RU2779472C1 - Three-phase stator assembly - Google Patents

Abstract

FIELD: electrical engineering.

SUBSTANCE: invention relates to the field of electrical engineering, in particular to the node (1) of the three-phase stator of the drive motor of the electric pump. The stator assembly (1) contains three sets of segments (S_{i, j}) placed in an annular arrangement around the stator axis (R) extending in the axial direction. Each set of segments (S_{i, j}) contains n ≥ 2 segments (S_{i, j}), with each specified segment (S_{i, j}) containing a coil (3) having a first end (5) and a second end (7) of the coil wire, and a plurality of 3n-3 connecting wires (W_{i, k}) placed on the axial front side (9) of the segments (S_{i, j}). Each connecting wire (W_{i, k}) connects two coils (3) of the corresponding set of segments (S_{i, j}) in series, while the first intermediate segment (S_{i, j}) and the second intermediate segment (S_{i, j}) of the other two sets of segments (S_{i, j}) are placed in a circular direction between two connected coils (3) of the specified set of segments (Si, j). At least 3n-5 connecting wires (W_{i, k}) pass through the first intermediate segment (S_{i, j}) at the first radial distance (r₁) to the stator axis (R) and through the second intermediate segment (S_{i, j}) at the second radial distance (r₂) to the axis (R) of the stator. The second radial distance (r₂) is greater than the first radial distance (r₁).

EFFECT: improving the manufacturability of the stator.

21 cl, 11 dwg

Description

The present invention relates to a three-phase stator assembly of an electric pump drive motor. Such a three-phase stator assembly can in particular be used in a permanent magnet synchronous motor (PMSM) of a pump assembly.

It is known to use stator assemblies containing a set of stator segments in electric motors. For example, US 2007/0232094 A1, WO 2011/108735 A1 or US 2007/0182265 A1 describe such stator assemblies.

However, there is a technical challenge to electrically connect the stator segments to each other, if necessary, in an efficient and safe manner. The installation and connection of coil wires, as is known in the prior art, often requires manual work and is thus subject to human error and quality issues. In addition, prior art connecting wires are often longer than necessary and waste unnecessary space and material.

Therefore, it is an object of the present invention to provide a three-phase stator assembly that can be assembled more automatically by a machine with little or no manual work, and that consumes less space and material.

Thus, the present invention provides a three-phase stator assembly according to claim 1. Preferred embodiments of the three-phase stator assembly can be obtained from the subclauses, descriptions and drawings.

The three-phase stator assembly as described herein is particularly applicable to an electric pump drive motor, such as a permanent magnet synchronous motor (PMSM). The stator assembly contains:

- three sets of stator segments, wherein the stator segments are placed in an annular arrangement around an axially extending stator axis, with each set of stator segments containing n ≥ 2 stator segments arranged in n-fold rotational symmetry around the stator axis, with each segment the stator comprises a coil having a first coil wire end and a second coil wire end, and

- a set of 3n-3 connecting wires placed on the axial front side of the stator segments, with each connecting wire connecting two coils of the corresponding set of stator segments in series, while the first intermediate stator segment and the second intermediate stator segment from the other two sets of stator segments are placed in in a circular direction between two connected coils of said respective set of stator segments.

At least 3n-5 connecting wires pass through the first intermediate stator segment at the first radial distance to the stator axis and through the second intermediate stator segment at the second radial distance to the stator axis, while the second radial distance is greater than the first radial state.

Thus, it is important to understand that the connecting wires do not simply follow a circular path concentric with the stator axis in order to connect two coils from a set of stator segments in series. Each connecting wire passes through two intermediate stator segments from the other two sets which are placed in the gap, i.e., the first intermediate stator segment and the second intermediate stator segment. By increasing the radial distance of the connecting wire in its path from the first stator segment to the second stator segment, the connecting wire is able to obtain a very short path and can be designed relatively short and easy to assemble. It is also important to note that there is no coil wire that runs through two or more stator segments. Thus, there is a need for a connecting wire to connect the coil wires of a set of stator segments.

The stator assembly contains a total of 3n stator segments arranged in three sets of n stator segments. In this case, i must be an index for the set, i.e., i={1, 2, 3}. In addition, j must be the index for the stator segment in the set, i.e., j={1, ..., n}. Thus, a particular stator segment can be denoted as S _{i, j} , which means the j-th stator segment in the i-th set. The stator assembly contains at least a total number of 3n-3 connecting wires, of which n-1 connecting wires belong to each set of stator segments. Therefore, k must be an index for the connecting wire for the set, i.e., k={1, ..., n-1}, so that a particular connecting wire can be denoted as W _i,k , which means the kth connecting wire in the i-th set. Preferably, the stator segments are completely separate units before they are placed in an annular arrangement to form the stator assembly during fabrication and assembly. Preferably, the coil wires of a set of stator segments are connected to each other by connecting wires after the stator segments are placed in an annular arrangement to form a stator assembly during manufacture and assembly.

