JP2018516048A - Electric machine stator having an encapsulated connection device and electric machine having such a stator - Google Patents

Abstract

A stator for an electric machine (10) having a stator winding (36) and a connection device (38) having a connection conductor (52a-c) to which winding ends (36a, b) are electrically connected ( 16) is disclosed. In order to connect the winding ends (36a, b), the stator (16) includes a connection device (38) having a plurality of connection conductors (52a-c). The connection conductor is enclosed in the resin body (54) in a state of being electrically insulated from each other so as to form a metal plastic composite part (56). The connection conductor (52a-c) includes a winding connector portion (520a-c), and this winding connector portion is provided outside the resin body (54). A resin body (54) having a tank-shaped receiving chamber (55) is formed, and the receiving chamber surrounds the winding connector portion (520a-c), and the receiving chamber (55) has a winding end portion (36a). , B), it is proposed that the potting material (66) covering the winding connector part (520a-c) can be filled.

Description

  The present invention relates to a stator for an electric machine according to the premise of claim 1 having an encapsulated (sealed) connection device and an electric machine according to claim 9 having such a stator.

  A stator for an electric machine having an encapsulated connection device is already known from German Patent Application No. JP-A-2001-259259. The stator includes a large number of coils, and ends of the coils are connected to three ring-shaped connection conductors by a connection device. These connection conductors have three phase connector portions in the form of tabs protruding axially from the stator for connection to a current source. The connecting conductor is incorporated in a ring-shaped holder member or holding member near the coil. The coil end portions are respectively introduced into the holding members through the inlet openings of the holder member, and are connected to connection conductors in the internal space. A ring-shaped second member is also placed on the holder member in order to form a potting tank (Vergus swanne). After completing the connection in the ring-shaped potting chamber made in this way, potting material that is liquid at the processing temperature and changes to the solid state at the time of curing is injected, which protects against external influences, especially moisture and foreign matter intrusion The member provided inside is covered.

  Manufacturing such a stator is relatively expensive, especially due to the large amount of potting material used.

  A stator of the kind mentioned at the beginning is known, for example, from US Pat. The stator includes a stator plate having a stator winding having a plurality of winding end portions and formed in a ring shape around a central axis, and includes a connection device having a plurality of connection conductors. A metal / plastic composite part is encapsulated in a resin body in a state where the connection conductors are electrically insulated from each other. At this time, the connection conductor has a plurality of winding connector portions, and these winding connector portions are formed so as to protrude in the radial direction from the main body of the connection conductor and disposed outside the resin body. In this winding connector portion, the winding end portion is electrically connected to the connection conductor. For this reason, the connection portion of the winding end is exposed in the space inside the electric machine, where it is not protected from external influences such as dirt and moisture, and is exposed to the risk of corrosion.

German Patent Application Publication No. 2020130014425 US Patent Application Publication No. 2006/0068617

  The present invention is a stator having a connection device which starts from the above-described prior art and is improved and does not cost, and can also provide a winding connector portion that is continuously prevented from corrosion due to external influences. It is an issue to provide. Furthermore, there is a need to provide an electric machine with this type of stator.

  This problem is solved by an electric machine stator having the characteristics of claim 1 and further solved by an electric machine according to claim 9. Advantageous embodiments and developments of the invention are derived from the dependent claims.

  Thus, in the stator of the kind mentioned at the beginning, the resin body or resin matrix of the metal-plastic composite part containing the connection conductor forms a tank-shaped receiving chamber, in particular a ring-shaped receiving chamber. It is proposed to surround or surround the winding connector portion of the wire. That is, resin is injected around the connection conductor, but the winding connector portion of the connection conductor is left as it is, that is, exposed, and can be connected to the winding end. The receiving chamber can be filled with a potting material as necessary after the winding end portions are connected (connected), and at that time, the resin continuously covers the winding connector portion.

