WO2006069841A1

WO2006069841A1 - Electric machine, in particular an ec-motor and method for the production thereof

Info

Publication number: WO2006069841A1
Application number: PCT/EP2005/055695
Authority: WO
Inventors: Gerald Zierer; Michael Albrecht; Andreas Wehrle; Michael Huber
Original assignee: Robert Bosch Gmbh
Priority date: 2004-12-27
Filing date: 2005-11-02
Publication date: 2006-07-06
Also published as: DE102004062816A1

Abstract

The invention relates to an electric machine, in particular to an EC motor (10) comprising a stator (11) whose stator laminate (12) is provided with pole teeth (17) uniformly distributed on the circumference thereof with a multiphase stator winding (25), wherein each phase comprises at least one phase winding consisting of several single tooth bobbins (18). A method for producing the inventive machine is also disclosed. In order to simplify as much as possible the embodiment of the stator winding (25) with regard to the manufacturing thereof, the single tooth bobbins (18) are continuously wound for each phase winding, the beginning and/or the end of said single tooth bobbins (18) are oriented respectively by a common contacting part (U, V, W, Stp1, Stp2) associated to several single tooth bobbins and thereby electrically connected thereto.

Description

Electric machine, in particular EC motor and method of its manufacture

State of the art

The invention relates to an electrical machine, in particular to an electrically commutated motor according to the preamble of claim 1 and to a method for

Production of the machine according to the preamble of claim 9.

In so-called EC motors, the three phases of the stator winding are electronically commutated to produce a rotating field. For six, nine, twelve or more poles

Machines are the individual pole teeth of the stator usually wound with Einzelzahnspulen, each belonging to a winding strand. Each phase of the stator winding has at least one phase winding of several Einzelzahnspulen. Usually, the

Single tooth coils of the individual winding strands connected in parallel or in series.

When using small EC motors in motor vehicles, for example for highly accurate actuators, these are powered by a relatively small on-board voltage. In this case, a series connection of the coils on the one hand advantageous because the coils can be wound by automatic winding machines. A disadvantage, however, is that at low voltages and high power the coil wires due to a relatively large current with their relatively large wire cross-section have a correspondingly high rigidity and thus a relatively high wire tension. This is problematic when winding Polzähnen with small tooth width and low winding space. In a parallel connection of the coils of a Winding strings can be produced more easily with the same engine power compared to a series connection with a smaller wire cross-section with a higher number of turns. However, the parallel circuit has the disadvantage that the coils of the winding strand are wound individually, since their beginnings with the respective phase connection and their ends must be contacted with a neutral point.

The present solution is aimed at a

Parallel connection of the coils of a winding strand to be able to wrap them consistently nonetheless.

Advantages of the invention

The machine according to the invention with the characterizing features of claim 1 has the advantage that when winding the Statorpolzähne the single-tooth coils are due to their parallel connection with a relatively small cross-section and correspondingly larger number of turns easily produce in a confined space. In addition, since the beginnings and the ends of these single-tooth coils are each guided for parallel connection via common, several single-tooth coils associated contact parts, now the single-tooth coils can be continuously wound by winding machines. This is significantly cheaper to manufacture than a parallel connection of individually wound coils, since their coil wire ends would otherwise have to be contacted individually with a so-called interconnection element. This solution is also winding technically cheaper, since it allows the use of thinner winding wires, which is a considerable simplification especially for small machines with tight stator slots for winding the stator teeth. In addition, this solution gives more degrees of freedom for the Characteristic of the winding layers as with a few, thick wires. In addition, with a smaller wire thickness, the groove slot can be narrower, which may increase the magnetic flux in the stator and thus the engine torque and so-called cogging torques can be reduced.

The measures listed in the dependent claims expedient refinements and developments of the features specified in claim 1 and 9.