Optionally, at least 3n-5 connecting wires may have the same or substantially the same shape and length. This eases automation and complexity a lot. It should be noted that the first (i=1, k=1) and last (i=3, k=n-1) of the total number of 3n-3 connecting wires can in principle have a different shape and/or length, but preferably have also the same shape and length as the other 3n-5 connecting wires, so that preferably all of the 3n-3 have the same shape and length.

Optionally, all connecting wires can be drawn along their entire length in a substantially common plane perpendicular to the stator axis. This is a very space-saving arrangement, and also useful for automatic assembly of the connecting wires by the machine, since no crossing or lifting of the connecting wires is necessary.

Optionally, the three-phase stator assembly may further comprise a star point wire, wherein the star point wire connects the first ends of the coil wire for a coil of (j-n)th stator segments of the three sets of stator segments to each other. When the stator segments of the set of stator segments are connected in series with each other, the last (j=n) stator segment of each set of stator segments can be connected to the star wire.

Optionally, the three-phase stator assembly may further comprise a three-phase power input line with three phases, with each phase connected to the second end of the coil wire for the coil from the first (j=1) stator segment of the corresponding set of stator segments. Thus, the first stator segment of each set of stator segments is connected to one of the three phases of the three-phase power input line. Preferably, the second ends of the coil wire for coils of the stator segments are located on the radially outer side of the stator segment, while the first end of the coil wire is preferably located on the radially inner side of the stator segment.

Optionally, all stator segments are identical to each other in order to facilitate the automation process and reduce the diversity of parts. Optionally, the three-phase stator assembly may further comprise a wire guiding element located on the axial front side of the stator segments, wherein the wire guiding element defines a plurality of wire paths, the wire paths being arranged in 3n times rotational symmetry around the stator axis. Thereby, the wire paths are identical between all stator segments, which ensures the exact 3n-fold rotational symmetry of the three-phase stator assembly before assembling the connecting wires. This is very useful for efficiently automating the build process.

Optionally, the wire guide element consists of a plurality of 3n separate and identical wire guide structures, with each wire guide structure being placed on the axial front side of a respective stator segment. Thus, each wire guide structure can be part of a stator segment before the stator segments are assembled to form a ring arrangement for the stator assembly. Alternatively, one or more wire guide structures can be connected to each other and mounted on the axial front side of the three-phase stator assembly after the stator segments are assembled to form an annular stator assembly. The wire guiding structures can all be connected to form a one-piece annular wire guiding member that is mounted on the axial front side of the axial front side after forming the stator segments into an annular arrangement.

Optionally, the structures for guiding the wire have a distance to each other in the circumferential direction. Such a distance can be useful for the connecting wire to "switch" to a more radially outer wire path between adjacent structures to guide the wires.

Optionally, the wire guiding member may be attached to the axial front side of the stator segments by means of a force fit. For example, it can be snapped into a snap mechanism provided on the axial front side of each stator segment.

Optionally, the wire guiding element may be positioned radially between the first end of the coil wire and the second end of the coil wire for the coil of the respective stator segment.

Optionally, the first end of the coil wire for the coil of each stator segment can be placed on the first side of the corresponding stator element, and the second end of the coil wire for the coil of each stator segment can be placed on the second side of the corresponding stator segment. The connecting wires may connect a first end of a coil wire for a coil of a stator segment of a set of stator segments to a second end of a coil wire for a coil of a next in sequence stator segment of said set of stator segments. Thus, placing the ends of the coil wire on different sides of the stator segment is useful in reducing the length of the connecting wires.

Optionally, each stator segment may further comprise a first insulation-cut terminal for connecting the lead wires to the first end of the coil wire and a second insulation-cut terminal for connecting the lead wires to the second end of the coil wire. These insulation cut-out terminals are also useful to facilitate the automation process. Insulation cut-out terminals cut through the insulation sheath of the respective wire to make an electrical connection to the wire and to mechanically secure the wire.

Optionally, the first insulation cut terminal is axially inserted into the first slot defined on the axial front side of the stator segment and the second insulation cut terminal is axially inserted into the second slot defined on the axial front side of the stator segment.

Optionally, the first slot and/or the second slot extend substantially tangentially with respect to the annular arrangement of the stator segments. Thus, the connection between the insulation-cutting terminal and the connecting wire is safer against pulling forces along the connecting wires because the connecting wire is bent around about 90 degrees near the insulation-cutting terminal. The orientation of the corresponding end of the connecting wire in the insulation-cutting terminal may be radial, while the remainder of the connecting wire runs between the two inserted stator segments of the other two sets of stator segments.

