EP4285468A1 - Stator und verfahren zur herstellung eines stators - Google Patents
Stator und verfahren zur herstellung eines statorsInfo
- Publication number
- EP4285468A1 EP4285468A1 EP21827592.3A EP21827592A EP4285468A1 EP 4285468 A1 EP4285468 A1 EP 4285468A1 EP 21827592 A EP21827592 A EP 21827592A EP 4285468 A1 EP4285468 A1 EP 4285468A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- busbar
- caulking
- carrier ring
- ring
- annular groove
- 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.)
- Withdrawn
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 7
- 238000004804 winding Methods 0.000 claims abstract description 30
- 239000004020 conductor Substances 0.000 claims abstract description 23
- 238000000034 method Methods 0.000 claims description 13
- 238000006073 displacement reaction Methods 0.000 claims description 3
- 238000003780 insertion Methods 0.000 claims 1
- 230000037431 insertion Effects 0.000 claims 1
- 230000004907 flux Effects 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 210000000078 claw Anatomy 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910001208 Crucible steel Inorganic materials 0.000 description 1
- 229910001060 Gray iron Inorganic materials 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
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
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/14—Casings; Enclosures; Supports
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/09—Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
Definitions
- the present invention relates to a stator for an electrical machine, with a winding comprising a plurality of conductors assigned to one or more phases, which are connected to one another, the ends of at least some of the conductors protruding axially or radially beyond the winding, and a connecting ring with at least one support ring, on which at least one busbar is arranged, is placed axially onto the winding, and the support ring is formed from a plastic and has concentric annular grooves, in each of which at least one busbar is arranged, with at least one end of a conductor having a power rail is connected.
- the invention also relates to a method for manufacturing a stator.
- PSM permanent magnet synchronous machines
- connection rings usually made of copper can be arranged on or in a common or separate support ring made of plastic.
- this type of interconnection rings were also referred to as switching rings or contact bridges.
- Such interconnection rings are generally placed axially onto the winding stack.
- DE102008007409A1 describes a three-part switching ring for a stator, with three busbars and a star point ring being arranged in one plane, lying flat next to one another in a carrier ring made of a temperature-resistant plastic.
- the contact points of the busbars and the star point ring protrude from the carrier ring and are connected to the wire ends of the partial windings of the stator. Fixing the busbars in or on the carrier ring often turns out to be very difficult, since the installation space for this is tight.
- busbars are often encapsulated in plastic in the carrier ring or are placed in a shell-like receptacle of the carrier ring and then closed with a cover. This type of integration is often expensive and not space-neutral.
- the object of the invention is therefore to integrate the busbars in the carrier ring without using additional components and at the same time not taking up any additional space.
- a stator for an electrical machine with a winding comprising a plurality of conductors assigned to one or more phases, which are interconnected, with the ends of at least some of the conductors protruding axially or radially beyond the winding, and with a connecting ring with at least one support ring, on which at least one busbar is arranged, is placed axially on the winding, and the support ring is formed from a plastic and has concentric annular grooves, in each of which at least one busbar is arranged, with at least one end of a conductor having a busbar is connected, at least one busbar arranged in an annular groove being captively held in the annular groove by means of a busbar securing element at least partially covering the annular groove in the radial direction, the busbar securing element being caused by a plastic deformation g of a caulking member formed integrally with the support ring in the axial direction from the support ring between two adjacent ring grooves.
- a stator can be provided which realizes a secure, non-detachable fixing of a busbar in an annular groove without requiring additional components for fixing.
- Plastic deformation is also possible using cost-effective and process-reliable forming processes.
- Electrical machines are used to convert electrical energy into mechanical energy and/or vice versa, and generally include a stationary part referred to as a stator, stand or armature and a part referred to as a rotor or runner and arranged movably relative to the stationary part.
- a radial flux machine is characterized in that the magnetic field lines extend in the radial direction in the air gap formed between rotor and stator, while in the case of an axial flux machine the magnetic field lines extend in the axial direction in the air gap formed between rotor and stator.
- the motor housing encloses the electric machine.
- a motor housing can also accommodate the control and power electronics.
- the motor housing can also be part of a cooling system for the electric machine and can be designed in such a way that cooling fluid can be supplied to the electric machine via the motor housing and/or the heat can be dissipated to the outside via the housing surfaces.