Since in most applications of the EC motor in the motor vehicle, the stator per phase is wound with only one phase winding of several Einzelzahnspulen, it is advantageous for the production of the stator winding, if at least two, preferably all

Winding strands are wound continuously. However, if necessary, after contacting the individual toothed coils with the contact points, in order to avoid short circuits between the individual phases of the stator winding, it is necessary to separate a wound connection between two contact parts. Conveniently, all contact parts are arranged for parallel connection of the wound through Einzelzahnspulen on a front side of the stator and each provided with a contact hook, is hooked on each in a reliable manner by means of winding machines lying between two Einzelzahnspulen section of the winding wire. After winding, the winding wires suspended on the contact hooks are electrically and mechanically connected to the respective contact part.

Conveniently, the beginnings and the ends of the winding strands are each hooked on the contact hook of a trained as a phase connection or neutral contact part and electrically contacted, preferably welded. To the star point interconnection of the three If it is not necessary to hook all the ends of the individual toothed coils on a contact hook, it is proposed that the star point be formed from at least two contact parts which are spaced apart from each other and which are electrically connected to one another as required for equipotential bonding via a conductor. In order to ensure the hanging of the winding wire to the Kontakteilen by means of winding machines as easily as possible, it is proposed that on an end face of the stator, a Isolierstoffring is attached with axially projecting outer collar, the

Contact parts carries, which are preferably made of an axially aligned sheet metal strip with free-punched, axially outwardly open contact hook. In this case, the outer collar is expediently provided with radial recesses for the supply and discharge of the winding wire of the radially inner single tooth coils. The interconnection of the individual tooth coils is thus completely on the one end side of the stator. In order to lead the winding wires between the individual teeth coils as possible arranged to their respective contact part, the Isolierstoffring is provided on its outer side, preferably in the region of the outer collar with a plurality of mutually parallel circumferential grooves in which more or less many winding wire sections are added in sections.

drawing

The invention will be explained in more detail below by way of example with reference to FIGS. Show it:

1 shows an EC motor in a simplified representation in longitudinal section, 2 shows a stator of the EC motor with frontal Isolierstoffring and contact parts, before winding, in three-dimensional view,

FIG. 3 shows a contact part in an enlarged spatial representation,

FIG. 4 shows an outbreak of the insulating ring in an enlarged spatial representation,

Figure 5 shows the interconnection of the three winding strands with their three each wound through Einzelzahnspulen to the contact parts as a first embodiment.

Figure 6 shows a second embodiment, the interconnection of the single-tooth windings and the three wound winding strands with the contact parts, Figure 7 shows an enlarged view of a cross section through the stator of the EC motor with schematically outwardly directed contact parts and their interconnection with the Einzelzahnspulen of Figure 6 and

FIG. 8 shows the stator teeth with the single-tooth coils, the contact parts and their interconnection as development of the stator from FIG. 7.

Description of the embodiments

In Figure 1, an EC motor is shown in longitudinal section and designated 10 as the electric machine according to the invention. It has a stator 11 with a stator 12 and a housing 13. Within the stator 12, a rotor 14 is mounted on a rotatably mounted motor shaft 15. The rotor 14 is provided with evenly distributed on the circumference arranged permanent magnet 16, which cooperate with the stator 12 of the stator 11. The stator 12 consists of a plurality of poles, each forming a radially inwardly directed pole tooth 17. Each pole tooth 17 carries a single tooth coil 18 which is one of three winding strands of one described below belongs to three-phase stator winding. In the example, it is a nine-pole stator 11, which interacts with a twelve-pole rotor.

Figure 2 shows the separately producible stator 12 in a three-dimensional view with its nine poles 12a before the winding of its pole teeth 17. On the right front side of the stator 12 is a Isolierstoffring 19 is attached, which is provided with an axially projecting outer collar 20. In the outer collar 20 are a total of five

Contact members 21 embedded at a distance from each other or inserted and anchored in corresponding slots, which are made of a metal strip and protrude axially from the outer collar 20.

Figure 3 shows an enlarged spatial representation of such a contact part 21. The outer portion of the sheet metal strip is formed as a connector tongue 21a, which can be used as a phase connection. On the sheet metal strip of the contact parts 21, a contact hook 22 is also punched free and bent radially inward so far back that the hook opening 22a is directed axially outward.

