor element overlaps with the circumferential angular range covered by a second conductor element, this means that for certain angular ranges the first conductor element is arranged in front of or behind the second conductor element in the radial direction from the ring axis, i.e. overlaps in this projection direction . However, the two conductor elements do not touch one another, since they are radially spaced apart from one another, particularly in this overlapping angular range.
  • each conductor element overlaps at most with one further conductor element, in particular in circumferential angles and/or radial sections
  • each conductor element overlaps at most with one further conductor element, in particular in circumferential angles and/or radial sections.
  • Seen in the axial direction i.e. in the viewing direction parallel to the ring axis, there is Areas in which a conductor element is arranged in front of or behind another conductor element, i.e. they overlap in the axial direction.
  • a projection of the conductor elements in the axial direction onto a plane perpendicular to the axis of the ring would result in overlapping areas which are covered by at most two conductor elements.
  • the advantage of the interconnection unit is that it can be easily prefabricated and simple interconnection, in particular in a star connection, is made possible.
  • the carrier ring has exactly four conductor elements, in particular with the conductor elements each having a different shape.
  • the carrier ring encloses the conductor elements at least in sections in the cross section of the conductor element completely and in a material-to-material manner. This means that in the circumferential direction relative to the ring axis there are areas in which the cross section of the conductor elements is completely surrounded by the material of the carrier ring, for example plastic.
  • the support ring is preferably produced by an injection molding process, with the conductor elements preferably being partially overmoulded, ie enclosed, and the integral connection between the conductor element and the support ring thereby being produced.
  • the advantage here is that a stable connection can be produced between the conductor element and the carrier ring.
  • the at least one contacting section has an essentially U-shaped cross section in a plane parallel to the ring axis, i.e. in a tangential plane, and/or the at least one contacting section has a notch, which runs in the circumferential direction and in particular on the radial outwardly facing surface of the contacting section is introduced.
  • the notch can also be made on the radially inward-pointing surface of the contacting section.
  • three, in particular exactly three, of the multiple conductor elements each have exactly one connection section for electrical contacting with a phase connection, in particular with these three conductor elements each having a step-like offset section, in particular in a direction parallel to the ring plane, and/or two contacting sections each exhibit.
  • a step-like offset section is to be understood as meaning a kink in the conductor elements, which are advantageously shaped in sections essentially in the shape of a circular arc.
  • this kink runs in a direction parallel to the plane of the ring, so that, for example, a conductor element has two circular arc sections which differ in radius.
  • the advantage here is that a more compact design can be achieved.
  • the advantage of the two contacting sections is that a parallel star connection can thereby be realized in which, for example, each of the three phases has two parallel coils.
  • one, in particular exactly one, of the plurality of conductor elements has three or six, in particular exactly three or exactly six, contacting sections and in particular a step-like offset section, in particular in a direction parallel to the plane of the ring.
  • One conductor element can be described as a star point element, since it connects the coils of the multi-phase winding in a star point configuration.
  • a parallel star connection two coils in parallel per phase
  • the star point element has six contacting sections, whereas with a serial star connection (two coils in series per phase) only three contacting sections are necessary.
  • all of the contacting sections of the plurality of conductor elements protrude from the carrier ring in a direction parallel to the ring axis, that is to say in the axial direction.
  • the advantage here is that simple contacting of the winding sections with the conductor elements is possible.
  • all contacting sections are arranged on the radially outer side of the respective conductor elements.
  • all of the contacting sections and/or all of the conductor elements intersect at least one plane perpendicular to the axis of the ring.
  • connection unit is made possible in the axial direction.
  • all contacting sections are spaced essentially the same distance from the ring axis in the radial direction.
  • the advantage here is that a compact design of the interconnection unit is made possible in the direction parallel to the plane of the ring.
  • the stator has a stator core surrounding a stator axis with a closed yoke ring and a plurality of stator teeth pointing radially inwards from the yoke ring, in particular the stator core being designed as a laminated core, the stator furthermore having a substantially ring-shaped, has an insulating end disk, the end disk being attached to an axial end of the stator core in such a way that both the yoke ring and the stator teeth are covered by the end disk at least in the direction parallel to the stator axis, i.e.
  • the end plate having a plurality of connection projections, in particular projecting in the axial direction, for receiving winding wire sections, with each connection projection, in particular in axia Ldirection, one contacting element can be used in such a way that an electrical connection is made between the contacting element that can be used and a winding wire section accommodated in a respective connecting projection.
