EP4275265A1 - Procédé pour fabriquer un stator ainsi que stator - Google Patents

Procédé pour fabriquer un stator ainsi que stator

Info

Publication number
EP4275265A1
EP4275265A1 EP22757235.1A EP22757235A EP4275265A1 EP 4275265 A1 EP4275265 A1 EP 4275265A1 EP 22757235 A EP22757235 A EP 22757235A EP 4275265 A1 EP4275265 A1 EP 4275265A1
Authority
EP
European Patent Office
Prior art keywords
winding
stator
winding base
base body
bodies
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
EP22757235.1A
Other languages
German (de)
English (en)
Inventor
Markus OETTEL
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.)
Additive | Drives GmbH
Original Assignee
Additive | Drives GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Additive | Drives GmbH filed Critical Additive | Drives GmbH
Priority to EP23187853.9A priority Critical patent/EP4253051A3/fr
Priority to EP23187808.3A priority patent/EP4249253A3/fr
Priority to EP23187634.3A priority patent/EP4253050A3/fr
Priority to EP23187735.8A priority patent/EP4249251A3/fr
Priority to EP23187779.6A priority patent/EP4249252A3/fr
Publication of EP4275265A1 publication Critical patent/EP4275265A1/fr
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0025—Shaping or compacting conductors or winding heads after the installation of the winding in the core or machine ; Applying fastening means on winding heads
    • H02K15/0037—Shaping or compacting winding heads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0056—Manufacturing winding connections
    • H02K15/0068—Connecting winding sections; Forming leads; Connecting leads to terminals
    • H02K15/0081—Connecting winding sections; Forming leads; Connecting leads to terminals for form-wound windings

