WO2015082270A2 - Winding segment for forming a winding of an electrical machine, method for producing a winding segment - Google Patents

Winding segment for forming a winding of an electrical machine, method for producing a winding segment Download PDF

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Publication number
WO2015082270A2
WO2015082270A2 PCT/EP2014/075630 EP2014075630W WO2015082270A2 WO 2015082270 A2 WO2015082270 A2 WO 2015082270A2 EP 2014075630 W EP2014075630 W EP 2014075630W WO 2015082270 A2 WO2015082270 A2 WO 2015082270A2
Authority
WO
WIPO (PCT)
Prior art keywords
winding
conductor
insulating
segment
conductor element
Prior art date
Application number
PCT/EP2014/075630
Other languages
German (de)
French (fr)
Other versions
WO2015082270A3 (en
Inventor
Christoph Radtke
Thomas SÖMMER
Bodo Von Moltke
Original Assignee
Continental Automotive Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Continental Automotive Gmbh filed Critical Continental Automotive Gmbh
Publication of WO2015082270A2 publication Critical patent/WO2015082270A2/en
Publication of WO2015082270A3 publication Critical patent/WO2015082270A3/en

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
    • H02K3/345—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation between conductor and core, e.g. slot insulation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/06—Embedding prefabricated windings in machines
    • H02K15/062—Windings in slots; salient pole windings
    • H02K15/064—Windings consisting of separate segments, e.g. hairpin windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/06—Insulation of windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/30—Windings characterised by the insulating material

Definitions

  • Winding segment for forming a winding of an electric machine Method for producing a winding segment
  • the present invention relates to a winding segment for forming a winding of a winding carrier, that is, a stator or a rotor, an electric machine. Furthermore, the invention relates to a method for producing a previously mentioned winding segment. In addition, the invention relates to a winding support and an electrical machine with ⁇ at least one aforementioned winding segment.
  • Winding carriers which have a laminated core together with windings wound in the laminated core and are designed as stators or rotors of the electrical machines.
  • the windings of a plurality of hairpin or U-shaped winding pins are out ⁇ forms and interlaced to form the windings in the laminated core with a spreading step corresponding to a winding step of Wick ⁇ ment carrier and inserted into the corresponding Blechunpolnuten the laminated core.
  • exposed end portions of the two bent legs of the respective winding pins protrude from the laminated core, which are interconnected to form the windings according to the winding step of the winding support and then electrically connected to each other.
  • Winding pins and the laminated core is made by means of insulating ⁇ paper.
  • the insulating paper and the winding pin are successively inserted into respective Polnut of the laminated core. Subsequently, the insulating paper and the Winding pin in a complicated process of impregnation or trickling mechanically bonded together and fixed in the Polnut.
  • the winding pins are coated with an insulating lacquer layer so that the two legs of each individual winding pin, which are inserted in one and the same laminated core pole, can be electrically insulated from one another and from the laminated core.
  • the insulating lacquer layer is used only for electrical insulation and has no own mechanical stability and requires a carrier, here in the form of the winding pins.
  • the Iso ⁇ lierlack Anlagen is vulnerable to external mechanical effects such. B. scratching by tools, whereby the paint layer during transport or when inserting the winding spins in the Blechmultipolnuten is often damaged and thus no longer provides sufficient electrical insulation.
  • the lacquer layer makes it difficult to form an intact winding and thus leads to additional expense and costs in the manufacture of electrical machines.
  • the object of the present invention is therefore to provide a way to produce electrical machines easily and inexpensively. This object is solved by subject matters of the independent claims. Advantageous embodiments are the subject of Un ⁇ terlay.
  • a winding segment for forming a winding of a winding carrier, that is to say a stator or rotor, of an electrical machine.
  • the winding segment has a first electrically conductive rod-shaped conductor element for forming the winding and an electrically insulating and independently mechanical stable insulating element, which encloses the first conductor element and electrically insulated.
  • the insulating element is attached directly and mechanically to the first conductor element.
  • an independent mechanical stability of the insulating element is about a mechanical strength of the insulating against external mechanical effects by tools that act in subsequent manufacturing steps for inserting the winding segment in a laminated core or to form the winding on the insulating.