Optionally, the first end of the coil wire and the first end of the connecting wire both extend radially through the first slot, with the first end of the coil wire received in the first recess of the first insulation-cutting terminal and the first end of the connecting wire received in the second recess of the first mounting terminal and/or the second end of the coil wire and the second end of the connecting wire pass radially through the second slot, while the second end of the coil wire is received in the first recess of the second terminal for insulation cutting, and the second end of the connecting wire is received in the second recess of the second terminals for mounting with insulation cut. Preferably, the first insulation-cutting terminal and the second insulation-cutting terminal are identical in shape and size. Optionally, the first recess and the second recess of the insulation cut-out terminal may be placed on opposite axial sides of the respective insulation cut-out terminal. Thus, the insulation cut-out terminal can be inserted axially into the appropriate slot to establish electrical contact with the respective end of the coil wire. The corresponding end of the connecting wire is then pressed axially into the other recess of the insulation-cutting terminal.

Optionally, the connecting wires do not cross each other. In other words, the stator assembly is preferably free from any crossed connection wires. This makes automation much easier.

Optionally, for each stator segment, the first end of the coil wire may be placed on the radially inner side of the stator segment and the second coil wire may be placed on the radially outer side of the stator segment. Each connecting wire is preferably placed between the radial inner side of the stator segments and the radial outer side of the stator segments. Preferably, the connecting wire does not extend into the radial interior of the stator segments or out of the radial exterior of the stator segments. Thus, the connecting wires are neatly placed in the annular region between the radial inner side of the stator segments and the radial outer side of the stator segments.

Optionally, all stator segments may be substantially identical and differ only in their connection to the connecting wires, star wire and/or input line phases.

до

.Optionally, each connecting wire may extend a maximum azimuth angular distance ranging from

before

.

до

.Optionally, the first end of the coil wire for the coil of the set of stator segments and the second end of the coil wire for the next connected coil in sequence from the set of said stator segments have an azimuth angular distance to each other in the range of

before

.

In the following, the present invention is described in more detail with reference to the accompanying drawings, in which:

Fig. 1 is a perspective view of an exemplary embodiment of a fully assembled three-phase stator assembly according to the present invention;

Fig. 2 is a plot of the radial distance of the connecting wire to the stator axis as a function of the azimuthal angle for the stator assembly as shown in FIG. one;

Fig. 3 is an exploded perspective view of the coil-forming portions of the stator segment of FIG. one;

Fig. 4 is a perspective view of the coil-forming parts of the stator segment of FIG. 3;

Fig. 5 is a perspective view of the coil-forming parts of the stator segment of FIG. 4, after the coil is wound, and before the first and second insulation-cutting terminals are inserted;

Fig. 6 is a perspective view of the stator segment of FIG. 5, after the first and second insulation cutting terminals have been inserted;

Fig. 7 is a perspective view of the stator segment of FIG. 6 after installation of the structure for guiding the wire to the axial front side of the stator segment;

Fig. 8 is a perspective view of the annular arrangement of the nine stator segments of FIG. 7;

Fig. 9 is a perspective view of the annular arrangement of FIG. 8 after installing the connecting wires;

Fig. 10 is a perspective view of the annular arrangement of FIG. 9 after the insulation of the star point wire; and

Fig. 11 is a perspective view of an alternative embodiment of a one-piece wire guide ring comprising nine separate and identical wire guide structures.

Fig. 1 shows a three-phase stator node 1 comprising nine identical stator segments S _{i, j} , i being the index of a set of a total of three sets, i.e., i={1, 2, 3}. Each set of stator segments contains n ≥ 2 stator segments S _{i, j} arranged in n-fold rotational symmetry around the stator axis R. In the example shown in FIG. 1, each set of stator segments contains three stator segments, i.e., n=3, where j must be the index of the stator segment in the set of stator segments, i.e., j={1, ..., n}.

To make the drawings more understandable, it is useful to define a cylindrical coordinate system as shown in FIG. 1, where the axial position is referred to as z along the R-axis of the rotor, the position in the circumferential direction is referred to as the azimuth angle j, and the radial distance to the R-axis of the rotor is referred to as r. By independent convention, positive z-direction may be "front" or "front", and negative z-direction may be "rear" or "back".

Each stator segment S _{i, j} comprises a coil 3 having a first coil wire end 5 and a second coil wire end 7 . Both the first end 5 of the coil wire and the second end 7 of the coil wire are placed on the axial front side 9 of the stator segments S _{i, j} . The axial rear side 11 of the stator assembly 1 faces in the opposite direction in FIG. one.