Definitions

  • the invention relates to a method for producing a stator for an electrical machine, in particular for an electric motor or generator, and a corresponding stator.
  • Methods for producing a stator for an electrical machine are known in principle. For example, it is known to introduce solid copper wires (e.g. flat copper wires) into the stator slots of the laminated core by means of what is known as hairpin technology.
  • solid copper wires e.g. flat copper wires
  • Hairpins can replace windings that are produced using classic winding processes such as needle winding.
  • hairpins represent a different form and/or type of winding.
  • a hairpin can be produced in particular by a wire, for example a solid copper wire, and/or reshaping of a wire.
  • the known methods for producing a stator are regarded as fundamentally in need of improvement.
  • the known methods are comparatively complex, in particular due to the type, number and/or extent of the required forming and/or forming tools felt and / or they do not meet the requirements placed on the stator, in particular with regard to the installation space, thermal and / or electrical properties in the desired manner.
  • the task with stators is to further optimize their parameters, in particular with regard to the installation space, thermal and/or electrical properties, and also to design them flexibly. This is also due to the fact that electric motors are used more widely, in particular when they can better meet the requirements placed on them, such as energy efficiency, flexibility and/or a limitation and/or reduction of the required installation space.
  • the at least one object is achieved by a method for producing a stator, comprising at least one winding, preferably at least one hairpin winding for an electrical machine, in particular for an electric motor or generator, comprising the steps: - Bringing in, in particular plugging in (or other insertion), of winding base bodies in stator slots and
  • the at least one object is achieved in particular by a method for producing a stator, in particular for an electric motor or an electric generator, comprising at least the steps:
  • the at least one section of the at least one winding overhang, the winding overhang or the winding overhangs is preferably applied in such a way that the at least one winding is formed in the stator as a result.
  • the at least one object is achieved in particular by a method for producing a stator, in particular for an electric motor or an electric generator, comprising at least the steps:
  • the method according to the invention can in particular reduce the thermal and/or electrical power loss in the stator and/or reduce and/or minimize the installation space for the stator. In addition, a fast, flexible and efficient production is possible.
  • the winding overhang can have connecting elements that are produced by an additive method, in particular by direct additive application to the winding base body, and/or connect a first and a second winding base body in such a way that the height and/or the installation space of the winding overhang is minimized and/or or be reduced.
  • At least one connecting element is essentially triangular and/or extends at an angle, preferably of more than 120° and/or between 60° and 80° in relation to a longitudinal direction of the winding base body.
  • At least one end winding is preferably produced or produced entirely by additive application.
  • Additive application or production is understood to mean, in particular, production by means of 3D printing, in particular 3D copper printing, and/or by means of an additive printing process and/or a primary shaping process.
  • the elements and/or connections of the end winding are therefore preferably produced in one piece and directly in their final form, in particular by applying building material in layers and preferably selective hardening, preferably using a beam impinging on it, for example a laser beam.
  • Additive application is therefore preferably understood to mean applying a component in layers to an existing, prefabricated component without using welded connections, in particular without using welded connections between two or more prefabricated components, and/or forming tools and/or tools in general.
  • a layered application means in particular the creation or manufacture of a component by layered application to an existing other component.
  • the end winding is preferably produced by means of a single production, work or process step.
  • the additive application preferably takes place on the basis of data sets that define the respective geometries. These data sets are preferably generated during construction and/or by a CAD or CAE program. These data sets then control a 3D printing system, which applies the construction material additively, in particular in layers, and preferably selectively solidifies it, and thus produces at least one section of the at least one end winding and/or the laminated core.
  • the stator is preferably manufactured in a two-stage process.
  • the active area of the stator with the winding carrier and its stator slots, the first end winding and the winding base bodies extending through the stator slots is produced in particular in the first stage.
  • the laminated core of the stator with the stator slots is preferably produced and the winding base bodies are introduced into the stator slots or also produced additively at the same time as the laminated core of the stator.
  • the winding base bodies can be produced additively at least partially within the stator slots.
  • the winding base bodies preferably also form the first end winding.
  • both the first and second stages of manufacturing the stator are by or include an additive process.
  • both the first and the second stage of the production of the stator comprise an additive method, with the winding base bodies being produced additively in the first stage, in particular, which are then inserted into the winding carrier in the axial direction.
  • the winding base body and the winding support can also be produced together in an additive process.