  • This mechanical strength of the insulating member, the winding segment along with the Iso ⁇ lierelement can be inserted without destruction in the laminated core and are folded to form the winding, without the iso ⁇ lierelement is damaged, so that it after inserting and interleaving of the winding segment still sufficient electrical insulation offers between the winding segment and the laminated core.
  • the insulating element is positively, frictionally or materially ⁇ fastened to the first conductor element.
  • the insulating element is formed as a molded around the first conductor element injection molded part.
  • the insulating element can be produced inexpensively.
  • a mechanically stable connection between the conductor element and the insulating element can be produced at the same time during the molding of the insulating element.
  • the insulating element is simply attached by means of an adhesive connection to the first conductor element.
  • the insulating member surrounds the first conductor element circumferentially completely except for a first and a second end region of the first conductor element.
  • the two end portions which are not closed by the insulating member by ⁇ , are used to form electrical connections of the first conductor element of the coil segment to the circuit elements of other corresponding to the winding step in the
  • the winding segment comprises a second electrically conductive rod-shaped conductor element for forming the winding, wherein the insulating element also surrounds the second conductor element circumferentially and the first and the second conductor element mechanically interconnects and at the same time electrically insulated from each other.
  • the number of conductor elements is not a ⁇ side set to two.
  • the coil segment can preferably comprise a third and / or further electrically conductive bar-shaped conductor elements for forming the winding from ⁇ , wherein the insulating member, the third and the further conductor ⁇ elements also encloses circumferentially and the first, second, third and / or mechanically connects each further conductor element with ⁇ each other and at the same time electrically insulated from each other.
  • the preferred embodiments are described below always with reference to a winding segment with two conductor elements, these configurations also being valid for winding segments with three or more conductor elements.
  • the independent mechanical stability of the insulating member of ranges to fix the first and second circuit members together so that the winding segment inserted destruc ⁇ approximately freely in the corresponding Blechbpolnut and in accordance with the winding pitch of the winding support in
  • the insulating member also serves as a mechanical support of the two conductor elements.
  • the insulating member is also positively, positively or materially secured to the second conductor element.
  • the insulating element is formed as an over-molded around the first and the second conductor element injection-molded part.
  • the insulating element is simply attached by means of an adhesive connection to the first and the second conductor element. According to another preferred embodiment, this encloses
  • the second conductor element also with the exception of a third and a fourth end region of the first conductor element circumferentially completely, wherein the third and the fourth end region also serve to form electrical connections to the conductor elements of other winding segments.
  • a winding carrier that is to say a stator or a rotor, is provided for an electrical machine which has at least one winding which is formed from at least one winding segment described above.
  • an electrical machine which has a winding support with at least one winding, wherein the at least one winding is formed from at least one winding segment described above.
  • a method of manufacturing a winding for a coil carrier that is, a stator or a rotor, an electric machine. The method comprises the following method steps :
  • a first electrically conductive rod-shaped conductor element is thus provided.
  • a mechanically stable insulating element is fixed to the first conductor element, which also serves to strengthen the me chanical stability of the ⁇ first conductor member and circumferentially encloses said first conductor element and thus electrically isolated.
  • the first conductor element and the insulating ⁇ comprehensive element winding segment is inserted to form the winding in a laminated core.
  • the insulating element is formed by injection molding a casting compound around the first conductor element and at the same time attached to the first conductor element.
  • a further preferred embodiment of the method is provided according to the method step of providing that, in addition to the first conductor element, a second electrically conductive rod-shaped guide element for forming the winding is provided.
  • the insulating element is attached to the first conductor element and to the second conductor element for forming the winding segment, wherein the insulating element surrounds the first and the second conductor element circumferentially.
  • the insulating member is used for electrical insulation of the first and second conductor element from each other and from the laminated core and to strengthen the mechanical stability in the first and the second conductor element.
  • the winding segment comprising the first and second conductor element and the insulating element is inserted into the laminated core after the insulating element has been secured to the first and second conductor elements to form the winding.
  • the insulating element is formed by injection molding of the casting compound around the first and the second conductor element.
  • FIG. 1 shows an electrical machine according to an embodiment of the invention in a schematic cross-sectional view
  • FIG. 2 shows a stator of the electrical illustrated in FIG
  • FIG. 3 shows a winding segment of a winding of the stator illustrated in FIG. 3 in a schematic bird's-eye view
  • FIG. 4 shows a method for producing the winding segment shown in FIG. 3 in a schematic diagram.