  • connection points serve as connection points instead of the winding wire ends for later interconnections, and these connection points can therefore be shaped advantageously in order to enable simpler and more reliable interconnection.
  • the phrase "substantially annular, insulating end plate” is to be understood as follows:
  • the end plate is a part which has a central opening and around it opening around is closed. Therefore, it can be described as "substantially ring-shaped".
  • the wording does not stipulate that the cross section of the end disk is a perfect circular ring.
  • the cross section can deviate from this shape, for example due to the introduction of grooves, depressions, projections or the like, both on the radially inner and on the radially outer circumference.
  • the wording "end plate” is only intended to imply that the expansion of the end plate in the axial direction is less than the expansion in a plane perpendicular to the stator axis, i.e. perpendicular to the axial direction.
  • the contacting elements are designed as insulation displacement contacts, so that the electrical connection between the respective contacting elements and the respective winding wire sections is made by means of an insulation displacement connection.
  • the advantage here is that a simple and secure connection to the winding wire is made possible.
  • the contacting elements can each be inserted completely into the respective connection projection.
  • the advantage here is that a compact design of the stator can be achieved.
  • the phrase "completely insertable" means that the entire contact element can be inserted into the connection projection and therefore does not protrude from the connection projection, particularly in the axial direction.
  • the contacting element is a separate part compared to the conductor element mentioned above.
  • the contacting element is therefore in particular not part of the interconnection unit.
  • the advantage of separate contacting elements that are part of the stator is that the stator can be prefabricated as a separate structural unit with contacted wires, in particular automatically, and the contacting elements then serve as connection points for the conductor elements of the interconnection unit.
  • the interconnection unit can also be prefabricated as a separate structural unit. The coils are then interconnected later by the interconnection unit being applied to the stator, with electrical connections being produced between the contacting sections of the interconnection unit and the contacting elements of the stator.
  • connection projections have shaft-like housing contours for, in particular complete, receiving a contacting element, with a slot-like depression being provided in the radially inner and the radially outer shaft wall for receiving a winding wire section.
  • the end plate has groove-like depressions running in the circumferential direction on its radially outer circumferential region for guiding winding wire sections, in particular with the groove-like depressions running exclusively in planes, in particular at most three, perpendicular to the stator axis and/or in particular with the groove-like depressions running in the circumferential direction are partially interrupted.
  • the advantage here is that when several stator teeth are wound with the same winding wire (through winding), exact guidance and positioning of the winding wire is made possible, and this also prevents different winding wires from touching one another.
  • the electric motor has a rotor arranged to be rotatable about an axis of rotation, a stator concentrically surrounding the rotor and an interconnection unit, the stator having a stator core surrounding a stator axis with a closed yoke ring and several of the yoke ring has stator teeth pointing radially inwards, in particular the stator core being designed as a laminated core, the stator also having a substantially ring-shaped, insulating end disk, the end disk being fastened to an axial end of the stator core in such a way that both the return ring and the stator teeth are covered by the end plate at least in the direction parallel to the stator axis, i.e.
  • the interconnection unit having a carrier ring surrounding a ring axis, in particular concentrically, and a plurality of, in particular exactly four or at least four, spaced-apart metallic conductor elements which, in particular in sections, are essentially shaped in the shape of a circular arc in which the carrier ring at least partially encloses the conductor elements, in particular completely and cohesively at least in sections in the cross section of the conductor element, with each conductor element having at least one contacting section for making electrical contact
  • each conductor element in particular in circumferential angle and/or radial sections, overlaps at most with one further conductor element, in particular wherein the ring axis of the interconnection unit, the stator axis of the stator core and the axis of rotation of the rotor coincide, with each contacting element being an elec tric connection can be produced between a winding wire section accommodated in a respective connection projection and a respective contacting section of a conductor element for connecting the winding wires to form a multi-phase winding, in particular with the connection unit for connection in the direction parallel to the axis of rotation, i.e. in the axial direction, being able to be plugged onto the end plate.
  • the advantage here is that quick, simple and reliable electrical interconnection of the winding wires is made possible. Because the winding wires in the stator are already electrically connected to the contacting elements, the contacting elements now serve as connection points for the conductor elements accommodated in the interconnection unit. This enables a simple connection of the interconnection unit to the stator, for example plugging in or plugging in. In this way, the stator can be prefabricated and, in a final processing step, the interconnection can be carried out safely using simple means.