  • One idea of the invention is, on the one hand, to separate the production of the winding overhang from the production of corresponding winding base bodies in terms of process and, on the other hand, to produce the winding overhangs by additive application (or an additive manufacturing process, for example laser sintering or laser melting), and in doing so in particular the properties of the stator to improve overall.
  • one idea of the invention is to produce at least one end winding at least essentially without reshaping, in particular by direct application to the winding base body.
  • undesired changes in wall thickness, springback, stretching and/or material flow in the end winding can be avoided or reduced, which otherwise arise or can arise in particular as a result of forming.
  • twisting, twisting and/or twisting in the, in particular upper and/or lower, area of the end winding and/or for connecting the end winding is not required.
  • bending and/or twisting in the area of the end winding, in particular the upper one, is not required can also reduce production costs and time, while at the same time the disadvantages associated with bending and/or twisting in terms of tolerances in the course of connecting elements and deterioration of conductivity can be reduced or avoided.
  • radii of connecting elements in the end winding can be minimized or set to zero or almost zero and/or cross sections, distances and/or layer jumps can be adjusted in a targeted and precise manner.
  • tolerances in production are reduced, in particular with regard to the course and cross sections of the connecting elements.
  • Another idea of the invention is to do without welds and/or segmentations of the laminated core.
  • this can improve the electrical and magnetic properties of the laminated core and thus also of the electrical machine as a whole.
  • dispensing with welds in the area of the winding overhang, in particular for connecting the winding base bodies, can further improve the conductivity in the area of the winding overhang.
  • the cross section of the stator slots within the laminated core can vary in the radial and/or axial direction of the stator, so that at least some of them have a smaller cross section than the conductors routed through them.
  • transition points, for example connections can be realized within the laminated core, in particular within the slots, which require a larger cross section than the other conductor parts.
  • welding is understood as meaning the non-detachable connection of existing components, for example electrical conductors, using heat and/or pressure.
  • additive application is understood to mean in particular a layered application of building material which is selectively solidified, in particular using a beam impinging on it, for example a laser beam. Therefore, two existing components are preferably connected during "welding", whereas during additive application in particular a second component is applied in layers to an existing first component and is therefore preferably newly created thereon, in particular on the basis of a control of the hardening by a data set.
  • welding in this sense should in particular not be understood as an additive manufacturing process.
  • Applications of the invention are in particular in the field of prototyping and/or in series production.
  • At least one or more or all of the winding base bodies are/are partially or completely not produced by an additive manufacturing process, preferably by forming a wire, in particular copper wire, and/or drawing from wire, in particular copper wire.
  • a (respective) winding base body can be introduced in such a way that the winding base body is already assembled outside the slot and/or is not first built up in the slot.
  • winding base bodies can be I-shaped or U-shaped.
  • stator blanks can be interconnected by pressing on one end winding (or both end windings).
  • winding blanks can include mounted, cast and insulated (in particular by means of primary insulation) conductors in a laminated stator core.
  • stator blank can thus have a different behavior (for example with regard to a torque and/or a speed, etc.) as a result of different interconnections.
  • This different interconnection is preferably produced exclusively digitally, in the construction, in particular by varying data sets for the additive application, and/or without using physical tools.
  • the data sets are preferably generated using a CAD or CAE program.
  • winding base bodies can be adapted, combined and/or varied in a targeted manner in order to optimize the stator for a specific frequency response, for example.
  • the cross-sectional areas of individual winding base bodies can also be maximized for low frequencies.
  • a stator slot can be divided into segments running next to one another in the axial direction, with the or each winding base body at least essentially completely filling the respective segment.
  • the stator is preferably provided for operating frequencies of a current through the winding base bodies of at most 10 kHz.
  • the cross section of one or each winding base body can be divided into at least two or at least three partial cross sections, which are electrically insulated from one another, in particular in order to reduce the current displacement inside the conductor caused by skin effects, for example, and thus the eddy current losses to reduce.
  • the stator is preferably provided for operating frequencies of a current through the winding base bodies of at least 100 kHz.
  • the invention enables or can enable the following improvements in the manufacture of a stator:
  • connection elements in the end winding can be defined exactly or more exactly and with small tolerances and/or distances with regard to their own course and their course relative to other connection elements.
  • Loss reduction Electrical and/or thermal losses in the stator can preferably be reduced since, in particular for the connection of the end winding, neither welding points nor segmentation of the laminated core, nor bending or twisting processes are required.
  • conductor cross-sections can be adjusted or increased in a targeted and precise manner at required points in order to reduce current densities there.
  • conductor cross-sections can be adapted to the frequencies prevailing in the stator.