  • FIG. 1 an electrical machine EM according to an embodiment of the invention is depicted in a schematic cross-sectional representation.
  • the electric machine EM comprises a housing GH, in which a winding support ST designed as a stator is arranged in a rotationally fixed manner in the housing GH with respect to the housing GH.
  • the electric machine EM further comprises a rotor RT with a rotor shaft RW, which is rotatably mounted in the housing GH via two shaft bearings WL relative to the stator ST.
  • FIG. 1 A detailed representation of a portion of the stator ST is shown in FIG.
  • the stator ST comprises a laminated core BP, which is designed in the manner of a hollow cylinder.
  • the laminated core BP has a number of BlechUnpolnuten NT, which are uniformly distributed in the direction of the cylinder axis AS on one of the cylinder axis AS facing inside of the laminated core BP from one axial end of the laminated core BP to another axial end of the laminated core BP extending.
  • the stator ST windings WL which are formed from a number of winding segments WS in the manner to be described below.
  • the number of winding segments WS corresponds to the number of Blechwovenpolnuten NT or the number of poles so a two times the number of pole pairs of the stator ST.
  • One of the winding segments WS is shown in detail in Figure 3, wherein in the left half of the figure A Wick ⁇ ment segment WS in its original form and in the right half of the figure, the winding segment WS is shown schematically in a state of a finished winding WL.
  • the winding segment WS in its original form comprises a first conductor element LI and a second conductor element L2 and a
  • Insulating element IS which encloses the first and the second conductor element LI, L2 circumferentially and mechanically interconnects.
  • the two conductor elements LI, L2 are rod-shaped and formed from ⁇ have a same length. Depending on requirements, the two conductor elements LI, L2 can also be designed differently long. In addition, the two conductor elements LI, L2 spatially next to each other, however, are spaced from each other.
  • the insulating element IS is formed by injection molding a casting compound around the two conductor elements LI, L2.
  • the casting compound used consists of an electrically insulating material, so that the insulating element IS after hardening the two conductor elements LI and L2 from each other and electrically isolated from the environment.
  • the casting compound After hardening, the casting compound also forms the insulating element IS, which forms an H-shaped insulating body with a central main section HA as a "fuselage" and two each from the
  • the insulating element IS preferably has a higher material thickness or thickness in the main section HA than in the four sections TAI, TA3, TA2 and TA4.
  • the insulating element IS in the main section HA higher independent mechanical stability than in the four Operaab ⁇ sections TAI, TA3, TA2 and TA4, whereby the two conductor elements LI, L2 can be held together by this main section HA with sufficient mechanical forces.
  • the insulating element IS has a certain elasticity in the four sections TAI, TA3, TA2 and TA4, so that the four sections TAI, TA3, TA2 and TA4 can also be bent during bending or when interleaving the conductor elements LI, L2, without to break apart.
  • the two conductor elements LI, L2 are cast in such a way by the casting compound that a first end region EB1 and a second end region EB2 of the first conductor element L1 and a third end region EB3 and a fourth end region EB4 of the second conductor element L2 are not separated from the casting compound or the insulating element IS are covered.
  • These four end regions EB1, EB2, EB3 and EB4 are used for electrical connection with other winding segments to form the winding WL.
  • the winding segment WS or its two conductor elements LI, L2 together with the insulating element IS are inserted into a designated Polnut NT.
  • the two conductor elements LI, L2 are respectively in an inner, the cylinder axis AS of the laminated core BP facing position of a pole groove NT and in an outer, the cylinder axis AS of the laminated core BP remote from the position of the pole groove NT. Viewed from the cylinder axis AS, the two conductor elements LI and L2 thus lie radially one behind the other.
  • the main section HA of the insulating element IS is pressed together with the corresponding portions of the two conductor elements LI, L2 enveloped by this main section HA into the pole slot NT of the laminated core BP or lowered into it.
  • the four subsections TAI, TA3, TA2 and TA4 of the insulating element IS are, together with the sections of the two conductor elements LI, L2 enveloped by these subsections TAI, TA3, TA2 and TA4 and the four end regions EB1, EB2, EB3 and EB4 of the two conductor elements LI, L2 protrude from the pole groove NT and thus from the laminated core BP.