Node 1 of the three-phase stator, as shown in FIG. 1 further comprises a plurality of 3n-3=6 connecting wires W_{i, k}, while i={1, 2, 3} must denote the index for the associated set of segments S_{i, j} stator, and k={1, …, n-1} should be the index of the connecting wire in the mentioned set. Each connecting wire W_{i, k} connects two coils of the corresponding set of segments S_{i, j} stator in series. Therefore, each set of segments S_{i, j} stator contains n - 1=2 connecting wires W_{i, 1} and W_{i, 2}. Therefore, the connecting wire W_eleven connects coils of 3 segments S_1.1 and S_1.2 stator; connecting wire W_1.2 connects coils of 3 segments S_1.2 and S_1.3 stator; connecting wire W_2.1 connects coils of 3 segments S_2.1 and S_2.2 stator; connecting wire W_2.2 connects coils of 3 segments S_2.2 and S_2.3 stator; connecting wire W_3.1 connects coils of 3 segments S_3.1 and S_3.2 stator; and connecting wire W_3.2 connects coils of 3 segments S_3.2 and S_3.3 stator. Between the two series-connected stator segments of the set, there is a first intermediate stator segment and second intermediate stator segments of the other two sets of stator segments arranged in a circular direction between said two series-connected stator segments. This means that the connecting wires W_{i, k} must be pulled through at least two intermediate stator segments to connect the two coils of the set in series.

For example, a first intermediate stator segment S _2.1 and a second intermediate stator segment S _3.1 are placed circumferentially between two connected coils of stator segments S _1.1 and S _1.2 of the first (i=1) set of stator segments. Similarly, intermediate first and second stator segments S _3.1 and S _1.2 are placed between stator segments S _2.1 and S _2.2 of the second (i=2) set of stator segments, and so on. Six connecting wires W _{i, k} have the same shape and length. However, in an alternative embodiment, the first connection wire W _1.1 and the last connection wire W _3.2 may have more options for slightly different shapes and/or lengths. Here, all connecting wires W _{i, k} pass between the first intermediate stator segment (the first stator segment of the other two sets of stator segments placed between the two connected coils of the stator segments of the corresponding set of stator segments) at the first radial distance r ₁ to the stator R. In addition, , each connecting wire W _{i, k} passes between the second intermediate stator segment (the second stator segment from the other two sets of stator segments placed between the two connected coils of the stator segments of the mentioned corresponding set of stator segments) at the second radial distance r ₂ to the stator axis R. The second radial distance r ₂ is greater than the first radial distance r ₁ , i.e., r ₂ > r ₁ . This means that the connecting wires Wi _{, k} do not follow a strict circular path coaxial with the stator axis R, but effectively extend radially outward along their path between two connected coils of stator segments from a corresponding set of stator segments. For example, the first connecting wire W _1.1 connects the coils of segments S _1.1 and S _1.2 of the stator. The connecting wire W _1.1 crosses the first stator segment S _2.1 at the first radial distance r ₁ and the second stator segment S _3.1 at the second radial distance r ₂ , the second radial distance r ₂ being greater than the first radial distance r ₁ . Thus, the connecting wire W _{i, k} follows a "spiral" path for a shape that is similar to the circular strands of a web with a linear section. In other words, the connecting wires W _{i, k} spiral outward radially along their path to connect the coils 3 of the two stator segments S _{i, j} and S _{i, j+1} .

, азимутальная позиция j₂ между соседними сегментами S_2,1 и S_3,1 статора здесь определяется как 40°, и азимутальная позиция j₃ между соседними сегментами S_3,1 и S_1,2 статора здесь определяется как 80°. Таким образом, соединительные провода W_{i, k} проходят по азимутальному угловому диапазону более чем на 80°. В этом диапазоне между j₁ и j₃ радиальное расстояние r(j) соединительного провода W_{i, k} до оси R статора изменяется на протяжении соединительного провода W_{i, k}. Как может быть видно на фиг. 2, второе радиальное расстояние r₂ в диапазоне между j₂ и j₃ всегда больше первого радиального расстояния r₁ в диапазоне между j₁ и j₂. Существует несколько вариантов для определения первого радиального расстояния r₁ и второго радиального расстояния r₂, для всех из которых r₂ > r₁ удовлетворяется. Например,

и

, т.е., средние радиальные расстояния в соответствующем азимутальном диапазоне могут быть сравнены. Альтернативно, медианное значение радиального расстояния в соответствующем азимутальном диапазоне может сравниваться. Альтернативно, значения радиального расстояния в центральных азимутальных позициях 20° и 60° могут быть сравнены. Следует отметить, что радиальное расстояние может непрерывно увеличиваться на протяжении соединительного провода W_{i, k}, но не обязано. Как может быть видно на фиг. 2, радиальное расстояние может даже кратковременно уменьшаться, например, в диапазонах 10°-20° и 50°-60°. Причина в том факте, что соединительные провода W_{i, k} здесь имеют три линейных участка в диапазоне между j₁ и j₃, между этими участками существуют два изгиба или перекручивания в азимутальных позициях 10° и 50°. Эти изгибы или перекручивания являются видимыми на фиг. 2 как пики в функции r(j).Fig. 2 shows a plot of the radial distance r (on an arbitrary relative scale) of the connecting wire Wi _{, k} to the stator axis R as a function of the azimuthal angle j r(j) for the stator assembly 1 shown in FIG. 1. The azimuth position j ₁ between adjacent stator segments S _1,1 and S _2,1 is here defined as 0°, where r(j) is arbitrarily set to 1. Since each stator segment spans an azimuthal angular range