  • each contacting section has a notch running in the circumferential direction, in particular with the notch being made on the surface of the respective contacting section pointing radially outwards or radially inwards, and with all contacting elements each having a spring section, with the respective spring section being such cooperates with the respective notch that a latching connection or clip connection can be produced between the respective contacting element and the respective contacting section.
  • the carrier ring has a circumferential collar section on its outer circumference, which can be slipped over the end plate in the axial direction, in particular the carrier ring and the end plate being releasably connectable to one another, in particular clip-connectable.
  • connection unit can be easily installed on the end plate of the stator.
  • An advantageous, stable mechanical connection also results here, in particular in conjunction with the latching or clip connection between the contacting elements and contacting sections. If, for example, the motor is used in an environment in which high shaking vibrations can occur, the load on the mechanical connection between contacting elements and contacting sections is reduced by the collar section mechanically fixing the support ring. As a result, it is less common for a mechanical and thus electrical connection between contacting elements and contacting sections to break off or be interrupted.
  • the advantage of the detachable connection compared to hot caulking, for example, is that the interconnection unit can be fitted in one work step. Additional work steps are not necessary.
  • the end disk has one or more centering pins, which interact with corresponding centering pin receptacles in the support ring in such a way that the support ring can be plugged onto the end disk in a twist-proof manner.
  • connection unit on the end plate of the stator is made possible.
  • a safeguard against axial displacement ie in particular a safeguard against loss, can also be implemented.
  • the carrier ring has at least one recess in the axial direction for the passage of a temperature sensor, with which the temperature of the winding can be measured.
  • the method has the following steps: producing an interconnection unit as described above, producing a stator as described above, each contacting element being used to establish an electrical connection between a winding wire section accommodated in a respective connection projection and a respective contacting section a conductor element is produced for interconnecting the winding wires to form a multi-phase winding, in particular the interconnection unit being plugged onto the end plate for interconnection in the direction parallel to the axis of rotation, ie in the axial direction.
  • the advantage here is that quick, simple and reliable electrical interconnection of the winding wires is made possible.
  • the method has the following steps: in a first step, manufacturing an interconnection unit according to one of claims 1 to 5, in a second step, manufacturing a stator according to one of claims 6 to 9, in a third step connecting the interconnection unit to the stator, wherein in the third step an electrical connection between a winding wire section accommodated in a respective connection projection and a respective contacting section of a conductor element is established by means of each contacting element for interconnecting the winding wires to form a multi-phase winding, in particular the interconnection unit for connection in the direction parallel to the axis of rotation, i.e. in the axial direction, is plugged onto the end plate.
  • connection unit can be easily installed on the end plate of the stator.
  • the interconnection unit produced in the first step is produced by the following sub-steps: in a first sub-step, production of metallic conductor elements by means of a stamping and bending process, in a second sub-step, the conductor elements are placed in an injection mold, in a third sub-step, the conductor elements are overmolded with an insulating material, in particular plastic.
  • the interconnection unit produced in the first step is either a first interconnection unit or a second interconnection unit, the first and the second interconnection unit each being produced by a method with the sub-steps mentioned above, the first interconnection unit comprising first conductor elements, which are divided into a first injection mold are inserted and the second interconnection unit comprises second conductor elements, which are inserted into a second injection mold, the number and/or shape of the first conductor elements differing from the second conductor elements and the first and second injection molds are identical or the first and the second injection mold are identical.
  • the advantage here is that different interconnection topologies can be produced with a single injection mold. For example, a parallel and a serial star connection can be implemented without having to use a separate injection mold for each.
  • the carrier ring made of plastic has the same shape in both cases, only the shape and/or number of the conductor elements embedded in the carrier ring differ depending on the interconnection topology.
  • the stator produced in the second step is produced by the following sub-steps: in a first sub-step, production of a stator core by means of stamped packaging of laminations, in a second sub-step production of an end disk by means of an injection molding process, in a third sub-step, placing the end disk on one end side of the stator core, in a fourth sub-step winding the stator teeth of the stator core with winding wire, in particular by means of an automated needle winding process, in a fifth sub-step inserting winding wire ends into the shaft-like depressions of the connection projections of the end plate and in a sixth sub-step inserting contacting elements into the connection projections for electrical contacting the winding wires with the contacting elements.
  • the advantage here is that automated and reproducible production can be carried out.