  A ring-shaped tank-shaped receiving chamber made in this way can basically have any cross-sectional shape. At this time, the tank having a rectangular cross section can be manufactured without any special effort in terms of process technology when manufacturing a composite part manufactured as a resin injection molded product. Generally, the formed tank body receiving chamber has radially inner and radially outer walls, both of which extend circumferentially in the stator and further between these walls. Can be provided with a bottom. The connecting conductor is embedded in the bottom portion, and the winding connector portion is provided in the receiving chamber by protruding from the bottom portion. This receiving chamber is defined by the bottom and the above-mentioned wall part laterally adjacent to the winding connector part. The height of the tank, which generally determines the maximum injection level that can be achieved by the potting material, matches the axial direction or axial length of the stator and the metal plastic composite part.

  Therefore, with the proposed stator configuration, it is still possible to reliably encapsulate the winding connector portion with the winding end fixed against external influences. At the same time, the amount of potting material used is reduced. Relatively few. As the potting material, generally a resin such as an epoxy resin, silicone, polyurethane or a combination thereof can be used, or a resin whose arbitrary treatment is commonly used by those skilled in the field of electric machines can be used. Is preferred.

  Advantageously, the connecting conductor has a body which extends in a generally ring shape and is provided on the stator concentrically with respect to the central axis of the electric machine. Furthermore, the connecting conductor can be formed with a particularly rectangular cross-section as a bent conductor, or preferably as a strip-shaped conductor member which is bent or stamped into a ring shape. These can extend over the entire circumference or almost the entire circumference in the stator, and are provided in the stator in a radial or axial direction (stepwise). Can do.

  In particular, in a material-saving embodiment, the winding connector part is formed in the body of the connecting conductor itself by deforming the material (Materialumforming) while ensuring the cross-sectional area required especially for the current capacity (Stromtagfaigkeit). . In this case, since a portion protruding from the main body in the radial direction is not required in order to form the winding connector portion, there is almost no waste in using the base material.

  When these connecting conductors are arranged with their positions shifted in the radial direction, the winding connector portion is axially directed toward the receiving chamber with respect to the radial surface formed in common by the other portions of the connecting conductor. It is practical to stick out. Alternatively, these connection conductors may be arranged with their positions shifted in the axial direction, and may have protrusions bent in the axial direction as winding connector portions.

  According to a further preferred embodiment, the winding connector part may be provided in a substantially common radial plane, which provides the advantage of automatically connecting the winding end to the winding connector part. It is. Similarly, the height, especially the axial spread of the potting material, can be kept small.

  Further, the receiving chamber may be divided (segmented) in the circumferential direction by a separating web, and a plurality of chambers having a winding connector portion may be formed. In this case, two or more winding connector portions can be provided in a common room. Similarly, one room may be provided for each winding connector portion. The separating web preferably connects the radially inner peripheral surface and the radially outer peripheral surface of the receiving chamber, wherein the height of the separating web may extend over the entire height of the vessel, or It may extend only partially over the height. If there is a crack in the injected potting material due to service conditions or aging, especially during the operation of the electric machine, it will be cracked in the circumferential direction due to the presence of the separating web. Spreading can be effectively prevented. The separating web can be provided with an arbitrary width in the circumferential direction, and may fill all or almost all of the circumferential space between two adjacent winding connector portions. Can also save a considerable amount. By inserting the separating web, a room existing outside the winding connector portion can be formed. This room is not filled with potting material and is therefore formed without potting material.

  In a further embodiment of the present invention, the connection conductor can have a phase connector conductor materially connected to the connection conductor to connect the stator to the electrical energy source, the phase connector conductor having a termination portion. Is encapsulated or insert-molded in a plastic body of a plastic metal composite part. The phase connector conductor may then be completely or partially insert molded with resin. In the latter case, the potting material can be injected for coating into the connection area of the phase connector conductor in the connection conductor, as already described above in the winding connector part. This section of the receiving chamber can be formed in the same way, forming at least one or more chambers with a separating web as described above. The phase connector conductors can be connected, inter alia, to the connecting conductors in a material-bonded manner, for example by soldering, welding, bonding or also by plastic pressing against each other. Instead of encapsulating the phase connector conductor, the phase connector conductor can also be disposed or fixed to the connecting conductor after production of the metal-plastic composite part. The shape must be as stable as possible against the heat of treatment that may occur in some cases when fixing to the connecting conductor. Furthermore, the phase connector conductor generally may have an insulating layer, in particular a resin coating. In this case, the resin coating can be encapsulated or insert-molded in the resin body of the plastic metal composite part as described above. The insulating layer can also be formed as a hose, fabric, powder coating, paint, or the like.