  • the two sections of the two conductor elements LI, L2 enveloped by the sections TAI, TA3 of the insulating element IS are, together with the two sections TAI, TA3, entangled with a spreading step corresponding to the winding step of the stator ST, as illustrated in the right half of FIG.
  • the two sections of the first conductor element LI enveloped by the subsections TAI, TA2, together with the two subsections TAI, TA2 are entangled in two mutually opposite directions.
  • the two sections of the second conductor element L2 enveloped by the sections TA3, TA4, together with the two sections TA3, TA4, are entangled in two mutually opposite directions.
  • the first end region EB1 of the first conductor element LI is connected to a third end region EB3 ⁇ of a second conductor element L2 ⁇ of another, corresponding to the winding step of the stator ST of FIG the winding segment WS spaced in the laminated core BP to ⁇ ordered winding segment WS ⁇ directly electrically connected.
  • Winding segments WS are in each case directly electrically connected to an end region of a further winding segment , not shown, corresponding to the winding step of the stator ST, spaced apart from the winding segment WS in the laminated core BP.
  • Such an arrangement and such electrical connections of the winding segments WS continue over the entire laminated core BP and thus form a winding WL.
  • winding segments having three or more conductor ⁇ elements and be provided with an insulating member, said insulating element then encloses the three or more conductor elements in the previously described manner circumferentially together mechanically holds together and apart and electrically insulated from the environment.
  • a first and a second electrically conductive rod-shaped conductor element LI, L2 are provided.
  • the two conductor elements LI, L2 cut or punched from a metal wire or metal bar to the same or different predetermined final length.
  • Insulating element IS attached to the first and the second conductor element L I, L2.
  • a casting compound of an electrically insulating material is poured onto the two conductor elements L I, L2 in an injection molding process. After hardening, the casting compound forms the insulating element IS with an independent mechanical stability, which electrically isolates and mechanically holds the two conductor elements L I, L2 apart from one another and from the environment.
  • the two conductor elements L I, L2 to the respective two end portions EBL, EB2, EB3 and EB4 with the casting compound poured over, so that the end portions EBL, EB2, EB3 and EB4 are not covered by the insulating element IS and electrically insulated.
  • the insulating element IS thus forms with the first and the second conductor element L I, L2 a one-piece and mechanically stable winding segment WS for forming a winding WL.
  • two "endless" metal wires or metal rails can first be cast with the casting compound and cut or punched in the conductor elements LI, L2 after hardening of the casting compound.
  • EB3 and EB4 of the two conductor elements LI, L2 are removed again, so that these four end regions EBL, EB2, EB3 and EB4 are not covered by the casting compound or the insulating element IS.
  • the insulating element IS can also be produced by extrusion of a viscous curable composition of an electrically insulating material.
  • the mass can be applied in an extrusion process to the two conductor elements LI, L2 except for respective two end regions EB1, EB2, EB3 and EB4. After hardening, the mass then forms the insulating element IS.
  • the winding segment WS is inserted according to a method ⁇ step S300 in a corresponding Polnut NT of a laminated core BP and then in a manner known to those skilled in accordance with the winding step of the stator ST with

Abstract

The invention relates to a winding segment (WS) for forming a winding (WL) of an electrical machine (EM), having a first electrically conductive, rod-shaped conductor element (L1) for forming the winding (WL) and an electrically insulating and independent, mechanically stable insualting element (IS), which circumferentially surrounds and electrically insulates the first conductor element (L1), wherein the insulating element (IS) is fastened to the first conductor element (L1). An electrical machine (EM) having such winding segments (WS) is simple and cost-effective to produce.

Description

Beschreibung description
Wicklungssegment zur Bildung einer Wicklung einer elektrischen Maschine, Verfahren zur Herstellung eines Wicklungssegments Winding segment for forming a winding of an electric machine, method for producing a winding segment
Die vorliegende Erfindung betrifft ein Wicklungssegment zur Bildung einer Wicklung eines Wicklungsträgers, sprich eines Stators oder eines Rotors, einer elektrischen Maschine. Ferner betrifft die Erfindung ein Verfahren zur Herstellung eines zuvor genannten Wicklungssegments. Außerdem betrifft die Erfindung einen Wicklungsträger und eine elektrische Maschine mit zu¬ mindest einem zuvor genannten Wicklungssegment. The present invention relates to a winding segment for forming a winding of a winding carrier, that is, a stator or a rotor, an electric machine. Furthermore, the invention relates to a method for producing a previously mentioned winding segment. In addition, the invention relates to a winding support and an electrical machine with ¬ at least one aforementioned winding segment.