, the azimuth position j ₂ between adjacent stator segments S _2,1 and S _3,1 is here defined as 40°, and the azimuth position j ₃ between adjacent stator segments S _3,1 and S _1,2 is here defined as 80°. Thus, the connecting wires Wi _{, k} extend over an azimuth angular range of more than 80°. In this range between j ₁ and j _{3 ,} the radial distance r(j) of the connecting wire W _{i, k} to the stator axis R varies along the connecting wire W _{i, k} . As can be seen in FIG. 2, the second radial distance r ₂ between j ₂ and j ₃ is always greater than the first radial distance r ₁ between j ₁ and j ₂ . There are several options for determining the first radial distance r ₁ and the second radial distance r ₂ , all of which r ₂ > r ₁ are satisfied. For example,

and

, i.e., the average radial distances in the corresponding azimuth range can be compared. Alternatively, the median value of the radial distance in the corresponding azimuth range can be compared. Alternatively, the radial distance values at the center azimuth positions of 20° and 60° can be compared. It should be noted that the radial distance may increase continuously over the length of the connecting wire W _{i, k} , but need not. As can be seen in FIG. 2, the radial distance may even shortly decrease, for example in the ranges of 10°-20° and 50°-60°. The reason is the fact that the connecting wires Wi _{, k} here have three linear sections in the range between j ₁ and j ₃ , between these sections there are two bends or twists at azimuth positions of 10° and 50°. These bends or twists are visible in FIG. 2 as peaks in the function r(j).

Returning to FIG. 1, each stator segment S _{i, j} is provided with a wire guide structure 13 provided on the axial front side 9 of the corresponding stator segment S _{i, j} . All nine structures 13 for guiding the wire are placed in the same plane, perpendicular to the axis R of the rotor. All nine wire guide structures 13 can be considered together as a wire guide element 15 . The wire guide member 15 may be an annular one-piece structure, with the wire guide structures 13 being connected to each other as shown in FIG. 11. In the embodiment, as shown in FIG. 1-10, however, the wire guide structures 13 are separate from each other and have a distance from each other in the circumferential direction. All structures 13 for guiding the wire are identical to each other. Each wire guide structure 13 is attached to the axial front side 9 of the respective stator segment S _{i, j} by means of a force fit, such as a clip connection or snap connection.

Each wire guidance structure 13 defines a first practical tangential path 13a for guiding a connecting wire W _{i, k} through the first intermediate stator segment and a practically tangential second path 13b for guiding another connecting wire W _{i, k} through the second intermediate stator segment S _{i, j} . The first path 13a is positioned radially further inward than the second path 13b. The structure 13 for guiding the wire further defines an almost tangential third path 13c for guiding the wire 16 to the neutral point of the star. The third path 13c is positioned radially further inward than the first path 13a. The star wire 16 connects the first ends 5 of the coil wire for the coils 3 of the last (j=n) stator segments S _1.3 , S _2.3 and S _3.3 to each other. The star wire 16 may have a larger diameter than the connecting wires W _{i, k} . Pathways 13a-c are all linear here, but may be at least partially non-linear in other embodiments not shown.

The second ends 7 of the coil wire of the first (j=1) stator segments S _1,1 , S _2,1 and S _3,1 of each set are each connected to one phase 17a, b, c of a three-phase power input line containing three phases 17a , b, p.

Fig. 3-7 show the step-by-step assembly of the stator segment S _{i, j} . Fig. 3 shows an exploded view of the coil-forming elements of the stator segment S _{i, j} . The coil-forming elements comprise an axially central core 19 of high magnetic permeability, ie iron, having an H-shaped cross section. The coil-forming members further comprise an axial front portion 21a and an axial rear portion 21b attached to opposite axial sides of the core 19. The front portion 21a and the rear portion 21b may be composed of an electrically insulating material, i.e., plastic, composite, or ceramic material. The front portion 21a and the rear portion 21b may be formed mirror-symmetrical to each other about an axially central symmetry plane A extending perpendicular to the rotor axis R. The front part 21a includes a first slot 23a and a second slot 23b, both of which open in the axially forward direction. The first slot 23a and the second slot 23b extend tangentially with respect to the annular arrangement of the stator segments S _{i, j} . The first slot 23a and the second slot 23b are offset at an angle to each other in units of the azimuth angle j, so that the first slot 23a is positioned on the first side 25a of the stator segment S _{i, j} and the second slot 23b is positioned on the second side 25b of the segment S _{i, j} of the stator.

The first slot 23a and the second slot 23b comprise V-shaped notches into which the first end 5 of the coil wire and the second end 7 of the coil wire, respectively, can be placed. The V-shaped notches in the first slot 23a and the second slot 23b form radially extending grooves 26a, b into which the first end 5 of the coil wire and the second end 7 of the coil wire, respectively, can be inserted.