- the motor housing protects the electrical machine and any electronics that may be present from external influences.
- a motor housing can be formed in particular from a metallic material.
- the motor housing can be formed from a cast metal material, such as gray cast iron or cast steel.
- the motor housing In principle, it is also conceivable to form the motor housing entirely or partially from a plastic. In connection with the present invention, it is preferred that the stator is arranged inside a motor housing.
- the stator of a radial flow machine is usually constructed cylindrically and generally consists of electrical laminations that are electrically insulated from one another and are constructed in layers and packaged to form laminated cores. This structure keeps the eddy currents in the stator caused by the stator field low. Distributed over the circumference, grooves or circumferentially closed recesses are let into the electrical lamination running parallel to the rotor shaft and accommodate the stator winding or parts of the stator winding. Depending on the construction towards the surface, the slots can be closed with locking elements such as locking wedges or covers or the like in order to prevent the stator winding from being detached.
- a carrier ring can accommodate one or more busbars and, in particular, can be arranged at a distance from one another and in an electrically insulating manner.
- a carrier ring has a circular ring-shaped basic shape with a plurality of circular ring-shaped and concentrically arranged receptacles, such as grooves, in which the corresponding busbars are arranged.
- a carrier ring is preferably made of a plastic material. In principle, it is conceivable for a support ring to be designed in one piece or in multiple pieces.
- annular grooves have a contour that is U-shaped in cross section.
- the stator has a stator support in which the stator is accommodated at least in sections and by means of which torque of the stator can be transmitted to a machine housing of the electrical machine.
- the basic functions of the stator carrier in of an electrical machine consist of supporting the stator itself and transmitting the torque of the electrical machine from the stator into the motor housing of the electrical machine.
- the torque can be transmitted from the stator support to the motor housing, for example, by means of fastening lugs on the stator support, which can be designed as drawn sheet metal parts.
- the stator carrier can be axially pretensioned by means of clamping claws, ie brackets.
- torque can also be transmitted, for example, by means of a tongue and groove system and additional axial prestressing via clamping claws.
- busbar securing element 5 engages radially from an annular wall in two adjacent annular grooves 4 and so a busbar securing element 5 captively holds two busbars 29 in their respective annular grooves 4, whereby the manufacturing effort can be correspondingly reduced.
- each of the busbars arranged in an annular groove is captively held in the respective annular groove by means of a busbar securing element.
- the object of the invention is also achieved by a method for producing a stator for an electrical machine, with a winding comprising a plurality of conductors assigned to one or more phases, which are interconnected, the ends of at least some of the conductors extending axially or radially via the winding protrude, comprising the following steps: a) Provision of an interconnection ring with at least one carrier ring, the carrier ring being formed from a plastic and having concentric annular grooves, in each of which at least one busbar can be arranged, and at least one between two adjacent annular grooves in axial direction protruding from the carrier ring integrally formed with the carrier ring caulking element, b) inserting the at least one busbar into one of the annular grooves, c) forming a busbar securing element by plastic deformation of the caulking element formed in the axial direction from the carrier ring between two adjacent annular grooves in one piece with the carrier ring in such a way that the at least one is arranged
- the plastic deformation of the caulking element takes place by caulking in the axial direction.
- the caulking can be cold caulking or hot caulking.
- Hot caulking is very particularly preferred, since the plastic material is caused to melt when heat is supplied, and caulking can therefore be carried out more precisely and with greater process stability.
- the caulking forms the busbar securing element in such a way that it contacts the busbar inserted in the annular groove in the axial direction in such a way that the busbar is fixed in a non-positive manner in the radial direction in the groove.
- the invention can also be further developed such that the carrier ring has concentrically extending annular walls delimiting the annular groove, with a caulking element protruding from at least one annular wall in the axial direction of the carrier ring.
- the annular wall in the region of the caulking element has an annular wall section which is set back axially inwards in relation to the annular wall. In this way it can be achieved that caulked material can flow into these ring wall sections, so that a ring wall that is space-optimized in the axial direction can be realized.
- the caulking element and the caulking process are configured in such a way that after the caulking element has been caulked, it does not protrude axially beyond the annular wall.