  • FIG. 1 shows an oblique view of an arrangement of conductor elements of a first interconnection unit according to the invention, which is suitable for a serial star connection.
  • FIG. 2 shows an oblique view of an arrangement of conductor elements of a second interconnection unit according to the invention, which is suitable for a parallel star connection.
  • FIG. 3 shows the first interconnection unit according to the invention in a plan view, which contains the arrangement of conductor elements shown in FIG.
  • FIG. 4 shows the second interconnection unit according to the invention in a plan view, which contains the arrangement of conductor elements shown in FIG.
  • FIG. 5 shows a perspective side view of a stator for an electric motor according to the invention.
  • FIG. 6 shows an oblique view of an electric motor according to the invention with a mounted connection unit.
  • FIG. 7 shows an oblique view of a contacting section and an associated contacting element before the interconnection unit is plugged on.
  • FIG. 8 shows an oblique view of a contacting section and an associated contacting element after the interconnection unit has been plugged on.
  • FIG. 9 shows a detailed view of a contacting element.
  • FIG. 10 shows a section of a cross section through the electric motor before the interconnection unit is pushed onto the end plate.
  • FIG. 11 shows a section of a cross section through the electric motor after the interconnection unit has been pushed onto the end plate.
  • the cross section runs through a different plane than in Figure 10.
  • FIG. 1 shows, by way of example, an arrangement of conductor elements (1, 2, 3, 4) for a first interconnection unit according to the invention, which is suitable for realizing a serial star connection.
  • the figure shows the spatial arrangement of the conductor elements before they are overmoulded with a plastic, for example by means of an injection molding process, in order to form the carrier ring.
  • the first embodiment has four conductor elements of the first type (1, 2, 3, 4), which are produced from flat metal strips by means of a stamping and bending process.
  • the conductor elements of the first type (1, 2, 3, 4) are essentially arranged in a plane parallel to the ring plane of the carrier ring. In other words, there is at least one plane parallel to the plane of the ring, which intersects all the conductor elements of the first type (1, 2, 3, 4).
  • the conductor cross section of all conductor elements of the first type (1, 2, 3, 4) is essentially rectangular and the extension in the direction of the ring axis, ie in the axial direction, is greater than the extension in the radial direction.
  • a round or polygonal cross section is also conceivable.
  • each phase element of the first type (1, 2, 3) has a connection section 6 for making electrical contact with a phase connection 7.
  • each phase element of the first type (1, 2, 3) each assigned to a phase. An electrical connection of the phases to coils of the winding is then established via the contacting sections 5 .
  • the stator has twelve stator teeth, with a coil being wound around each stator tooth using winding wire.
  • each of the three phases has four coils, these four coils being connected in series and each being wound through by means of a winding wire.
  • One end of each winding wire is connected, in particular indirectly, to a contacting section 5 of a phase element of the first type (1, 2, 3).
  • the other end of the winding wire is connected to one of the three Contacting sections 5 of the fourth conductor element of the first type 4, hereinafter referred to as the star point element of the first type, connected.
  • This connection is also advantageously carried out indirectly with the aid of a contacting element, as will be described in more detail later.
  • the star point element of the first type 4 ensures that the three phases are interconnected by means of a common star point, which is why it has three contact sections 5 .
  • All of the conductor elements of the first type (1, 2, 3) are essentially shaped in the form of a circular arc in sections.
  • the contacting web 8 of the first phase element of the first type 1 which is bent in the radial direction, does not run completely parallel to the connection section 6 in the ring plane, so that this phase element 1 can also be described as being shaped essentially like a circular arc.
  • the second and third phase elements of the first type (2, 3) each have a circular arc section and a straight section between the contacting web 8 and the connecting section 6.
  • the star point element of the first type 4 in turn has three circular arc sections 9, with a step-like offset section 10 being formed between each two circular arc sections 9.
  • two connected circular arc sections each have a different circle radius.
  • the offset section 10 runs in a direction which runs parallel to the plane of the ring. Alternatively, a course exactly in the radial direction is also conceivable.
  • the respective contacting webs 8 differ in their length in the radial direction. This length is selected in each case in such a way that the contacting sections 5 are essentially equidistant from the ring axis in the radial direction.
  • the contacting sections 5 have an essentially U-shaped cross section in a plane parallel to the axis of the ring, which can also be referred to as the tangential plane. They all protrude in the same direction, so that later only one side of the carrier ring is used for the interconnection. As can be seen from the figure, all the contacting sections are arranged on the radially outer side of the respective conductor elements.