  • winding bodies can be combined in the stator in order to adapt the electrical properties specifically to the existing parameters, e.g Example operating frequencies to adjust.
  • different winding bodies can be flexibly interchanged with one another.
  • a first winding base body and a second winding base body can be connected via connecting elements to form an endless loop and/or endless winding.
  • At least one winding base body can be arranged in an at least partially closed stator slot.
  • the stator slot can in particular be at least partially closed towards at least one end winding and/or towards an inner side and/or on all sides.
  • a stator can include a first additively applied end winding, which is printed on a first end face of a cylindrical winding carrier or laminated core. On the opposite end there is preferably a second additively applied end winding, which is preferably also printed on the winding carrier.
  • a stator can include a single additively applied end winding, which is printed on the winding base body on a first or second end face of a cylindrical winding carrier or laminated core.
  • a second end winding is preferably formed by a winding base body having an arc, in particular essentially U-shaped or also V-shaped.
  • These winding base bodies preferably extend with their limbs through different stator slots, these merging into the respective arcs on the opposite end face, on the second end winding.
  • the winding carrier, the stator blank or the laminated core preferably comprises a plurality of stator slots which preferably extend along a circumference of the winding carrier or the laminated core, in particular in the axial direction. Winding base bodies can be arranged in different radial positions within the stator slots.
  • connection cross-section and the connection angle are flexibly defined.
  • the course of the connecting elements in the end winding can be defined flexibly and with low tolerances.
  • both the structural height and the radial thickness can be reduced and/or adapted to the specific requirements, in particular by smaller tolerances and distances between the connecting elements and/or by adapting cross sections.
  • the invention also makes it possible to increase the proportion of the active area of the stator in relation to its overall height or length.
  • the active area is understood to mean the space within the winding carrier or laminated core.
  • the overall length of a stator is a balance or sum of the length or height of the end windings and the active length.
  • An active length is understood to mean, in particular, a length of the active area in the axial direction.
  • the associated electric motor or electric generator can in particular be an internal rotor, in which case the rotor running on the inside can be designed as a passive armature.
  • the associated electric motor or electric generator can be an external rotor.
  • the winding base bodies can in particular be so-called hairpins. These can be made either by bending raw material or directly by an additive process, preferably having two legs that are substantially rectilinear and parallel to each other run and extend through the active area of the stator when installed.
  • the production using an additive process enables a targeted adaptation of the respective cross-section to the specific requirements.
  • the cross section within the active area can be designed in such a way that it essentially completely fills the respective grooves or the intended part of the grooves.
  • the connection area between the two legs can be designed with a different, for example flat, cross-section.
  • All hairpins of a stator are preferably produced in a single additive work step and then inserted together into the winding support. Then, in the second step, the second end winding can be applied additively.
  • the hairpins can be combined to form a basket, in which case the hairpins can be bent from individual wires and assembled to form the basket.
  • the winding base bodies are preferably inserted into the winding support, the stator blank or the laminated core in such a way that they end approximately flush with the end face thereof, so that the winding overhang can then be applied additively.
  • the invention also enables the cross-sections in the stator to be adapted to changing requirements at very short notice.
  • a first stator with first electrical properties and/or cross sections and directly subsequently a second stator with second electrical properties and/or cross sections can be produced using the same or the same, in particular identical, raw material, in particular raw material type.
  • aluminum materials or aluminum powder, copper materials or copper powder, in particular pure copper, pure aluminum, aluminum alloys or copper alloys serve as raw materials.
  • the copper materials or copper powder used preferably have a purity of more than 99.5%.
  • High-purity copper and/or high-purity aluminum preferably offers good electrical and thermal conductivity.
  • the tensile strength is preferably at least 170 MPa and/or the yield point is at least 120 MPa and/or the elongation at break is more than 20%.
  • At least one of the winding base bodies can be designed in a U-shape (or as a U-pin) in particular for applying a winding overhang on both sides by means of an additive manufacturing process.
  • a U-shaped winding base body is to be understood as meaning a winding base body whose open ends are arranged at least essentially on the same side.
  • At least one of the winding base bodies can be I-shaped (or as an I-pin), preferably if a winding overhang is produced or produced on both sides by additive application.
  • An I-shaped configuration of the corresponding winding base body is preferably to be understood as meaning a winding base body whose open ends (before the connection) are arranged on opposite sides. The winding base does not (but can) be straight.
  • the winding base bodies can comprise at least one conductor type, in particular different conductor types.
  • a first winding base body can be formed from a first conductor type and a second winding base body can be formed from a second conductor type that differs from the first conductor type.
  • the first winding base body and the second winding base body can be introduced radially and/or axially adjacent with respect to a central axis of the stator.