Figure 4 shows an enlarged view of an outbreak of the insulating ring 19 of Figure 2 to make it clear that in the region of the outer collar 20 of the insulating ring 19 has on its outer side a plurality of mutually parallel, circumferential grooves 24. These grooves 24 serve to receive and guide the winding wire sections between the single-tooth coils, which - as explained below - each guided by one of the individual teeth coils 18 to one of the contact parts 21, hooked there on the contact hooks 22 and optionally continued from there to another single-tooth coil 18 have to. The outer collar 20 of the insulating ring 19 also has radial recesses 23rd for the supply and discharge of winding wires of the radially inner single-tooth coils 18.

FIG. 5 shows, for the nine-pole EC motor 10, a three-phase stator winding 25 with three winding phases 26, 27, 28, which each have three single-tooth coils 18. In the first embodiment of the invention, only the three single-tooth coils 18 of each winding strand 26, 27, 28 are wound through and interconnected in parallel via two contact parts 21. For the better

Understanding here are the nine pole teeth 17 numbered Zl to Z9 and also the single-tooth coils 18 with Sl to S9. The contact parts 21, on each of which the beginning of the winding strands is first hooked, form the phase terminals U, V and W. The contact parts 21, to each of which the end of the winding strands 26, 27 and 28 is hooked together form a star point and are therefore referred to as star point parts Stpl, Stp2 and Stp3.

For the first winding strand 26, the winding wire 29 is now first on the contact hook 22 of the

Phase connection part U hooked and then wound on the pole tooth Zl the coil Sl. Subsequently, the winding wire is hung on the star point part Stpl and then continued to the pole tooth Z4. There, the coil S4 is wound and then the winding wire is hooked again to the phase connection part U. It is then led to the pole tooth Z7, on which the coil S7 is then wound. From there, the coil end becomes the star point part again

Stpl out, hung there and cut the winding wire afterwards.

The same thing is repeated when winding through the single-tooth coils 18 for the second winding strand 27 of FIG Phase V. There, the winding wire 29 is first hooked on the contact hook of the phase connection part V and then wound on the pole tooth Z2, the coil S2. Subsequently, the winding wire is hooked to the star point part Stp2 and then continued to the pole tooth Z5. There, the coil S5 is wound and then the winding wire is hooked again to the phase connection part U. It is then guided to the pole tooth Z8, on which then the coil S8 is wound. From there, the coil end is now again guided to the star point part Stp2, hooked there and then cut off the winding wire.

The same is now repeated for the third winding phase 28 of the phase W. Also there, first the winding wire 29 at the contact hook 22 of the

Phase connection part W hooked and then wound on the pole tooth Z3, the coil S3. Subsequently, the winding wire is hooked to the star point part Stp3 and then continued to the pole tooth Z6. There, the coil S6 is wound and then the winding wire is hooked again to the phase connection part U. It is then guided to the pole tooth Z9, on which then the coil S9 is wound. From there, the coil end is now again guided to the star point part Stp3, hung there and then cut the winding wire.

In order to interconnect the three winding phases 26, 27 and 28 to form a star point, the three star point parts Stpl, Stp2, and Stp3 must now be connected to one another. For this connection, the triple cross-section of the winding wire 29 is required because it has to conduct the current of the three parallel-connected coils of a winding strand. This connection is made in the simplest way by a correspondingly thick connecting wire 30 which is hooked to the contact hooks 22 of the three star point parts. Alternatively, this connection can also be made via a bus bar in the insulating ring 19 or by repeated reciprocating the winding wire 29 between the three star point parts.

After the three winding strands have been produced and the winding strand catches and ends and the connections between the individual gear spools 18 are each hooked to one of the contact hooks 22, the contact hooks 22 are now compressed and the hinged there

Winding wires are contacted with each other and with the respective contact part 21 electrically and mechanically. After this contacting, the three wound coils 18 of each winding strand 26, 27, 28 are now connected in parallel to each other.