  The proposed electric machine has a rotor and a stator, the stator being formed by a combination of at least the features indicated in claims 1-8.

  Hereinafter, the present invention will be exemplarily described based on the embodiments shown in the drawings.

It is the schematic of the axial cross section of the electric machine of the inner rotor type | mold with which the connection apparatus was provided in the stator at radial inside. FIG. 2 is a partial perspective view of the wiring device schematically shown in FIG. 1 having a metal plastic composite part and a phase connector conductor.

  Identical objects, operational units or equivalent components are denoted by the same reference numerals throughout the drawings. Further, for components and objects that are commonly shown for one or more features, generic symbols are used even though they appear more than once in an embodiment or drawing. Components or objects denoted by the same or generic reference are the same in terms of their characteristics (eg, their sizing) unless explicitly or implicitly resulting from something else. However, other embodiments can be used if necessary.

  FIG. 1 shows an electric machine 10 having a rotor 14 rotatable around a rotor shaft 12 having a rotation axis A and a stator 16 surrounding the outer side in the radial direction, more specifically, an inner rotor type permanent magnet excitation type synchronization. 1 schematically shows an electric motor. The rotor 14 has a pan-shaped rotor holding portion 18, and a laminated rotor plate laminated body 20 is provided on the cylindrical outer circumferential surface, and the rotor plate laminated bodies are separated from each other on the circumferential surface. A plurality of permanent magnets 22 are held.

  The stator 16 has a ring-shaped stator holding portion 24, and an annular stator plate laminated body 26 formed of a plurality of plate pieces is disposed in the central recess. Therefore, the rotation axis A is simultaneously the center axis A of the stator. The stator holding part 24 may be, for example, an outer casing or an intermediate casing of the electric machine 10. The stator plate laminated body 26 is configured by being segmented and is assembled from a large number of stator segments, and these stator segments are accommodated in the stator holding portion 24 and integrally held. Alternatively, the stator plate stack 26 may consist of a stack of ring-shaped plate pieces in a conventional manner.

  Regardless of a specific configuration, the stator plate laminate 26 forms a stator yoke 30 closed in a ring shape that abuts the stator holding portion 24, and the stator yoke 32 is directed radially inward from the stator yoke. have. This tooth forms a stator winding by mounting a stator coil 36 by a known method. The winding ends or coil ends 36a, b of the stator coil 36 are connected by a connection device 38, which is shown only schematically in FIG. 1, via an output electronic circuit 39a and a control electronic circuit 39b. Connected to an electrical energy source 39c, this electrical energy source can supply current to the windings with variable phase and amplitude to operate the electrical machine 10.

  The stator coil 36 is wound around the teeth 32 from one copper wire using two heat-resistant plastic insulating frames or winding frames 40 and 42 before the stator 16 is attached, and does not come off there. It is fixed like so.

  Each of the winding frames 40 and 42 defines a bottom portion 40a; 42a that abuts on the plate laminated body 26 on the end face side, and a radial winding range that protrudes in the axial direction on the stator 16 at a right angle from the bottom portion. Leg portions 40b, c; 42b, c. An insertion groove is provided in the leg portion 40b on the radially inner side, and the coil end portions 36a and 36b are inserted into the groove and are oriented toward the connection device 38. The leg portion 40b abuts on a ring-shaped metal plastic composite component 56, which will be described in detail below, with substantially no gap, and supports this component. The metal plastic composite component 56 is secured to the stator 16 by a snap connection, not shown, or other method at the legs of the reel, as schematically shown in FIG.

  These coils 36 are provided so as to correspond electrically to individual series. For this reason, the coil end portions 36a and 36b are previously connected via the common connection conductors 52a-c by using the connection device 38. As determined, they are connected to each other at the winding connector portions 520a-c.

  The connection conductors 52a-c are formed by bending a copper strip material having a substantially rectangular cross section, have a main body extending in a substantially ring shape, and are provided on the stator 16 coaxially with the central axis A. The winding connector portions 520a-c are formed in the main body while extending so that the connection conductors 52a-c circulate, and are formed by the connection conductors 52a-c, particularly by the main bodies. Projecting in the axial direction relative to the radial plane. In the figure, the connection conductors 52a-c are arranged in a radial direction shifted (stepped) in the stator 16, and the winding connector portions 520a-c protruding in the axial direction are arranged on a substantially common radial surface. You can see that.