  • a winding base body can consist of a first conductor type in a first section and in a second section attached to the first section in the axial/longitudinal direction adjoining portion may be formed of a second conductor type different from the first conductor type.
  • the first conductor type can have a first conductivity and the second conductor type can have a second conductivity, so that ohmic losses during operation of the electrical machine can be reduced by suitably varying the conductivity.
  • the first type of conductor can have a first cross section/cross-sectional profile and the second type of conductor can have a second cross section/cross-sectional profile, so that thermal and/or electrical losses during operation of the electrical machine are reduced in sections with a high current flow.
  • the first conductor type can have a first number of parallel strands/conductors and the second conductor type can have a second number of parallel strands/conductors, so that losses when the electrical machine is operated at high frequencies are preferably reduced in the required sections.
  • the connecting elements can have a third conductivity, cross section/cross-sectional profile and/or number of parallel strands/conductors, so that losses during operation of the electrical machine are preferably reduced.
  • a conductor type can in particular be a stranded wire.
  • at least one of the basic winding bodies can comprise a strand at least in one section, with the basic winding body in particular consisting of a large number, in particular at least 30, extending along a longitudinal direction, in particular from one another and/or by at least one lacquer layer insulated and not specifically layered, thin , Preferably round, individual wires or veins is formed, in particular with a diameter of at least 0.1 mm or at least 0.5 mm.
  • At least one of the winding base bodies and/or conductor type can be produced at least in a section by an additive manufacturing process, with at least a second area having a lower conductivity than at least a first area in a cross section.
  • the second region can include at least one gap, intermediate space or cavity extending transversely through the cross section and/or longitudinally through the winding base body, in particular along a straight line and/or plane, so that the winding base body is split into at least two partial winding base bodies.
  • the (respective) second region can be formed at least in sections by a (preferably filled, e.g. gas-filled and/or filled with a liquid and/or solid material) cavity or intermediate space.
  • a preferably filled, e.g. gas-filled and/or filled with a liquid and/or solid material
  • the (respective) second region can be introduced during additive manufacturing by multi-material processing, for example in such a way that the respective first region(s) are provided by supplying a first material and the respective second region(s). /n by supplying a different material, for example with a lower conductivity.
  • the at least one second region (possibly several or all of the second regions) is (are) preferably designed to be electrically insulating, more preferably at least in sections formed by an electrically insulating material and/or at least in sections by a (e.g. gas or air-filled ) cavity formed.
  • a cavity can result from the removal of build-up material that is still in powder form. For this purpose and/or for other reasons, openings can be provided since end areas (otherwise) may be completely closed (particularly sintered).
  • the (respective) second area can result from non-exposure or a different exposure. It can run from one layer level to the next layer level in such a way that at least a certain surface area overlaps, so that a continuous cavity (gap) is produced. At least one second (possibly several or all second) region(s) can (can) extend over at least 0.5 cm of the length of the conductor (or the winding), if necessary over at least 1.0 cm or at least 2, 0 cm.
  • the partial winding base bodies can only be electrically connected to one another by the end winding.
  • the conductivities to be compared of the first areas and of the at least one second area should preferably be determined at a temperature of 20.degree.
  • the conductivity of at least one second region is preferably a maximum of 0.5 times, more preferably a maximum of 0.1 times, even more preferably a maximum of 0.001 times or a maximum of 0.001 times the electrical conductivity Conductivity of at least one (possibly several or all) first areas.
  • the electrical conductivity of at least (possibly several or all) first areas is preferably at least 0.1 ⁇ 10 6 S/m, more preferably at least 1.0 ⁇ 10 6 S/m, more preferably at least 20 ⁇ 10 6 S/m and /or at most 200 x 10 6 S/m or at most 100 x 10 6 S/m.
  • the conductivity of at least one second area can be at most 1 ⁇ 10 6 S/m, possibly at most 0.1 ⁇ 10 6 S/m, further alternatively at most 1.0 ⁇ 10 3 S/m , further alternative at most 1.0 S/m, further alternative at most 1.0 x 10 3 S/m, even further alternative at most 1.0 x 10 6 S/m, even further alternative at most 1.0 x 10 9 S/m m and/or at least 1.0 x 10 20 S/m, alternatively at least 1.0 x 10 15 S/m.
  • a conductor type can in particular be solid copper, a waveguide and/or a hairpin.
  • at least one of the basic winding bodies can be made of solid copper, hairpin and/or as a waveguide, at least in a section, wherein the basic winding body can be made in particular of a single copper wire extending in a longitudinal direction, in particular with a (circular) round and /or flat and/or rectangular cross-section and/or as flat wire and/or an outer diameter of at least 1.0 mm and/or with an inner diameter of at least 0.5 mm.
  • a ladder type can in particular be a Roebel bar.
  • at least one of the basic winding bodies can comprise a Roebel bar in at least one section, with the basic winding body being formed in particular from a large number, in particular at least 10, of thin individual wires or cores, in particular insulated from one another and specially layered, extending along a longitudinal direction, preferably helically is, in particular with a diameter of at least 0.4 mm.