Fig. 4 shows the paths in FIG. 2 put together. Coil-forming paths as shown in FIG. 3, ready to accept coil wire. In FIG. 5, the coil wire is wound around the coil forming members to form the coil 3. The first end 5 of the coil wire is inserted into the groove 26a of the first slot 23a so that it extends radially inward to cross the first slot 23a. Similarly, the second end 7 of the coil wire is inserted into the groove 26b of the second slot 23b, in which the second end 7 of the coil wire extends radially outward through the second slot 23b. Fig. 5 further shows the first insulation cutting terminal 27a and the second insulation cutting terminal 27b before being axially inserted into the first slot 23a and the second slot 23b, respectively. The insulation cutting terminals 27a, b are identical to each other and have a V-shaped first recess 29 facing (backwards) towards the slots 23a, b. The insulation cutting terminals 27a, b have a shape that is mirror-symmetrical with respect to a central plane of symmetry running perpendicular to the R-axis of the rotor. Thus, the insulation cutting terminals 27a, b each comprise a V-shaped second recess 31 facing axially from the slots 23a, b. As shown in FIG. 6, the insulation cut-out terminals 27a, b are pressed axially downwards into the slot 23a, b so that the first recess 29 receives the respective end 5, 7 of the coil wire. Thus, the ends 5, 7 of the coil wire are fixed in place by means of terminals 27a, b for insulation cutting. In addition, the insulation cutting terminals 27a, b cut into the insulation coating of the ends 5, 7 of the coil wire, so that there is electrical contact between the insulation cutting terminal 27a, b and the corresponding end 5, 7 of the coil wire. The terminals 27a, b for insulation cutting are preferably metal. Fig. 6 shows the situation after the insulation cutting terminals 27a, b have been inserted into the slots 25a, b.

Fig. 7 shows a fully assembled stator segment S _{i, j} with a wire guide structure 13 placed on the axial front side 9 of the stator segment S _{i, j} . The wire guide structure 13 substantially extends in a plane perpendicular to the stator axis R and snaps into a positive fit with the front portion 21a of the stator segment S _{i, j} .

с

, тогда как конструкции 13 для направления провода проходят на менее чем

, например, на

относительно азимутального центра соответствующего сегмента S_{i, j} статора.Fig. 8 shows the situation after nine identical stator segments S _{i, j} as shown in FIG. 7 are placed in an annular arrangement to form the stator assembly 1. The stator segments S _{i, j} are attached to each other on their sides 25a, b, wherein the first side 25a of the stator segment S _{i, j} is connected by a forced action to the second side 25b of the adjacent stator segment S _{i, j} . As can be seen in FIG. 8, the wire guide structures 13 have a distance to each other in the circumferential direction, i.e., there is an azimuth angular distance of about 20° between them. That is, the reason is that they are narrower compared to the stator segments S _{i, j} . In other words, the stator segments S _{i, j} extend through the azimuth angular distance

With

, while the structures 13 for guiding the wire run for less than

, for example, on

relative to the azimuth center of the corresponding segment S _{i, j} of the stator.

, чтобы принимать следующий соединительный провод из машины точно в той же самой позиции. Первый конец 33a соединительного провода, таким образом, вставляется во второе углубление 31 первой клеммы 27a для монтажа с прорезанием изоляции в первой прорези 23a параллельно первому концу 5 провода катушки. Аналогично, второй конец 33b соединительного провода прижимается во второе углубление 31 второй клеммы 27b для монтажа с прорезанием изоляции во второй прорези 23b параллельно второму концу 7 провода катушки. Таким образом, клеммы 27a, b для монтажа с прорезанием изоляции врезаются в изоляционное покрытие соединительного провода W_{i, k} на первом конце 33a соединительного провода и втором конце 33b соединительного провода, соответственно, для того, чтобы устанавливать электрический контакт с соответствующим концом 5, 7 провода катушки.Fig. 9 shows the situation after assembling the connecting wires Wi _{, k} . The six connecting wires W _{i, k} are identical in shape and length and can be placed by the machine simultaneously or one after the other into place by purely axial movement. For example, the machine may simply push the connecting wire Wi _{, k} in the axial "downward" direction in FIG. 9, i.e., back in the negative z-direction along the R-axis of the stator. The machine does not even have to change its angular position, since the annular arrangement of the stator segments S _{i, j} can rotate by

to receive the next connecting wire from the machine in exactly the same position. The first end 33a of the connecting wire is thus inserted into the second recess 31 of the first insulation-cutting terminal 27a in the first slot 23a parallel to the first end 5 of the coil wire. Similarly, the second end 33b of the connecting wire is pressed into the second recess 31 of the second insulation cutting terminal 27b in the second slot 23b parallel to the second end 7 of the coil wire. Thus, the insulation cutting terminals 27a, b cut into the insulating coating of the connection wire W _{i, k} at the first end 33a of the connection wire and the second end 33b of the connection wire, respectively, in order to make electrical contact with the corresponding end 5, 7 coil wires.