  • each conductor element (1, 2, 3, 4) of the first type covers a circumferential angular range relative to the axis of the ring.
  • the covered circumferential angular range of the second phase element of the first type 2 overlaps in one angular range with the covered circumferential angular range of the first phase element of the first type 1 and in another angular range with the covered circumferential angular range of the star point element first type 4.
  • areas arise which are covered by two conductor elements of the first type and areas which are covered by only one conductor element of the first type.
  • the former are referred to as overlap areas.
  • each conductor element overlaps with at least one circumferential angle area covered by another conductor element.
  • the circumferential angle range of the first phase element of the first type 1 and of the third phase element of the first type 3 each overlaps with a further covered circumferential angle range of another conductor element of the first type, whereas the covered circumferential angle ranges of the second phase element of the first type 2 and the neutral point element 4 each have two overlap other covered circumferential angle areas of other conductor elements of the first type. The overlap takes place in each case in other angular ranges.
  • a further feature according to the invention is that in the direction parallel to the ring axis, ie in the axial direction, each conductor element overlaps at most one further conductor element, in particular in circumferential angle and/or radial sections.
  • each conductor element overlaps at most one further conductor element, in particular in circumferential angle and/or radial sections.
  • viewed in the axial direction in all areas only at most one conductor element of the first type is always arranged above another conductor element of the first type.
  • a projection in the axial direction onto a plane parallel to the plane of the ring creates areas that are covered by a maximum of two conductor elements, i.e. “axial overlapping areas”.
  • this axial overlap occurs only at two points, namely where the contacting webs 8 of the star point element of the first type 4 each run axially above the second and third phase element of the first type (2, 3).
  • the conductor elements are therefore not stacked one on top of the other in the axial direction, but there are only isolated areas in which at most two conductor elements are arranged one above the other. This makes it possible to achieve a compact design in the axial direction.
  • FIG. 2 shows, by way of example, an arrangement of conductor elements (21, 22, 23, 24) for a second interconnection unit according to the invention, which is suitable for realizing a parallel star connection.
  • This second connection unit is suitable for the same stator as the first connection unit, ie for a stator with twelve teeth, each of the three phases having four coils. In this case, however, two series-connected coils wound from a winding wire are connected to two other series-connected coils wound from a winding wire per phase.
  • the three phase elements of the second type (21, 22, 23) have two contacting sections 5 in addition to their connection section 6.
  • the star point element of the second type 24 correspondingly has six contacting sections in order to implement the star connection.
  • all conductor elements of the second type have a step-like offset section 10 . Furthermore, obvious similarities with the first exemplary embodiment that can be seen in the figure are not described again separately.
  • each conductor element overlaps at most one further conductor element, in particular in circumferential angle and/or radial sections.
  • a projection parallel to the ring axis, ie in the axial direction, onto a plane parallel to the ring plane only leads to areas that are covered by at most two conductor elements.
  • the third phase element of the second type 23 is arranged with a contacting section 5 axially over the star point element of the second type 24 and with another contacting section 5 axially over both the first and the second phase element of the second type (21, 22), these axial overlapping areas are located however, at different positions, in particular in the circumferential and/or radial direction.
  • the circumferential angle area covered by each conductor element overlaps with at least one circumferential angle area covered by another conductor element.
  • the covered circumferential angle range of the first phase element of the second type 21 even overlaps in a circumferential angle range with the covered circumferential angle ranges of all other conductor elements of the second type.
  • FIG. 3 shows a top view of a first embodiment of an interconnection unit 30 according to the invention.
  • This first interconnection unit 30 has a first carrier ring 31, which in this exemplary embodiment consists of plastic and was produced by means of an injection molding process. Inside the first carrier ring 31 - not visible in this view - the conductor elements of the first type (1, 2, 3, 4) are arranged in the spatial arrangement according to FIG. In the center of the first carrier ring 31, the ring axis (RA) is indicated by a point, to which the first carrier ring 31 is arranged concentrically, that is to say surrounding it. The essentially ring-shaped shape of the first support ring can be clearly seen in the figure.
  • the figure is a plan view of that side of the first carrier ring 31 which will later be placed on an end side of the stator for connection.
  • This view also clearly shows that the contacting sections 5 are all essentially at the same distance from the ring axis (RA).
  • the contact plug 32 contains the phase connections 7 (not visible) and can simply be plugged onto the first carrier ring 31 for easy contacting with the connection sections 6, which are not shown in this figure.