Elektrische Maschinen weisen Wicklungsträger auf, die ein Blechpaket samt in dem Blechpaket gewickelten Wicklungen aufwiesen und als Statoren oder Rotoren der elektrischen Maschinen ausgebildet sind. Dabei sind die Wicklungen aus einer Vielzahl von haarnadel- oder U-förmigen Wicklungspins ausge¬ bildet und zur Bildung der Wicklungen in dem Blechpaket mit einem Spreizschritt entsprechend einem Wickelschritt des Wick¬ lungsträgers verschränkt und gekröpft in die entsprechenden Blechpaketpolnuten des Blechpakets eingefügt. Dabei ragen freiliegende Endbereiche der beiden gekröpften Schenkel der jeweiligen Wicklungspins aus dem Blechpaket heraus, die zur Bildung der Wicklungen zueinander entsprechend dem Wickelschritt des Wicklungsträgers verschränkt und anschließend miteinander elektrisch verbunden sind. Electrical machines have winding carriers which have a laminated core together with windings wound in the laminated core and are designed as stators or rotors of the electrical machines. The windings of a plurality of hairpin or U-shaped winding pins are out ¬ forms and interlaced to form the windings in the laminated core with a spreading step corresponding to a winding step of Wick ¬ ment carrier and inserted into the corresponding Blechpaketpolnuten the laminated core. In this case, exposed end portions of the two bent legs of the respective winding pins protrude from the laminated core, which are interconnected to form the windings according to the winding step of the winding support and then electrically connected to each other.
Elektrische Isolierung zwischen den Wicklungen bzw. den Electrical insulation between the windings or the
Wicklungspins und dem Blechpaket wird dabei mittels Isolier¬ papier hergestellt. Hierzu werden das Isolierpapier und der Wicklungspin nacheinander in jeweilige Polnut des Blechpakets eingefügt. Anschließend werden das Isolierpapier und der Wicklungspin in einem aufwendigen Tränk- oder Träufelprozess miteinander mechanisch verbunden und in der Polnut fixiert. Winding pins and the laminated core is made by means of insulating ¬ paper. For this purpose, the insulating paper and the winding pin are successively inserted into respective Polnut of the laminated core. Subsequently, the insulating paper and the Winding pin in a complicated process of impregnation or trickling mechanically bonded together and fixed in the Polnut.
Alternativ oder zusätzlich zu dem Isolierpapier werden die Wicklungspins mit Isolierlackschicht beschichtet, sodass die beiden Schenkel jedes einzelnen Wicklungspins, die in einer und derselben Blechpaketpolnut eingefügt werden, voneinander und von dem Blechpaket elektrisch isoliert werden können. Dabei dient die Isolierlackschicht lediglich zur elektrischen Isolierung und weist keine eigene mechanische Stabilität auf und erfordert einen Träger, hier in Form des Wicklungspins. Damit ist die Iso¬ lierlackschicht anfällig gegenüber äußeren mechanischen Einwirkungen wie z. B. Kratzen durch Werkzeuge, wodurch die Lackschicht beim Transportieren oder beim Einfügen der Wick- lungspins in die Blechpaketpolnuten oft beschädigt wird und somit keine ausreichende elektrische Isolierung mehr bietet. Damit erschwert die Lackschicht die Bildung einer intakten Wicklung und führt folglich zu Mehraufwand und -kosten bei der Herstellung von elektrischen Maschinen. As an alternative or in addition to the insulating paper, the winding pins are coated with an insulating lacquer layer so that the two legs of each individual winding pin, which are inserted in one and the same laminated core pole, can be electrically insulated from one another and from the laminated core. The insulating lacquer layer is used only for electrical insulation and has no own mechanical stability and requires a carrier, here in the form of the winding pins. Thus, the Iso ¬ lierlackschicht is vulnerable to external mechanical effects such. B. scratching by tools, whereby the paint layer during transport or when inserting the winding spins in the Blechpaketpolnuten is often damaged and thus no longer provides sufficient electrical insulation. Thus, the lacquer layer makes it difficult to form an intact winding and thus leads to additional expense and costs in the manufacture of electrical machines.