  • only one end winding in particular in the case of U-shaped winding base bodies
  • both end windings can also be produced at least in sections by additive application, in particular by layered application of a construction material and additive hardening of the construction material by irradiation with at least one beam impinging on the construction material, particularly in the case of I-shaped winding base bodies.
  • the winding base bodies are preferably spread apart (against one another) at their ends (in particular directly adjacent to a slot liner or insulating paper (or: slot insulation) which is/are arranged in the stator slot).
  • a spreading can be realized in that the winding base bodies are already produced in a mold so that after their arrangement in the corresponding slot they are spread open (against one another) or spread apart from one another.
  • the winding base bodies can be spread open at their ends (in particular directly adjacent to the slot liner) (in a separate step, after arranging/inserting into the stator slot, in particular before the additive application of the corresponding winding overhang).
  • Such a spreading or spreading the conductor ends apart
  • optional post-processing steps can be facilitated by improved accessibility (e.g. in the case of surface treatment and/or insulation).
  • the spreading preferably begins as directly as possible adjacent to a slot liner (or at one end of the respective slot liner), in particular in order to lose as little end winding height as possible.
  • the spread can be produced directly during the manufacturing process (for example, in an additive manufacturing process for the winding base body) or by mechanical forming (either before or after introduction into the stator slot).
  • a slot liner can be understood in particular as an insulating paper or a slot insulation become.
  • the slot liner is intended in particular to insulate the laminated core electrically from the winding base bodies.
  • the winding base bodies are spread open towards or towards one another at at least one of their ends. At their ends, the winding base bodies that are spread out towards or towards one another are preferably at a distance of at least 0.5 mm, preferably at least 1.0 mm, from one another.
  • the winding base body section in which the winding base bodies are spread out against or to each other, has a height of at least 5 mm, preferably at least 10 mm, in the axial direction.
  • a winding base section in which the winding bases are not spread apart relative to one another protrudes in the axial direction by at least 5 mm, preferably at least 10 mm, relative to the stator blank or laminated core.
  • the winding base bodies project in the axial direction by at least 10 mm, preferably at least 20 mm, from the stator blank or laminated core.
  • the winding base bodies can be produced by drawing and/or forming, possibly drawn, blanks and/or an additive manufacturing process. Combinations are also conceivable in which the winding base bodies are produced partly by forming a blank and partly by an additive manufacturing process. It is also conceivable that at least one winding body is produced by (conventional) forming and at least one winding body is produced by an additive manufacturing process.
  • the winding (particularly in the area of the end winding) has a changing cross section.
  • the cross section can increase (at least in sections) and/or decrease (at least in sections) and/or change its shape (at least in sections).
  • a cross-sectional area particularly preferably remains constant, with the shape of the cross-section changing.
  • a cross-sectional shape remain constant while the cross-sectional area changes.
  • both the cross-sectional area and the cross-sectional shape can change. In particular, this allows space to be gained between the individual conductor sections, so that less shaping work is required, for example.
  • the dimensions of the conductor (or of the winding as a whole) can be adjusted advantageously as a result.
  • the additive application also allows connectors to run along one layer each with a layer jump in between.
  • a plurality of at least essentially identical stator blanks can be produced, which are provided with different winding overhangs.
  • different stator structures or stator types which are preferably optimized for specific applications, can be produced in a comparatively simple manner.
  • ends of the winding base bodies can be leveled (or brought to a common level), in particular by milling, and/or cleaned.
  • ends of the winding base bodies can be leveled (or brought to a common level), in particular by milling, and/or cleaned.
  • a subsequent additive application of the end winding structures can take place in a particularly simple manner.
  • a position and / or extent or shape of the ends of the winding base body can possibly before the additive application by a z.
  • B. optical, measuring device are determined. This enables a precise additive manufacturing process to be carried out in a simple manner.
  • stator comprising a winding, preferably a hairpin winding, for an electrical machine, in particular an electric motor or generator, produced using the above method.
  • the object mentioned above is also achieved in particular by an electrical machine, in particular an electric motor or generator, comprising the above stator. Further embodiments emerge from the dependent claims.
  • the object is achieved in particular by a stator, in particular for an electric motor or for an electric generator, the stator comprising
  • stator slots for introducing and/or supporting winding base bodies and/or windings, - winding base bodies inserted, in particular inserted (or otherwise introduced) into the stator slots and
  • At least one winding head with at least one additively applied section, in particular at least one additively applied winding head or two additively applied winding heads.
  • the at least one section of the at least one is/are preferred
  • FIG. 1 shows a schematic view of an embodiment of a stator (partially in an exploded view);
  • FIG. 2 shows a schematic representation of a further embodiment of a stator (partially in an exploded representation);
  • FIG. 3 shows a section of a stator blank (without end winding); 4 shows a further detail view of a stator blank (without end winding);