FIGS. 6 to 8 show a second exemplary embodiment of the invention with a parallel connection of the three single-tooth coils 18 of each winding strand 26, 27 and 28, this time not only through the three coils of a winding strand. Here, the three winding strands and thus all single-tooth coils 18 are wound through and then the coils of each winding strand are connected in parallel to each other and the three winding strands connected in a star. The designations of the single-tooth coils 18, the pole teeth 17 and the contact parts 21 are the same as in the example according to FIG. 5. However, the third neutral point part Stp3 can be dispensed with here. For a better understanding of the sequence of steps in the continuous winding of the nine single-tooth coils, reference is made to FIG. However, the winding sequence can also be reproduced in the sectional view of the stator 11 according to FIG. 7 as well as in the development of the stator 11 in FIG. The winding wire 29 is first hung with its beginning 29a on the contact hook 22 of the phase connection part U and guided from there to the pole tooth Zl. Now the coil Sl is wound and then the winding wire 29 is hooked on the contact hook 22 of the star point part Stp2 and guided from there to the pole tooth Z4. Now the coil S4 is wound and then the winding wire in turn hooked to the phase terminal U. From there it goes to Polzahn Z7. The coil S7 is wound there and then you hang the winding wire on the contact hook 22 of the star point part Stpl. Then it goes to the pole tooth Z8, where the coil S8 is wound. Thereafter, the winding wire is hooked to the phase terminal part V and then continued to the pole tooth Z2. There, the coil S2 is wound and then the winding wire is hung again at the star point part Stp2. From there it goes to the pole tooth Z5 and it is wound the coil S5. Then, the winding wire is hooked again to the phase connection part V and looped from there to the phase connection part W. This connection 31 is shown in dashed lines, since it must be removed later. From the phase connection part W, the winding wire 29 is now guided to the pole tooth Z6 and there the coil S6 is wound. Thereafter, the winding wire is hooked again to the star point part Stp2 and then guided to the pole tooth Z3. There, the coil S3 is wound and then the winding wire is also hung again on the phase connection part W. Now it goes to the pole tooth Z9 to wind the last coil S9. Thereafter, the winding wire 29 is hooked to the star point part Stpl and finally he is with his end 29b until the

Star point part Stp2 out. Now the connection hooks 22 of the contact parts 21 are compressed as in the example of Figure 5 and the winding wires suspended there are contacted with the contact parts 21, suitably welded. As a result of this contacting, the two star point parts Stpl and Stp2 are connected to one another and, furthermore, the three individual toothed coils 18 of each of the three winding phases 26, 27 and 28 are connected in parallel with one another. To avoid a short circuit between the phases V and W, finally, the connection 31 between the two phase terminals V and W is separated out. Since in a symmetrical design of the complex winding resistances of all single-tooth coils 18 during operation of the EC motor at the neutral point parts Stpl and Stp2 virtually always the same potentials, can be dispensed with if necessary, even on the electrical connection 29c between them.

In FIG. 7, the phase connection parts U, V and W as well as the star point parts Stpl and Stp2 have been laid radially outside the stator 11 shown in cross-section for better recognition of the winding pattern. There is also recognizable that the beginnings and ends of the single-tooth coils

18 first radially outward and then in the circumferential direction must be performed to their associated phase connection or star point part. By the insulating ring 19 shown in Figure 2 with the outer collar 20 for this, the necessary order can be created by the beginnings and

Ends of the coils are each routed through one of the recesses 23 from the inside to the outside and then laid in one of the grooves 24 on the outer collar 20. Furthermore, it can be seen that the connection 31 between the phase connection parts V and W in the region of the recesses 23 of the outer collar 20 can be cut out relatively easily.

FIG. 8 once again shows the development of the stator 11 with the winding pattern for the nine single-tooth coils 18, wherein the Winding direction of the winding wire 29 is made visible in each case by arrows. The contacting of the

Winding wire 29 with the contact parts 21 is shown in each case as a continuous connection of the wire to the respective contact part. Consequently, in the case of the connections shown in the region of the contact parts, there is no contact with them.