  • the first carrier ring 31 has two centering mandrel receptacles 33, which are used for the non-rotating assembly of the first carrier ring 31 on the end plate of the stator. This functionality is described more clearly in FIG.
  • the first carrier ring has first, second and third bulges (34, 35, 36) in the radial direction.
  • the second bulges 35 are shaped in such a way that a contacting section 5 can be accommodated and protrudes axially from the second bulge.
  • the third bulges also accommodate a contacting section 5, but they extend further in the circumferential direction, so that the position of the contacting section 5 can be changed in the circumferential direction, ie the contacting section 5 can be positioned at different positions.
  • the first bulges 34 do not accommodate any contacting sections 5 in the first exemplary embodiment; these are blind bulges 34, so to speak.
  • FIG. 4 shows a top view of a second embodiment of an interconnection unit 40 according to the invention.
  • This second interconnection unit 40 has a second support ring 41, which in this exemplary embodiment consists of plastic and was produced by means of an injection molding process.
  • the conductor elements of the second type 21, 22, 23, 24
  • the external geometric shape of the second carrier ring 41 is identical to the shape of the first carrier ring 31. This is due to the fact that both carrier rings (31, 41) were produced using the same, ie identical, injection mold. Alternatively, two identical injection molds can also be used.
  • the only difference between the two support rings (31, 41) is that they each accommodate different conductor elements in order to implement the different interconnection topologies.
  • the outer shape of the carrier rings (31, 41) is therefore adapted in such a way that there are corresponding bulges in the carrier ring for both interconnection topologies.
  • the first bulges 42 of the second exemplary embodiment correspond to the second bulges 35 of the first exemplary embodiment. Consequently, the second bulges 43 of the second embodiment correspond to the first bulges 34 of the first embodiment.
  • the assignment with contact sections 5 is just the opposite.
  • the third bulges (36, 44) of both embodiments each have a contacting section 5, although their position in the circumferential direction differs from one another.
  • Figure 5 shows a stator 50 according to the invention for an electric motor in a perspective side view, consisting of a stator core 51 designed in particular as a laminated core and an end sheath 52 attached to an axial end of the stator core 51.
  • the end plate 52 is preferably made of plastic and advantageously produced by means of an injection molding process .
  • a separate end disk ie one with a different shape, is used.
  • the functions described below are the same.
  • connection projections 53 distributed over its circumference, which protrude from the end disk 52 in the direction parallel to the stator axis SA, ie in the axial direction.
  • connection projections 52 advantageously have shaft-like housing contours, a slot-like depression 54 being provided in the radially inner and radially outer shaft wall for receiving a winding wire section 55 .
  • the wire ends of the coils accommodated on the stator teeth are thus accommodated by the slit-like indentations and spatially fixed.
  • an advantageously as an insulation displacement contact 56 executed contacting element inserted into the connection projection in the axial direction, so that an insulation displacement connection between the insulation displacement contact 56 and the winding wire 55 is formed.
  • the insulation displacement contact 56 later serves as a connection point for the interconnection unit (31, 41).
  • the end disk 52 has, on its radially outer peripheral region, groove-like indentations 57 running in the peripheral direction for guiding winding wire sections.
  • Such guides are necessary when several coils connected in series, each coil being wound around a respective stator tooth, are wound through by means of a winding wire. Since the respective stator teeth are not necessarily exactly adjacent, the winding wire can be easily and reliably guided to a stator tooth which is arranged further away in the circumferential direction by means of the indentations 57 . This ensures that different winding wire sections do not touch.
  • these indentations 57 advantageously run exclusively in planes perpendicular to the stator axis.
  • these depressions 57 are interrupted in sections by recesses in the end disk 52 in order to enable the wire to be guided into the interior of the stator, ie to the stator teeth.
  • a centering mandrel 58 which protrudes axially from the end disk 52 can also be seen in this figure.
  • FIG. 6 shows an oblique view of an electric motor 60 according to the invention with a mounted connection unit (30, 40).
  • the stator teeth 61 projecting radially inward can be seen here, which are covered in the axial direction by inward-pointing winding aids 62 of the end cap 52 .
  • the winding aids 62 ensure that the winding wire (not shown) wound around the stator teeth is electrically insulated from the face of the corresponding stator tooth. Insulating paper is advantageously used for insulation in the stator slots.