Fig. 10 shows the situation after assembling the star wire 16 running along the third radially innermost path 13c of the structure 13 for guiding the wire of the stator segment S _2,n . The star point wire 16 is shorter than the connecting wires W _{i, k} but has a larger diameter. It connects the coils of the last 3 (j=n) stator segments S _{i, n} of the three sets to each other at their first ends of the 5 coil wires. Therefore, the star wire 16 comprises three ends of the star point axially pressed into the second recess 31 of the first insulation cutting terminal 27a in the first slots 23a of the stator segments S _{i, n} of the three sets of stator segments. Finally, in order to achieve a fully assembled stator assembly 1 as shown in FIG. 1, the three phases 17a, b, c of the three-phase power input lines 17 are pressed axially into the second recess 31 of the second insulation-cutting terminal 27b in the second slot 23b of the respective first (j=1) segment S _i,1 of the three sets of stator stator segments.

An alternative embodiment with respect to nine separate and identical wire guidance structures 13 is shown in FIG. 11. FIG. 11 shows a wire guide element 15 defining a plurality of wire paths 13a, b, c arranged in 3n-fold rotational symmetry around the stator axis R. The wire guide element 15 is a substantially annular one-piece structure connecting the wire guide structures 13 into a single structure. Instead of mounting separate structures 13 for guiding the wires to the stator segments S _{i, j} , as shown in FIG. 7, the wire guide element 15 according to FIG. 11 is installed on the complete annular arrangement of the stator segments S _{i, j} .

List of reference positions

1 - stator assembly

3 - coil

5 - the first end of the coil wire

7 - the second end of the coil wire

9 - axial front side

11 - axial rear side

13 - design for wire guidance

15 - element for guiding the wire

15a, b, c - wire paths

16 - wire of the neutral point of the star

17a, b, c - phases of the three-phase power input line

19 - core

21a - front

21b - back

23a - first slot

23b - second slot

25a - first side

25b - second side

27a - first terminal for insulation cut-out mounting

27b - second terminal for insulation cut-out mounting

29 - first recess

31 - second recess

33a - first end of the connecting wire

33b - second end of the connecting wire

i - index for the set of stator segments

j - index for the stator segment in the set of stator segments

k is the index for the connecting wire for the set of stator segments

S _{i, j} - stator segment

W _{i, k} - connecting wire

R - stator axis

φ - azimuth angle

A - plane of symmetry

r ₁ - first radial distance

r ₂ - second radial distance

Claims (26)