  When connecting in such a way that Δ connection can be made, it is preferable to connect two adjacent coil end portions 36a, b of two coils 36 adjacent on the peripheral surface to one winding connector portion 520a-c. The connection of the coil ends 36a, b to the connection conductors 52a-c is made by material bonding, in particular by soldering or welding.

  In order to provide the connection conductors 52 a-c in the stator 16, the connection conductors 52 a-c are sealed in the resin body 54 while being electrically insulated from each other under the formation of the metal-plastic composite component 56 described above. At this time, the winding connector portions 520a-c are left behind from the resin body 54, and accordingly, are provided outside the resin body 54.

  As schematically shown in FIG. 1, the metal-plastic composite component 56 is fixed to the legs 40 b on the radially inner side of the coil 36, more precisely on the radially inner side of the winding frame 40. Thus, the coil end portions 36a and 36b enter the connection region, that is, the receiving chamber 55 of the holding member 56 through the radially outer wall portion 56b.

  As can be seen from FIG. 2, the receiving chamber 55 in the resin body 54 has a tank shape and is formed with one side open for connection, and the winding connector portions 520a-c The chamber 55 is confined or surrounded by a plurality of surfaces. The receiving chamber 55 is defined by a radially inner wall portion 56c, a radially outer wall portion 56b, and a bottom portion 56a extending therebetween, from which the winding connector portions 520a-c protrude in the axial direction. Yes.

  Further, the receiving chamber 55 is formed by being segmented (divided) in the circumferential direction by the separating web 56e, and has a plurality of chambers 55a, and one chamber 55a is provided for each of the winding connector portions 520a-c. You can see that it is provided. Here, since the opened portion faces the opposite side to the stator 16 in the axial direction, it can be freely accessed for connection.

  Unlike the schematic view of FIG. 1, in this example, the inner radial wall 56c is placed on one of the walls 56b, c so that the coil ends 36a, b enter the receiving chamber 55 of the metal plastic composite part 56. An entrance notch 56d is provided. These are formed as a muldenform or slit-like recess from the free side in the axial direction of the side wall portion 56b with respect to the stator 16, and the coil end portions 36a, b led into the insertion groove are formed. Is provided in such a way that it can be inserted into the receiving chamber 55 of the connection device 38 through the radial wall 56c in a radial direction and in a relatively short path. Thus, the notch portion 56d is provided on the circumferential surface so as to correspond to one of the connector portions 520a-c, and is a coil end portion of each of the two coils 36 immediately adjacent to each other. 16, it may be formed slightly larger in the circumferential direction as necessary than the one corresponding to the distance between the two coil end portions 36a, b adjacent to each other. Thus, in the illustrated arrangement, the coil end portions 36a and 36b can be reliably introduced into the metal plastic composite component 56 even when the positional tolerance is small due to manufacturing conditions. Unlike the one shown in FIG. 1, the connection device 38 shown in FIG. 2 is basically formed to be disposed on the leg portion 40 c on the radially outer side of the winding frame 40.

  The connection device 38 is made of material on the connection conductors 52a-c to connect the stator 16 to an electrical current source 39c, as schematically shown in FIG. 1 and illustratively shown in FIG. There are further connected phase connector conductors 60a-c, which are sealed and introduced into the receiving chamber 55.

  As shown in FIG. 2, the phase connector conductors 60a-c are also formed as strip conductors having a substantially rectangular cross-section and are provided together on the peripheral surface of the metal-plastic composite part 56, where the metal Projecting radially from the plastic composite part 56. The phase connector conductors 60 a-c are provided with resin insulating covers 620 a-c until reaching the respective terminal portions, and one terminal portion 610 a-c is sealed in the resin body 54. The insulating covers 620a-c are then encapsulated together so that they are not attacked by the corrosion process at this location.