  • FIG. 7 shows an example of a section of a conductor element, for example the star point element 4 of the first type, before it is connected to the contacting element 56 .
  • the contacting element 56 was connected to the winding wire in a previous production step.
  • Figure 8 shows the conductor element 4 of Figure 7 already attached in the axial direction.
  • the attachment is advantageously carried out in such a way that a notch 70 made in the radially outward-facing surface of the contacting section 5 in the circumferential direction, in particular parallel to the ring plane, with a spring section 71 of the Contacting element 56 interacts in such a way that a snap-in occurs.
  • the notch can accordingly also on the Are mounted radially inwardly facing surface when the spring portion 71 of the contacting element 56 is shaped accordingly.
  • the notch 70 is made on both legs of the U-shaped contacting section 5, for example.
  • the shape of the contacting sections 5 can also be shaped differently, that is, the notch 70 is not only advantageous in connection with the U-shaped cross section.
  • the only advantage of the U-shaped cross section is that it can be adapted to the geometry of the wire, for example in that the radius of the U is slightly larger than the radius of the winding wire.
  • the insulation displacement connection is made by means of the two connecting brackets (72, 73).
  • FIG. 9 shows a detailed view of a contacting element 56 according to the invention with its two connecting brackets (72, 73) for receiving the winding wire.
  • the spring section 71 can also be seen. By attaching the contacting section 5, the spring section 71 is pressed in the direction of that side of the contacting element 56 to which it is attached. As soon as the tip of the spring section 71 reaches the notch 70 when plugging in, the elastic spring force causes the spring section 71 to clip into the notch 70. This produces a stable mechanical and correspondingly stable electrical connection.
  • FIG. 10 shows a section of a cross section along a radial direction through the electric motor before the interconnection unit (30, 40) is plugged onto the end disk 52.
  • the section runs through the center of a centering mandrel 58 or a centering mandrel receptacle 33.
  • This illustration shows how the winding wire 55 is guided in the groove-like depressions on the outside of the end plate 52 and how it is guided inside the stator 51 the stator teeth 61 and the winding aids 62 to form coils 100 .
  • the winding wire 55 is advantageously guided through notches 104 in the end plate 52 from the inside to the outside or vice versa. Wire 55 is not shown in notch 104 in the present illustration.
  • connection unit (30, 40) being pushed onto the end plate 52 in the axial direction, as indicated by the arrow. This is used for centering and fail-safe assembly one or more centering pins 58 of the end disk 52, which interact with corresponding centering pin receptacles 33 of the interconnection unit.
  • the carrier ring (31, 41) has a collar section 101 running around its outer circumference, which can be slipped over the end plate 52 in the axial direction.
  • a clip connection or latching connection for example by a latching lug 102 located on the collar section 101, which interacts with a latching lug receptacle 103 of the end plate and thereby causes latching.
  • a detachable connection is thus created in a simple manner, which contributes to the mechanical stability.
  • FIG. 11 shows a section of a cross section along the radial direction through the electric motor before the interconnection unit (30, 40) is plugged onto the end disk 52.
  • the section runs through the center of a connecting projection 53 in which a contacting element 56 is accommodated.
  • the winding wire which is advantageously connected to the contacting element 56 by means of an insulation displacement connection, is hidden in this representation. It can be seen how a contacting section 5 engages in the contacting element 56 in order to produce an electrical connection between the conductor element 24 and the contacting element 56 and thus with the winding wire 55 (not shown).
  • the contacting element advantageously has a spring section 71, the tip of which can be accommodated in a notch in the contacting section 5 in order to achieve a stable connection.
  • the notch is not visible in FIG. 11 because the section in the figure runs through the center of the contacting section 5 (compared to this, see the detailed view of FIG. 7).
  • the contacting section 5 reaches approximately to the bottom of the connection projection 53. In this bottom itself, as shown in FIG.
  • the winding wire is laterally surrounded by the advantageous U-shaped cross section of the contacting section 5 .
  • Figure 11 shows the connection principle for the second embodiment of the connection unit 40. This principle also applies correspondingly to the first connection unit 30.