Die Aufgabe der vorliegenden Erfindung besteht somit darin, eine Möglichkeit bereitzustellen, elektrische Maschinen einfach und kostengünstig herzustellen. Diese Aufgabe wird durch Gegenstände der unabhängigen Ansprüche gelöst. Vorteilhafte Ausgestaltungen sind Gegenstand der Un¬ teransprüche . The object of the present invention is therefore to provide a way to produce electrical machines easily and inexpensively. This object is solved by subject matters of the independent claims. Advantageous embodiments are the subject of Un ¬ teransprüche.
Gemäß einem ersten Aspekt der Erfindung wird ein Wicklungssegment zur Bildung einer Wicklung eines Wicklungsträgers, sprich eines Stators oder Rotors, einer elektrischen Maschine bereitgestellt. Demnach weist das Wicklungssegment ein erstes elektrisch leitendes stabförmiges Leiterelement zur Bildung der Wicklung und ein elektrisch isolierendes und eigenständig mechanisch stabiles Isolierelement, das das erste Leiterelement umfangmäßig umschließt und elektrisch isoliert. Dabei ist das Isolierelement an dem ersten Leiterelement direkt und mechanisch befestigt. Als eigenständige mechanische Stabilität des Isolierelements wird dabei etwa eine mechanische Festigkeit des Isolierelements gegenüber äußeren mechanischen Einwirkungen durch Werkzeuge, die in anschließenden Fertigungsschritten zum Einfügen des Wicklungssegments in ein Blechpaket bzw. zur Bildung der Wicklung auf das Isolierelement wirken. Durch diese mechanische Festigkeit des Isolierelements kann das Wicklungssegment samt dem Iso¬ lierelement zerstörungsfrei in das Blechpaket eingefügt und zur Bildung der Wicklung verschränkt werden, ohne dabei das Iso¬ lierelement beschädigt wird, sodass es nach dem Einfügen und Verschränken des Wicklungssegments weiterhin eine ausreichende elektrische Isolierung zwischen dem Wicklungssegment und dem Blechpaket bietet. According to a first aspect of the invention, a winding segment is provided for forming a winding of a winding carrier, that is to say a stator or rotor, of an electrical machine. Accordingly, the winding segment has a first electrically conductive rod-shaped conductor element for forming the winding and an electrically insulating and independently mechanical stable insulating element, which encloses the first conductor element and electrically insulated. The insulating element is attached directly and mechanically to the first conductor element. As an independent mechanical stability of the insulating element is about a mechanical strength of the insulating against external mechanical effects by tools that act in subsequent manufacturing steps for inserting the winding segment in a laminated core or to form the winding on the insulating. This mechanical strength of the insulating member, the winding segment along with the Iso ¬ lierelement can be inserted without destruction in the laminated core and are folded to form the winding, without the iso ¬ lierelement is damaged, so that it after inserting and interleaving of the winding segment still sufficient electrical insulation offers between the winding segment and the laminated core.
Durch die direkte mechanische Befestigung des Isolierelements mit dem Leiterelement bilden diese beiden Elemente ein ein¬ heitliches Bauteil, das im Anschluss zur Bildung der Wicklung einfach in die entsprechende Blechpaketpolnut in einem einzigen Fertigungsschritt eingefügt werden kann. Dadurch, dass das Isolierelement eigenständig eine ausreichende mechanische Stabilität aufweist, ist das Isolierelement im Vergleich zu einer Isolierlackschicht wesentlich stabiler und somit einfacher handhabbar beim Transportieren und beim Einfügen in die Due to the direct mechanical attachment of the insulating member to the conductive element, these two elements form an integral ¬ a component which can be simply inserted in the port for forming the coil in the corresponding Blechpaketpolnut in a single manufacturing step. Due to the fact that the insulating element independently has sufficient mechanical stability, the insulating element is much more stable compared to an insulating lacquer layer and thus easier to handle during transport and when being inserted into the insulating layer
Blechpaketpolnut . Mit derartigen Wicklungssegmenten ist somit eine Möglichkeit geschaffen, den Wicklungsträger und folglich auch die elektrische Maschine einfacher und kostengünstiger herzustellen. Gemäß einer bevorzugten Ausgestaltung des Wicklungssegments ist das Isolierelement formschlüssig, kraftschlüssig oder stoff¬ schlüssig an dem ersten Leiterelement befestigt. Vorzugsweise ist das Isolierelement als ein um das erste Leiterelement umspritztes Spritzgußteil ausgebildet. Blechpaketpolnut. With such winding segments thus a possibility is created, the winding support and consequently also the electric machine easier and cheaper to produce. According to a preferred embodiment of the winding segment, the insulating element is positively, frictionally or materially ¬ fastened to the first conductor element. Preferably, the insulating element is formed as a molded around the first conductor element injection molded part.
