Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
  • H02K1/12—Stationary parts of the magnetic circuit
  • H02K1/14—Stator cores with salient poles
  • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
  • H02K1/148—Sectional cores
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
  • H02K1/22—Rotating parts of the magnetic circuit
  • H02K1/24—Rotor cores with salient poles ; Variable reluctance rotors
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/02—Details of the magnetic circuit characterised by the magnetic material

Definitions

• the invention is based on a main element which can be used as a rotor or stator for an electrical machine, in particular for a DC small motor, according to the preamble of claim 1.
• the magnetically conductive body of stators or rotors of an electric machine are increasingly made of SMC material (Soft Magnetic Powder Iron Composite) and displace the laminated iron body or laminated cores, especially in small DC motors, since they are much easier to produce.
• SMC material Soft Magnetic Powder Iron Composite
• the SMC material offers additional advantages compared to stator or rotor bodies
• Laminations such as the reduction of iron losses at high frequencies in high speed motors or a large number of poles, improved thermal characteristics through the use of thin toothed insulation, since the teeth can be pressed without sharp corners and edges, and a high flexibility in the design of the engine.
• the SMC material is usually pressed by means of a pressing tool into the desired shape of the stator or rotor and then heat-treated at a relatively low temperature of, for example, up to 500 ° C.
• a relatively high density of the material must be achieved, which comes as close as possible of iron (7.8 g / cm 3 ).
• Such a density can only be achieved if the shape ratio of the compact (aspect ratio) is as large as possible.
• the limit has been found to be a 1:15 ratio.
• Shape ratio is understood to mean the ratio of the smallest dimension of the cross section of the compact extending transversely to the pressing direction to the length of the compact in the pressing direction.
• Each ring segment of the return ring integrally carries a stator tooth with a tooth neck and a tooth shank which delimits the tooth neck at its end remote from the return ring.
• Each ring segment with tooth neck and tooth shoe is made of SMC material by pressing and heat treatment.
• the tooth necks are rounded at their axial ends or have an oval profile, so that due to omission of sharp edges on the tooth necks only a thin insulating layer must be applied to the then the toroidal coil can be wound up.
• the individual toroid coils of the stator winding are directly on the tooth necks with wound up using conventional mechanical winding technology. After winding the toroidal coils, the individual ring segments are put together in the circumferential direction and firmly connected.
• stator made of SMC material for an internal rotor machine (WO 00/69047)
• the return ring on the one hand and the stator teeth with tooth neck and tooth shoe on the other hand made separately from SMC material in the desired shape.
• the stator teeth are inserted in a form-fitting manner with the ends of the tooth necks remote from the tooth root in prepared recesses and secured thereto.
• the main element according to the invention for an electrical machine with the features of claim 1 has the advantage that the individual modules made of SMC material on the one hand have a relatively large shape ratio in the axial compression direction and therefore can be made with a high material density and on the other hand by joining of Only a few modules from only two module variants can represent a large axial length of the main element. This allows the low-cost production of small diameter electrical machines with a large axial length to achieve high performance, especially of small motors for automotive applications, such as DC motors for seat adjustment and window drive or brushless DC motors for gasoline direct injection.
• two identical modules are arranged outside as external modules and two identical modules as intermediate modules between the external modules.
• the outer modules are shaped so that when removing the two intermediate modules, the two outer modules are antsetzbar to an axially shortened return ring with molded teeth.
• FIG. 1 is a perspective view of a windingless stator made of SMC material of great axial length for an internal rotor motor
• FIG. 2 is a plan view of the wound stator in the direction of arrow II in Fig. 1,
• FIG. 3 shows a section of the windingless stator along the line III - III in Fig. 2,
• FIG. 4 shows a section of a teething of the stator along the line IV - IV in Fig. 3,
• Fig. 5 is an exploded view of the centrally separated stator in Fig. 1, wherein each
• Embodiment comprises,
• Fig. 6 is an end view of a stator half in