  • Reference List

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Windings For Motors And Generators (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)

Abstract

L'invention se rapporte à un moteur électrique comprenant un stator et une unité de câblage, ainsi qu'à un procédé de fabrication du moteur électrique. Grâce à l'unité de câblage, il est possible d'interconnecter, en particulier dans une connexion en étoile, des phases individuelles d'un enroulement électrique polyphasé du stator, et de connecter les phases individuelles à des connexions de phase afin de fournir de l'énergie. L'unité de câblage est munie d'une bague de support entourant un axe de bague, en particulier de manière concentrique, et est munie d'une pluralité, en particulier exactement quatre ou au moins quatre, d'éléments conducteurs métalliques mutuellement espacés qui présentent sensiblement, en particulier dans des parties, une forme d'arc de cercle. La bague de support entoure au moins partiellement les éléments conducteurs, notamment au moins des parties de la section transversale de l'élément conducteur, complètement et d'une manière solidaire. Chaque élément conducteur est muni d'au moins une partie contact permettant d'entrer en contact électrique avec une partie de l'enroulement électrique. Chaque élément conducteur, en particulier par rapport à l'axe de bague, recouvre une plage angulaire circonférentielle, la plage angulaire circonférentielle couverte par chaque élément conducteur chevauchant au moins une plage angulaire circonférentielle couverte par un autre élément conducteur, en particulier les plages angulaires circonférentielles couvertes de tous les autres éléments conducteurs, et dans une direction parallèle à l'axe de bague, c'est-à-dire dans la direction axiale, chaque élément conducteur chevauchant au plus un autre élément conducteur, en particulier en termes d'angle circonférentiel et/ou de partie radiale.
EP21820116.8A 2020-09-30 2021-09-08 Moteur électrique comprenant une unité de câblage et un stator, et procédé de fabrication dudit moteur électrique Pending EP4222842A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102020005986 2020-09-30
PCT/EP2021/025332 WO2022069069A1 (fr) 2020-09-30 2021-09-08 Moteur électrique comprenant une unité de câblage et un stator, et procédé de fabrication dudit moteur électrique

Publications (1)

Publication Number Publication Date
EP4222842A1 true EP4222842A1 (fr) 2023-08-09

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EP21820116.8A Pending EP4222842A1 (fr) 2020-09-30 2021-09-08 Moteur électrique comprenant une unité de câblage et un stator, et procédé de fabrication dudit moteur électrique

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EP (1) EP4222842A1 (fr)
DE (1) DE102021004542A1 (fr)
WO (1) WO2022069069A1 (fr)

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2923951B1 (fr) 2007-11-19 2009-11-27 Sonceboz Automotive Sa Ensemble de connexion electrique pour moteur sans balai.
DE102012023477A1 (de) 2012-11-28 2014-05-28 Ziehl-Abegg Se Schaltelement für einen Elektromotor, Stator mit einem solchen Schaltelement und Elektromotor
WO2015093138A1 (fr) * 2013-12-16 2015-06-25 三菱電機株式会社 Dispositif d'entraînement mécatronique et procédé permettant de fabriquer ce dernier
DE102014012824A1 (de) * 2014-08-28 2016-03-03 Audi Ag Schaltring für eine Elektromaschine
DE102015200093A1 (de) 2015-01-07 2016-07-07 Robert Bosch Gmbh Verschaltungsplatte eines Stators für eine elektrische Maschine und Verfahren zum Herstellen einer solchen
DE102016206657A1 (de) 2016-04-20 2017-10-26 Robert Bosch Gmbh Verschaltungsring und Verfahren zum Verschalten von Wicklungsdrähten eines Stators
DE102016211230A1 (de) 2016-06-23 2017-12-28 Robert Bosch Gmbh Verschaltungsvorrichtung eines Stators, elektrische Maschine beinhaltend eine solche Verschaltungsvorrichtung, und Verfahren zum Herstellen einer solchen
DE102017216084A1 (de) 2017-09-12 2019-03-14 Robert Bosch Gmbh Stator für eine elektrische Maschine, eine elektrische Maschine und Verfahren zum Herstellen eines solchen Stators
DE102017216080A1 (de) * 2017-09-12 2019-03-14 Robert Bosch Gmbh Stator für eine elektrische Maschine, eine elektrische Maschine und Verfahren zum Herstellen eines solchen Stators
DE102017223519B3 (de) 2017-12-21 2018-10-11 Bühler Motor GmbH Stator eines dreiphasigen elektronisch kommutierten Gleichstrommotors
DE102018215787A1 (de) 2018-09-18 2020-03-19 Robert Bosch Gmbh Stator für eine elektrische Maschine, eine elektrische Maschine und Verfahren zum Herstellen einer elektrischen Maschine

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DE102021004542A1 (de) 2022-03-31

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