  • 5 shows a schematic representation of winding base bodies
  • 6 shows a schematic oblique view of a stator with a winding overhang
  • FIG. 7 shows a schematic representation of a conductor according to an embodiment in a first side view
  • FIG. 8 shows the ladder according to FIG. 7 in a second side view
  • Fig. 9 shows a schematic view of a single coil (partially in
  • FIG. 10 shows the individual coil according to FIG. 9.
  • the same reference numerals are used for the same and identically functioning parts.
  • FIG. 1 shows a schematic representation of a stator according to an embodiment. This has a (possibly conventionally manufactured) stator blank 10 with a first end winding 11 .
  • the stator blank 10 itself has no second end winding.
  • the second end winding 12 is then only printed on (as indicated in FIG. 1) by an additive manufacturing process (in particular laser sintering).
  • FIG. 1 A fundamentally similar solution is shown in FIG. In contrast to FIG. 1, however, both the first end winding 11 and the second end winding 12 (on both sides) are printed onto the stator blank 10 here.
  • FIG. 3 shows a section of a stator blank 10 with (in this stage of manufacture) open ends of winding base bodies 13 (see also FIG. 5). These are or will be spread apart (before the step of additive application of the winding head or winding heads), as can be seen in particular in FIGS. In Fig. 6 is then the stator blank with printed end winding
  • the spreading begins immediately adjacent (above or below) a slot liner (not visible in the figures) or insulating paper.
  • the expansion can, for example, be produced directly by an additive manufacturing process (3D printing) or by mechanical forming.
  • the winding base bodies 13, which are spread open towards or towards one another at their ends have a distance 20 of at least 0.5 mm, preferably at least 1.0 mm, from one another at their ends.
  • the winding base body section, in which the winding base bodies 13 are spread open to one another has a height 21 of at least 5 mm, preferably at least 10 mm, in the axial direction.
  • a winding base body section in which the winding base bodies 13 are not spread apart, has a projection 22 of at least 5 mm, preferably of at least 10 mm, in the axial direction in relation to the stator blank or laminated core 10.
  • the winding base bodies 13 have a projection 23 of at least 10 mm, preferably at least 20 mm, in the axial direction relative to the stator blank or laminated core.
  • stator blank 10 or the (open) ends of the winding base body 13 are preferably milled (possibly after impregnation) in order to realize a surface that is as flat as possible for the printing of the respective winding overhang. This can be followed by cleaning in order to prevent inclusions from being produced in a joining zone. A calibration can then be carried out on or in an AM system or AM machine (AM for: additive manufacturing).
  • the winding base bodies 13 and/or the winding overhangs include conductors, in particular copper conductors.
  • the conductors can be produced additively.
  • the conductor measurements can be (advantageously) influenced.
  • a conventional wire has a constant cross-section due to the manufacturing process.
  • the outer dimensions of the copper conductor can be changed (or the cross-section can be changed).
  • a cross-sectional area can remain constant, increase or decrease.
  • An example in which the cross-sectional area remains constant (but this is not mandatory) but the cross-sectional shape and length changes is shown in FIGS. 7 and 8.
  • FIGS. 7 and 8. For example (see Fig. 7) can be a Reduce the cross section of the conductor 30 (in the plane of the drawing from bottom to top) viewed from a first side (within a transformation zone).
  • the conductor 30 can also have bends and/or angulations or kinks.
  • the same conductor 30 can expand from a second side view (rotated by 90°) in one direction (from bottom to top in the plane of the drawing), so that the cross-sectional area remains constant overall.
  • the cross-sectional area can also change if necessary.
  • Figures 9 and 10 show a single coil (partially exploded in Figure 9) which can be manufactured as follows.
  • a multiplicity of winding base bodies 13 are produced or provided.
  • the winding base bodies 13 are preferably designed here as (in particular U-shaped) metal sheets.
  • a connection (interconnection) of the winding base body 13 in the area of a second end winding 12 is preferably carried out by an additive manufacturing process (in particular laser sintering).
  • an additive manufacturing process in particular laser sintering.
  • (e.g. cut) metal sheets can be assembled and a wiring can then be printed on.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Power Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un stator, comprenant un enroulement, de préférence un enroulement en épingle à cheveux, pour une machine électrique, en particulier un moteur électrique ou un générateur, comprenant les étapes suivantes : introduction, en particulier insertion, de corps de base d'enroulement (13) dans des rainures de stator ; et application additive d'au moins une section d'au moins une tête d'enroulement (11, 12), en particulier par application par couches d'un matériau de construction et solidification localement sélective du matériau de construction par irradiation avec au moins un faisceau touchant le matériau de construction. L'invention concerne également un stator correspondant.
EP22757235.1A 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator Pending EP4275265A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
EP23187853.9A EP4253051A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187808.3A EP4249253A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187634.3A EP4253050A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187735.8A EP4249251A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187779.6A EP4249252A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102021119414.8A DE102021119414A1 (de) 2021-07-27 2021-07-27 Verfahren zur Herstellung eines Stators
PCT/EP2022/070637 WO2023006612A1 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator

Related Child Applications (10)

Application Number Title Priority Date Filing Date
EP23187735.8A Division EP4249251A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187735.8A Division-Into EP4249251A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187634.3A Division EP4253050A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187634.3A Division-Into EP4253050A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187808.3A Division EP4249253A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187808.3A Division-Into EP4249253A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187853.9A Division EP4253051A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187853.9A Division-Into EP4253051A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187779.6A Division EP4249252A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187779.6A Division-Into EP4249252A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator

Publications (1)

Publication Number Publication Date
EP4275265A1 true EP4275265A1 (fr) 2023-11-15

Family

ID=82943182

Family Applications (6)

Application Number Title Priority Date Filing Date
EP23187808.3A Pending EP4249253A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187779.6A Pending EP4249252A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187853.9A Pending EP4253051A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187634.3A Pending EP4253050A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP22757235.1A Pending EP4275265A1 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187735.8A Pending EP4249251A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator

Family Applications Before (4)

Application Number Title Priority Date Filing Date
EP23187808.3A Pending EP4249253A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187779.6A Pending EP4249252A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187853.9A Pending EP4253051A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator
EP23187634.3A Pending EP4253050A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator

Family Applications After (1)

Application Number Title Priority Date Filing Date
EP23187735.8A Pending EP4249251A3 (fr) 2021-07-27 2022-07-22 Procédé pour fabriquer un stator ainsi que stator

Country Status (3)

Country Link
EP (6) EP4249253A3 (fr)
DE (4) DE102021119414A1 (fr)
WO (1) WO2023006612A1 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024018055A1 (fr) 2022-07-22 2024-01-25 Additive │ Drives GmbH Stator pour machine électrique

Family Cites Families (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP3589134B2 (ja) * 2000-01-12 2004-11-17 株式会社デンソー ステータ製造方法及びその装置
DE10315361A1 (de) * 2003-04-03 2004-10-14 Robert Bosch Gmbh Verfahren zur Herstellung von Wicklungen und Wicklungsverschaltungen
ITBO20090262A1 (it) * 2009-04-29 2010-10-30 Magneti Marelli Spa Macchina elettrica rotante
DE102012212637A1 (de) * 2012-07-18 2014-01-23 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Gießtechnisch hergestellte elektrische Spule
KR101642243B1 (ko) * 2013-05-20 2016-07-22 미쓰비시덴키 가부시키가이샤 고정자 및 이 고정자를 사용하는 전동기
US20150076951A1 (en) 2013-09-16 2015-03-19 Hamilton Sundstrand Corporation Electric machine construction
US20160013692A1 (en) * 2014-07-08 2016-01-14 Hamilton Sundstrand Corporation Stator winding assembly
EP3297131A1 (fr) * 2016-09-19 2018-03-21 Siemens Aktiengesellschaft Stator pour une machine rotative electrique
JP6638008B2 (ja) * 2018-02-22 2020-01-29 本田技研工業株式会社 回転電機のステータ
GB2574409B (en) 2018-06-04 2023-02-08 Safran Electrical & Power Stator for a multi-phase electrical machine
JP2020048359A (ja) * 2018-09-20 2020-03-26 トヨタ自動車株式会社 ステータの製造方法
DE102019119745A1 (de) 2019-07-22 2021-01-28 Additive Drives GmbH Verfahren zur Herstellung einer Basiswicklungsbaugruppe und eines Stators für eine elektrische Maschine
DE102019130534B4 (de) * 2019-11-12 2023-08-10 Gehring Technologies Gmbh + Co. Kg Vorrichtung zum Umformen eines in einem Statorkern angeordneten Leiterstücks sowie ein entsprechendes Verfahren
DE102020120802A1 (de) 2020-08-06 2022-02-10 Technische Universität Bergakademie Freiberg, Körperschaft des öffentlichen Rechts Verfahren zur additiven Fertigung eines dreidimensionalen Bauteiles mit mindestens einer Wicklung
DE102022132247A1 (de) 2022-12-05 2024-06-06 Additive | Drives GmbH Bandleitervorrichtung, ausgebildet, um in Wechselstrom gespeiste elektrische Maschinen, insbesondere Motoren, eingesetzt zu werden

Also Published As

Publication number Publication date
EP4249251A3 (fr) 2024-02-14
EP4249252A3 (fr) 2024-02-21
EP4253050A3 (fr) 2024-02-07
EP4249252A2 (fr) 2023-09-27
EP4249253A2 (fr) 2023-09-27
EP4253051A2 (fr) 2023-10-04
EP4253051A3 (fr) 2024-03-06
EP4249251A2 (fr) 2023-09-27
EP4253050A2 (fr) 2023-10-04
DE202022002894U1 (de) 2023-12-23
DE102021119414A1 (de) 2023-02-02
DE102023102021A1 (de) 2024-01-25
DE202022002895U1 (de) 2023-12-23
EP4249253A3 (fr) 2024-02-21
WO2023006612A1 (fr) 2023-02-02

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