• FIG. 7 is a section along the line VII - VII in Fig. 6, 8 is an exploded view of a stator half in Fig. 5,
• FIG. 9 is an end view of the left in Fig. 8 module, in the direction of arrow IX,
• FIG. 11 is an end view of the right in Fig. 8 module in the direction of arrow XI,
• FIG. 13 is an exploded view of a windingless stator with shortened axial length
• FIG. 14 is a perspective view of the stator in Fig. 13,
• FIG. 15 is an end view of the stator in Fig. 14,
• the stator has an SMC body 11 made of magnetically conductive SMC material (Soft Magnetic Powder Iron Composite) with a yoke yoke or return ring 12 and integrally formed on the yoke ring 12, radially inwardly projecting teeth 13 which are offset by equal circumferential angle to each other , and a stator winding 10 schematically indicated in FIG. 2, which is wound onto the teeth 13 in the form of individual toroidal coils 101.
• the SMC body 11 consists of a total of four separately manufactured, axially aligned juxtaposed modules, of which two modules are identical and formed when juxtaposing against each other by 180 ° in the of the
• Module axes spanned plane are rotated.
• two identical modules are arranged outside as external modules 14 and two identical modules as intermediate modules 15 between the external modules 14.
• outside modules 14 and the intermediate modules 15 pretends, pressed, the pressing in the axial direction of the modules 14, 15 takes place, and then thermally treated.
• the modules 14, 15 are pressed to a density of about 7.3 g / cm 3 or greater.
• the thermal treatment is carried out, for example, for about 30 minutes in an air atmosphere at a temperature of about 500C 0 . So that the specified, desired high density of the Iron powder is achieved in the modules 14, 15, each module 14, 15 is shaped so that its so-called aspect ratio does not fall below a limit of 1:15. Under shape ratio, the ratio of the smallest dimension of the compact transverse to the pressing direction to the
• the axial length of the individual modules 14, 15 is selected so that the shape ratio at any point of the module is less than the predetermined minimum ratio.
• the modules 14, 15 each have an annular return element or segment 16 or 17 and an equal number of module teeth 18, 19 offset by equal circumferential angles on the return segment 16 or 17.
• Each return segment 16, 17 forms one of four axial sections of the return ring 12, and the module teeth 18, 19, which project unilaterally over the associated return segment 16 or 17, form the teeth 13 of the SMC body 11 when the modules 14, 15 are assembled
• the number of module teeth 18 or 19 on each outer module 14 or intermediate module 15 is half as large as the number of teeth 13 of the SMC body 11.
• one of the two identical outer modules 14 and the two identical intermediate modules 15 is shown in each case in perspective.
• 9 and 10 show the outer module 14 in front view and in longitudinal section.
• 11 and 12 show the intermediate module 15 in front view and in longitudinal section.
• the outer module 14 has three module teeth 18 which are arranged at equal circumferential angles to one another on the inner wall of the return segment 16 and which are designed in one piece with the return segment 16.
• Each module tooth 18 has a tooth neck or toothed shaft 20 and a tooth shoe 21, which is arranged on the end remote from the return segment 16 end of the toothed shaft 20 and the mutually remote, extending in the axial direction longitudinal sides of the tooth shank 20, ie in the circumferential direction, over the toothed shaft 20 protrudes.
• the toothed shoes 21 have the same axial length as the toothed shanks 20.
• the dental stems 20 are rounded off at their end faces, as can be seen in FIG. 17. Toothed shafts 20 and toothed shoes 21 are on one side with a part of their axial length, in the example with half the axial length on the
• the number of module teeth 18 is half as large as the total number of teeth 13 on the return ring 12 of the SMC body 11.
• the intermediate module 15 is shown in front view and in longitudinal section.
• the three module teeth 19 are in turn integrally formed on the inner wall of the return segment 17 by equal circumferential angles.
• the number of module teeth 19 is half as large as the total number of teeth 13 am
• each module tooth 19 has a tooth neck or toothed shaft 22 and a tooth shoe 23, which are formed in the same manner as in the module teeth 18 on the return segment 16.
• Die Modulzähne 19, die have the same axial length as the module teeth 18, but are available with a greater axial length over the front side of the Return segment 17, so that the transition surface of toothed shaft 22 to the return segment 17 is smaller than in the outer module 14.
• the lying outside of the return segment 17 front ends of the tooth shafts 22 are - as the tooth shafts 20 of the module teeth 18 on the outer module 14 - rounded.