- At least one support element is provided on the side of the carrier ring opposite the annular groove in the region of the caulking element to absorb the axial forces during the plastic deformation of the caulking element in order to prevent possible damage or unwanted plastic deformation of the carrier ring to avoid.
- the plastic deformation can be effected with a stamp which has a flat or contoured surface via which a force is applied to the caulking element in the axial direction.
- the invention can also be advantageously implemented in such a way that the plastic deformation of the caulking element is effected by the punch in a force- and/or displacement-controlled manner, as a result of which the process reliability of the caulking can be further improved.
- FIG. 2 Support ring of the stator with caulking elements in a perspective detail view
- FIG. 3 Carrier ring of the stator with busbars fixed by busbar safety elements in a perspective sectional view.
- stator 1 shows a stator 1 for an electrical machine, with a winding 2 comprising a plurality of conductors 3 assigned to one or more phases, which are interconnected, the ends of at least some of the conductors 3 protruding axially or radially beyond the winding 2.
- the stator 1 has an interconnection ring 28 with at least one carrier ring 7, on which at least one busbar 29 is arranged.
- the carrier ring 7 is placed axially onto the winding 2 .
- the carrier ring 7 made of plastic has concentric annular grooves 4, in each of which at least one busbar 29 is arranged.
- At least one end of a conductor 3 is connected to a busbar 29, for example by means of welding or soldering.
- a busbar 29 arranged in an annular groove 4 is held there captively by means of a busbar securing element 5 that at least partially covers the annular groove 4 in the radial direction.
- the conductor rail securing element 5 is formed by plastic deformation of a caulking element 6 formed in the axial direction from the carrier ring 7 between two adjacent annular grooves 4 in one piece with the carrier ring 7, which will be discussed in more detail below.
- each of the busbars 29 arranged in an annular groove 4 is captively held in the respective annular groove 4 by means of a busbar securing element 5 .
- the Busbar safety elements 5 are offset from one another in the circumferential direction on the ring walls 9 .
- the electric machine shown in FIG. 1 has a concentrated winding 2 .
- the winding 2 wraps individual teeth of the stator 1 several times.
- the input is coupled to the power rails 29 of the power electronics and the phase outputs are connected to form a so-called neutral point. This connection is also called interconnection.
- the interconnection ring 28 consists of three busbars 29 which are coupled directly to the phases of the power electronics. All phase inputs of the individual teeth of the stator 1 are connected in parallel to these three busbars 29 .
- the connection ring 28 has a fourth busbar 29, which forms the so-called star point.
- This busbar 29 can be divided according to the number of pole pairs. In the case of twelve pairs of poles, there are twelve decentralized star bars 29 or one common star bar 29. So-called decentralized star bars are often used to avoid circulating currents.
- a method for producing a stator 1 for an electrical machine, with a winding 2 comprising a plurality of conductors 3 assigned to one or more phases, which are interconnected, the ends of at least some of the conductors 3 protruding axially or radially beyond the winding 2, as shown, for example, in Figures 1-3, can include the following steps: a) Provision of a connection ring 28 with at least one carrier ring 7, the carrier ring 7 being formed from a plastic and having concentric annular grooves 4, in each of which at least a busbar 29 can be arranged, and at least one between two adjacent annular grooves 4 in the axial direction from the carrier ring 7 protruding integrally formed with the carrier ring 7
- Process step c) in particular becomes clear by looking at FIGS. 2-3 together.
- FIG. 2 shows the carrier ring 7 with the caulking elements 6 that have not yet been plastically deformed, while FIG.
- the plastic deformation of the caulking element 6 takes place by caulking in the axial direction.
- FIG. 2 also shows that the carrier ring 7 has annular walls 9 running concentrically and delimiting the annular groove 4 , a caulking element 6 protruding from at least one annular wall 9 in the axial direction from the carrier ring 7 .
- the annular wall 9 has an annular wall section 8 which is set back axially inwards in relation to the annular wall 9 and into which the plastic material flowing during the plastic deformation can be pressed. It can be seen clearly from FIG. 3 that the set-back annular wall sections 8 are filled with plastic material after the plastic deformation and the busbar securing element 5 is not in the axial direction protrudes beyond the annular walls 9 of the annular grooves 4, so that the carrier ring 7 is designed to be particularly compact in the axial direction.
- the busbar safety element 5 has a mushroom-shaped three-dimensional shape.