As an alternative to the exemplary embodiment according to FIGS. 6 to 8 with the three winding strands of the phases U, V and W wound one behind the other, it is equally possible for only the two winding strands of the phases U and V to be wound through in accordance with FIG. The third winding strand for the phase W is now wound separately, according to FIG. 6, starting at the phase connection part W. After winding through the coils S6, S3 and S9, the end of the phase W winding strand is finally hung on the star point part Stp2. Therefore, in this alternative solution, the connection 31 in FIG. 6 is intentionally dispensed with, since it must be removed again during winding through all three winding strands, in order to prevent a short circuit between the phases V and W.

The winding according to the invention of the single-tooth coils of winding strands of the stator winding can be realized not only according to the described embodiments of nine-pole EC motors, but also perform on six-pole, twelve-pole or EC motors with even higher number of poles. To the contact parts 21, z. B. when contacting multiple wires to the star point parts to avoid Kontaktierungsprobleme, there may be punched in case of need, more than one contact hooks 22 to be able to distribute the winding wires to be hooked there on these hooks.

Claims

claims

1. Electrical machine, in particular electrically commutated motor (10) with a stator (11) whose

Stator package (12) over its circumference uniformly distributed pole teeth (17) having a mehrphasigen Einzelzahnbewicklung, each phase (U, V, W) has at least one winding strand (26; 27; 28), which consists of a plurality of Einzelzahnspulen (18) characterized in that for each winding strand (26, 27, 28) the single-toothed coils (18) are continuously wound and connected in parallel to each other by the beginnings and / or ends of these Einzelzahnspulen (18) each via a common, a plurality of Einzelzahnspulen associated contact part (21 ) and are electrically connected therewith.

2. Electrical machine according to claim 1, characterized in that at least two of the winding strands (26, 27, 28), preferably all winding strands are wound continuously.

3. Electrical machine according to claim 1 or 2, characterized in that all contact parts (21) on one

Arranged front side of the stator (11) and are each provided with at least one contact hook (22) on which in each case at least one between two Einzelzahnspulen (18) lying portion of the winding wire (29) mounted and electrically contacted.

4. Electrical machine according to claim 3, characterized in that the beginnings and the ends of the winding strands (26, 27, 28) respectively on the contact hook (22) of a phase-connecting part (U, V, W) or Star point part (Stpl, Stp2) formed contact part (21) mounted and are electrically contacted.

5. Electrical machine according to claim 4, characterized in that the star point of at least two spaced-apart contact parts (Stpl, Stp2) is formed, which, if necessary, via a conductor (29c) are electrically connected together.

6. Electrical machine according to one of claims 3 to 5, characterized in that on one end face of the stator 11, an insulating ring (19) with axially projecting outer collar (20) is fixed, which carries the contact parts (21), preferably from an axial aligned sheet metal strip with punched, after axially outwardly open contact hook (22) are made.

7. Electrical machine according to claim 6, characterized in that the outer collar (20) radial recesses (23) for the supply and discharge of the

Winding wire (29) of the radially inner single tooth coils (18).

8. Electrical machine according to claim 7, characterized in that the insulating ring (19) on its outer side, preferably in the region of the outer collar (20) has a plurality of parallel, circumferential grooves (24) for receiving winding wire sections between the Einzelzahnspulen (18).

9. A method for producing an electrical machine according to the preamble of claim 1, characterized in that for each winding strand (26, 27, 28), the single-toothed coils (18) are wound continuously, wherein the beginnings and / or ends of these Einzelzahnspulen in each case via a common, a plurality of Einzelzahnspulen (18) associated contact part (21) and then electrically connected thereto.

10.A method according to claim 9, characterized in that at least two of preferably three winding strands (26, 27, 28), preferably all winding strands are wound continuously successively.

11.Verfahren according to claim 9 or 10, characterized in that the respectively between two Einzelzahnspulen (18) lying portion of the winding wire (29) mounted on a contact hook (22) of the contact part (21) and then electrically connected thereto, preferably welded ,

12.Verfahren according to claim 11, characterized in that the beginnings of the winding strands (26, 27, 28) respectively on the contact hook (22) of a phase connection (U, V, W) formed contact part (21) and the ends of the

Winding strands (26, 27, 28) each hooked on the contact hook (22) of a trained as a star point contact part (Stpl, Stp2, Stp3) and then electrically connected to this, in particular welded.