1. Assembly (1) of the three-phase stator of the drive motor of the electric pump, containing: - three sets of stator segments (S _{i, j} ), wherein the stator segments (S _{i, j} ) are placed in an annular arrangement around an axially extending stator axis (R), each set of stator segments (S _{i, j} ) containing n ≥2 stator segments (S _{i, j} ) arranged in n-fold rotational symmetry about the stator axis (R), with each stator segment (S _{i, j} ) containing a coil (3) having a first coil wire end (5) and the second end (7) of the coil wire, and - a set of 3n-3 connecting wires (W _{i, k} ) placed on the axial front side (9) of the segments (S _{i, j} ) of the stator, with each connecting wire (W _{i, k} ) connecting two coils (3) of the corresponding set segments (S _{i, j} ) of the stator in series, while the first intermediate segment (S _{i, j} ) of the stator and the second intermediate segment (S _{i, j} ) of the other two sets of segments (S _{i, j} ) of the stator are placed in a circular direction between two connected coils (3) of the mentioned corresponding set of segments (S _{i, j} ) of the stator, moreover, at least 3n-5 connecting wires (W _{i, k} ) pass through the first intermediate segment (S _{i, j} ) of the stator at the first radial distance (r ₁ ) to the axis (R) of the stator and through the second intermediate segment (S _{i, j} ) of the stator at a second radial distance (r ₂ ) to the axis (R) of the stator, while the second radial distance (r ₂ ) exceeds the first radial distance (r ₁ ). 2. The node (1) of the three-phase stator according to claim 1, in which at least 3n-5 connecting wires (W _{i, k} ) have the same shape and length. 3. The node (1) of the three-phase stator according to claim 1 or 2, in which all the connecting wires (W _{i, k} ) run along their entire length in almost a common plane perpendicular to the axis (R) of the stator. 4. Three-phase stator assembly (1) according to any one of the preceding claims, further comprising a star point wire (16), wherein the star point wire (16) connects the first ends (5) of the coil wire for the coils (3) (j=n )th segments (S _{i, j} ) of the three sets of segments (S _{i, j} ) of the stator with each other. 5. Three-phase stator assembly (1) according to any of the preceding claims, further comprising a three-phase power input line with three phases (17a, b, c), each phase (17a, b, c) connected to the second end (7) of the wire coils for coil (3) (j=1)-th segment (S _{i, j} ) of the stator from the corresponding set of segments (S _{i, j} ) of the stator. 6. The node (1) of the three-phase stator according to any of the preceding paragraphs, additionally containing an element (15) for guiding the wire, placed on the axial front side (9) of the segments (S _{i, j} ) of the stator, while the element (15) for guiding the wire defines a plurality of wire paths (13a, b, c) with wire paths (13a, b, c) arranged in 3n-fold rotational symmetry around the stator axis (R). 7. Three-phase stator assembly (1) according to claim 6, wherein the wire guiding element (15) consists of a plurality of 3n separate and identical wire guiding structures (13), with each wire guiding structure (13) placed on axial front side (9) of the corresponding segment (S _{i, j} ) of the stator. 8. The three-phase stator assembly (1) according to claim 7, wherein the structures (13) for guiding the wire have a distance from each other in a circular direction. 9. Node (1) three-phase stator according to any one of paragraphs. 6-8, in which the element (15) for guiding the wire is attached to the axial front side (9) of the segments (S _{i, j} ) of the stator by means of a forced landing. 10. Node (1) three-phase stator according to any one of paragraphs. 6-9, in which the element (15) for guiding the wire is placed radially between the first ends (5) of the coil wire and the second ends (7) of the coil wire for the coil (3) of the corresponding segment (S _{i, j} ) of the stator. 11. The three-phase stator assembly (1) according to any one of the preceding claims, wherein the first end (5) of the coil wire for the coil (3) of each stator segment (S _{i, j} ) is placed on the first side (25a) of the respective segment (S _{i , j} ) of the stator, and the second end (7) of the coil wire for the coil (3) of each segment (S _{i, j} ) of the stator is placed on the second side (25b) of the corresponding segment (S _{i, j} ) of the stator. 12. The three-phase stator assembly (1) according to any one of the preceding claims, wherein each stator segment (S _{i, j} ) further comprises a first terminal (27a) for cutting through the insulation to connect the corresponding connecting wire (W _{i, k} ) to the first end (5) of the coil wire and a second terminal (27b) for insulation cutting to connect the corresponding connecting wire (W _{i, k} ) to the second end (7) of the coil wire. 13. The three-phase stator assembly (1) according to claim 12, wherein the first insulation-cutting terminal (27a) is inserted axially into the first slot (23a) formed on the axial front side (9) of the segment (S _{i, j} ) of the stator, and the second terminal (27b) for insulation cutting is inserted axially into the second slot (23b) formed on the axial front side (9) of the stator segment (S _{i, j} ). 14. The three-phase stator assembly (1) according to claim 13, wherein the first slot (23a) and/or the second slot (23b) extend substantially tangentially with respect to the annular arrangement of the stator segments (S _{i, j} ). 15. The node (1) of the three-phase stator according to claim 13 or 14, in which - the first end (5) of the coil wire and the first end (33a) of the connecting wire pass radially through the first slot (23a), while the first end (5) of the coil wire is received in the first recess (29) of the first terminal (27a) for slot mounting insulation, and the first end (33a) of the connecting wire is received into the second recess (31) of the first terminal (27a) for insulation cutting, and/or - the second end (7) of the coil wire and the second end (33b) of the connecting wire pass radially through the second slot (23b), the second end (7) of the coil wire being received in the first recess (29) of the second terminal (27b) for insulation cutting , and the second end (33b) of the connecting wire is received into the second recess (31) of the second insulation-cutting terminal (27b). 16. The three-phase stator assembly (1) according to claim 15, in which the first recess (29) and the second recess (31) of the first terminal (27a) for insulation cutting and/or the second terminal (27b) for insulation cutting are placed on opposite axial sides of the respective terminal (27a, b) for insulation cut-out mounting. 17. Three-phase stator assembly (1) according to any one of the preceding claims, wherein the connecting wires (W _{i, k} ) do not cross each other. 18. Three-phase stator assembly (1) according to any of the preceding claims, wherein for each stator segment (S _{i, j} ) the first end (5) of the coil wire is placed on the radially inner side of the stator segment (S _{i, j} ), and the second end (7) coil wires are placed on the radially outer side of the stator segment (S _{i, j} ). 19. Three-phase stator assembly (1) according to any one of the preceding claims, in which all segments (S _{i, j} ) of the stator are practically identical and differ only in their connection to the connecting wires (W _{i, k} ), input phases (17a, b, c) and/or wire (16) of the neutral point of the star. 20. The three-phase stator assembly (1) according to any one of the preceding claims, wherein each connecting wire (W _{i, k} ) extends a maximum azimuthal angular distance in the range of

before

. 21. Three-phase stator assembly (1) according to any of the preceding claims, wherein the first end (5) of the coil wire for the coil (3) of the set of stator segments (S _{i, j} ) and the second end (7) of the coil wire of the next connected coil in series (3) said set of segments (S _{i, j} ) of the stator have an azimuth angular distance to each other in the range from

before

.

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