- the busbar 29 arranged in the annular groove 4 is thus held in a form-fitting manner in the annular groove 4 by means of the busbar securing element 5 partially covering the annular groove 4 in the radial direction.
- the busbar securing element 5 can contact the busbar 29 in the axial direction, as a result of which the busbar 29 can also be fixed in a non-positive manner in the radial direction in the groove 4 .
- busbar securing element 5 engages radially from an annular wall 9 in two adjacent annular grooves 4 and thus a busbar securing element 5 holds two busbars 29 in their respective annular grooves 4 in a captive manner.
- the plastic deformation of a caulking element 6 can be effected with a stamp which has a flat or contoured surface over which the caulking element 6 is subjected to a force in the axial direction. In this way, the three-dimensional shape of the busbar securing element 5 formed by the plastic deformation of the caulking element 6 can be defined.
- the plastic deformation of the caulking element 6 by the punch can be force and/or displacement controlled.
- At least one support element for absorbing the axial forces during the plastic deformation of the caulking element 6 can be provided on the side of the carrier ring 7 opposite the annular groove 4 in the region of the caulking element 6, but this is not shown in FIGS.
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Insulation, Fastening Of Motor, Generator Windings (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102021101914.1A DE102021101914A1 (de) | 2021-01-28 | 2021-01-28 | Stator und Verfahren zur Herstellung eines Stators |
PCT/DE2021/100985 WO2022161565A1 (de) | 2021-01-28 | 2021-12-09 | Stator und verfahren zur herstellung eines stators |
Publications (1)
Publication Number | Publication Date |
---|---|
EP4285468A1 true EP4285468A1 (de) | 2023-12-06 |
Family
ID=78957807
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP21827592.3A Withdrawn EP4285468A1 (de) | 2021-01-28 | 2021-12-09 | Stator und verfahren zur herstellung eines stators |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP4285468A1 (de) |
CN (1) | CN116601856A (de) |
DE (1) | DE102021101914A1 (de) |
WO (1) | WO2022161565A1 (de) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN117318359B (zh) * | 2023-09-04 | 2024-05-10 | 安徽致钲电驱动技术有限公司 | 一种多相扁线电机绕组出线结构 |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP5176283B2 (ja) * | 2006-03-30 | 2013-04-03 | 日産自動車株式会社 | 回転電機のバスバー絶縁構造 |
DE102008007409A1 (de) | 2008-02-04 | 2009-08-06 | Continental Automotive Gmbh | Kontaktring für einen Elektromotor, der in Sternschaltung betrieben wird |
JP2010119238A (ja) | 2008-11-13 | 2010-05-27 | Sumitomo Wiring Syst Ltd | モータ巻線用配電部材 |
DE102009001830A1 (de) * | 2009-03-25 | 2010-10-07 | Ferchau Engineering Gmbh | Stator für eine elektrische Maschine mit einer Verschaltungseinrichtung |
JP5655158B2 (ja) | 2011-11-22 | 2015-01-14 | 本田技研工業株式会社 | 回転電機 |
DE102016200115A1 (de) * | 2016-01-08 | 2017-07-13 | Zf Friedrichshafen Ag | Stator einer elektrischen Maschine mit einer Verschaltungseinrichtung für Statorspulen und elektrische Maschine mit einem derartigen Stator |
WO2018062006A1 (ja) | 2016-09-30 | 2018-04-05 | 日本電産株式会社 | モータ、および電動パワーステアリング装置 |
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 |
KR20200037585A (ko) | 2018-10-01 | 2020-04-09 | 현대모비스 주식회사 | 구동모터용 터미널 어셈블리 |
-
2021
- 2021-01-28 DE DE102021101914.1A patent/DE102021101914A1/de active Pending
- 2021-12-09 CN CN202180085255.0A patent/CN116601856A/zh active Pending
- 2021-12-09 WO PCT/DE2021/100985 patent/WO2022161565A1/de active Application Filing
- 2021-12-09 EP EP21827592.3A patent/EP4285468A1/de not_active Withdrawn
Also Published As
Publication number | Publication date |
---|---|
CN116601856A (zh) | 2023-08-15 |
WO2022161565A1 (de) | 2022-08-04 |
DE102021101914A1 (de) | 2022-07-28 |
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