  After connecting the winding ends 36a, b to the winding connector portions 520a-c, the receiving chamber 55 or individual chamber 55a is protected from external influences, in particular from the occurrence of corrosion, and also the stability of the connection device 38. In order to enhance the properties, the potting material 66 is at least partially filled. For example, in this regard, FIG. 2 shows a sealed chamber 55a. For the sealing, a potting material 66 that is liquid at the sealing processing temperature but changes to a solid state upon curing is used. By sealing, the coil ends 36a, b, the connecting conductors 52a-c and the phase connector conductors 60a-c are at least covered or encapsulated at their mutual connection.

  Instead of arranging the connecting conductors spaced apart from each other in the radial direction shown in the drawing, they may be arranged spaced apart from each other in the axial direction with respect to the stator. When necessary, it is necessary to adjust appropriately. Similarly, instead of arranging the coils in the radial direction with respect to the holding member of the connection device, these can also be arranged in the axial direction. Further, the special structure of the electric machine is not important with respect to the basic configuration of the stator connection device. For example, an outer rotor type electric machine is also possible.

DESCRIPTION OF SYMBOLS 10 Electric machine 12 Rotor shaft 14 Rotor 16 Stator 18 Rotor holding part 20 Rotor plate laminated body 22 Permanent magnet 24 Stator holding part 26 Stator plate laminated body 30 Stator yoke 32 Teeth 36 Stator coil 36a, b Coil end part 38 Line device 39a Output Electronic circuit 39b Control electronic circuit 39c Power source 40, 42 Winding frame 40a, 42a Bottom part 40b, c Leg part 42b, c Leg part 52a-c Connecting conductor 520a-c Winding connector part 54 Resin body 55 Receiving chamber 55a Room 56 Metal Plastic composite part 56a Bottom face 56b, c Side wall part 56d Entrance notch part 56e Separation web 60a-c Phase connector part 610a-c End part 620a-c Insulating cover 66 Potting material A Center axis

Claims (9)

A stator (16) for an electric machine (10),
A stator plate stack (26) having a stator winding (36) and ring-shaped around the central axis (A), the stator winding (36) having a plurality of winding ends (36a, b)
A connection device (38) having a plurality of connection conductors (52a-c), wherein the connection conductors (52a-c) are electrically insulated from each other so as to form a metal plastic composite part (56); Is enclosed in a resin body (54),
-These connecting conductors (52a-c) have winding connector parts (520a-c), and the winding connector parts (520a-c) are arranged outside the resin body (54), and In the stator in which the wire end portions (36a, b) are at least indirectly electrically connected to the connection conductors (52a-c) in the winding connector portions (520a-c),
The resin body (54) forms a tank-shaped receiving chamber (55), and the receiving chamber surrounds the winding connector portion (520a-c).   The stator according to claim 1, wherein the receiving chamber (55) is filled with a potting material (66) and covers the winding connector part (520a-c).   The stator according to claim 1 or 2, wherein the connection conductors (52a-c) have a main body extending substantially in a ring shape and are provided on the stator (16) concentrically with the central axis (A). A stator characterized by that.   The stator according to any one of claims 1 to 3, wherein the winding connector portion (520a-c) is formed in the main body itself.   The stator according to any one of claims 1 to 4, wherein the connection conductors (52a-c) are arranged so as to be displaced in the radial direction, and the winding connector portion (520a-c) is connected to the connection conductor. The stator projects in the axial direction toward the inside of the receiving chamber (55) with respect to the radial surface formed by (52a-c).   The stator according to any one of claims 1 to 5, wherein the winding connector parts (520a-c) are arranged in a substantially common radial plane.   The stator according to any one of claims 1 to 6, wherein the receiving chamber (55) is formed by being segmented in the circumferential direction by a separating web (56e) and has a plurality of chambers (55a). A stator characterized by that.   The stator according to any one of claims 1 to 7, wherein the connection conductors (52a-c) are connected to the connection conductors in a material-bonded manner in order to connect the stator (16) to an electrical energy source (39c). It has a connected phase connector conductor (60a-c), and the phase connector conductor (60a-c) has one end portion (610a-c) sealed in the resin body (54). A featured stator.   The electric machine (10) having a rotor (14) and a stator (16), wherein the stator (16) according to any one of claims 1 to 8 is formed.

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