• the lying within the yoke segment 17 front ends of the tooth shafts 22 are each provided with a concave curvature 24 having a same radius of curvature as the curves of the tooth shafts 22 at the other end of the tooth shafts 22 and at the ends of the tooth shafts 20 in the outer module fourteenth
• the toothed shoes 23 are shortened with respect to the tooth shanks 22 at the front end of the tooth shanks 22 carrying the indentation 24 and extend only to the lowest point of the indentation 24, as can be seen in FIG. 12 and also in FIG. 4.
• the return segment 17 of the intermediate module 15 has three recesses 25 arranged offset by equal circumferential angles from one another, which are introduced from that end side of the return segment 17 on which the module teeth 19 protrude.
• the recesses 25 have the same dimensions in the axial and circumferential directions. They are arranged centrally between the module teeth 19.
• the recesses 25 receive the regions of the return-path segment 17 of the other intermediate module 15 which carry the module teeth 19. On the one hand, this ensures that there is a sufficiently large connection area between the return segment 17 and the module tooth 19 and, on the other hand, that there is a torsionally rigid connection between the adjacent intermediate modules 15.
• an intermediate module 15 is first placed axially on an outer module 14, specifically in such a way that the module teeth 18 and 19 are aligned with one another.
• each composed of an outdoor module 14 and an intermediate module 15 components of the SMC - body 11 each carrying half of the total number of teeth 13 and corresponding to half of the total number of toroids 101 of the stator winding 10 are axially to the SMC Body 11 is assembled with stator winding 10, wherein prior to joining the one component of outdoor module 14 and intermediate module 15 in the plane in which the module axes are rotated by 180 ° relative to the other component of outdoor module 14 and intermediate module 15, so that the two
• Intermediate modules 15 are facing each other, as shown in Fig. 5 in perspective.
• one outer module 14 and the intermediate module 15 rigidly connected thereto are also rotated relative to the other outer module 14 and the intermediate module 15 rigidly connected thereto at an angle in the circumferential direction such that the teeth 13 of the one component of the SMC body 11 are gap-free Teeth 13 of the other component of the SMC body 11 are.
• the twist angle is 60 °.
• the twist angle is 360 ° / N when N is the total number of teeth 13 existing on the SMC body 11.
• the two components of the SMC body 11 are in this orientation, as can also be seen in Fig. 5, axially interleaved in the arrow direction, wherein mutually the module teeth
• the two outer modules 14 are aligned in the same way as described above, so that their end faces, on which the module teeth 18 protrude axially, facing each other and the module teeth 18 are in the one outer module 14 to gap with the module teeth 18 in the other outer module 14 ,
• the toroidal coils of the stator winding are wound onto the module teeth 18 of both outer modules 14.
• the composite SMC body 11 with an axially shortened overall length is shown in perspective in FIG. 14, in front view in FIG. 15 and in longitudinal section in FIG. 16.
• the return segments 16 of the two adjoining and non-rotatably interconnected outer modules 14 form the return ring II 1 of the axially shortened stator, and in each case a module tooth 18 of the two outer modules 14 forms a tooth 13 'of the axially shortened stator.
• Exterior module 14 each carries three module teeth 18, in turn results in the total number of six teeth 13 'on the shortened stator.
• the invention is not limited to the stator for an internal rotor machine described by way of example.
• a stator for an external rotor machine being constructed.
• the inventive composition of the SMC body is vorrismbar with rotors for electric machines with the same advantages.

Landscapes

• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Iron Core Of Rotating Electric Machines (AREA)

Priority Applications (4)

Applications Claiming Priority (2)

Publications (1)

Family

ID=34982566

Family Applications (1)

Country Status (5)

Families Citing this family (8)

Citations (3)

Family Cites Families (3)

• 2004
  • 2004-08-12 DE DE102004039180A patent/DE102004039180A1/de not_active Withdrawn
• 2005
  • 2005-06-30 DE DE502005010808T patent/DE502005010808D1/de not_active Expired - Lifetime
  • 2005-06-30 JP JP2007525273A patent/JP2008509647A/ja active Pending
  • 2005-06-30 WO PCT/EP2005/053099 patent/WO2006018346A1/de not_active Ceased
  • 2005-06-30 US US11/659,838 patent/US7705511B2/en not_active Expired - Fee Related
  • 2005-06-30 EP EP05763934A patent/EP1779493B1/de not_active Expired - Lifetime

Patent Citations (3)

Also Published As

Similar Documents

Legal Events