Als Spritzgußteil lässt sich das Isolierelement kostengünstig herstellen. Durch direktes Spritzgießen einer Gießmasse um das Leiterelement lässt sich beim Formen des Isolierelements zeitgleich eine mechanisch stabile Verbindung zwischen dem Leiterelement und dem Isolierelement herstellen. As an injection molding, the insulating element can be produced inexpensively. By direct injection molding of a casting material around the conductor element, a mechanically stable connection between the conductor element and the insulating element can be produced at the same time during the molding of the insulating element.
In einer alternativen bevorzugten Ausgestaltung ist das Isolierelement mittels einer Klebeverbindung einfach an dem ersten Leiterelement befestigt. In an alternative preferred embodiment, the insulating element is simply attached by means of an adhesive connection to the first conductor element.
Gemäß noch einer bevorzugen Ausgestaltung umschließt das Isolierelement das erste Leiterelement mit Ausnahme von einem ersten und einem zweiten Endbereich des ersten Leiterelements umfangsmäßig vollständig. According to another preferred embodiment, the insulating member surrounds the first conductor element circumferentially completely except for a first and a second end region of the first conductor element.
Die beiden Endbereiche, die nicht von dem Isolierelement um¬ schlossen sind, dienen zur Bildung von elektrischen Verbindungen von dem ersten Leiterelement des Wicklungssegments zu den Leiterelementen anderer entsprechend dem Wickelschritt imThe two end portions which are not closed by the insulating member by ¬, are used to form electrical connections of the first conductor element of the coil segment to the circuit elements of other corresponding to the winding step in the
Wicklungsträger beabstandet angeordneter Wicklungssegmenten zur Bildung der Wicklung. Winding support spaced winding segments to form the winding.
Gemäß noch einer weiteren bevorzugten Ausgestaltung umfasst das Wicklungssegment ein zweites elektrisch leitendes stabförmiges Leiterelement zur Bildung der Wicklung, wobei das Isolierelement das zweite Leiterelement ebenfalls umfangsmäßig umschließt und das erste und das zweite Leiterelement miteinander mechanisch verbindet und zugleich voneinander elektrisch isoliert. Dabei ist die Anzahl der Leiterelemente nicht auf zwei ein¬ geschränkt. Je nach Bedarf kann das Wicklungssegment vor¬ zugsweise ein drittes und/oder weitere elektrisch leitende stabförmige Leiterelemente zur Bildung der Wicklung umfassen, wobei das Isolierelement das dritte und die weiteren Leiter¬ elemente ebenfalls umfangsmäßig umschließt und das erste, das zweite, das dritte und/oder jedes weitere Leiterelement mit¬ einander mechanisch verbindet und zugleich voneinander elektrisch isoliert. Zur besseren Verständlichkeit werden die bevorzugten Ausgestaltungen nachfolgend stets in Bezug auf ein Wicklungssegment mit zwei Leiterelementen beschrieben, wobei diese Ausgestaltungen auch für Wicklungssegmente mit drei oder mehr Leiterelementen gelten. According to yet another preferred embodiment, the winding segment comprises a second electrically conductive rod-shaped conductor element for forming the winding, wherein the insulating element also surrounds the second conductor element circumferentially and the first and the second conductor element mechanically interconnects and at the same time electrically insulated from each other. The number of conductor elements is not a ¬ side set to two. Depending on requirements, the coil segment can preferably comprise a third and / or further electrically conductive bar-shaped conductor elements for forming the winding from ¬, wherein the insulating member, the third and the further conductor ¬ elements also encloses circumferentially and the first, second, third and / or mechanically connects each further conductor element with ¬ each other and at the same time electrically insulated from each other. For better understanding, the preferred embodiments are described below always with reference to a winding segment with two conductor elements, these configurations also being valid for winding segments with three or more conductor elements.
Die eigenständige mechanische Stabilität des Isolierelements reicht dabei aus, das erste und das zweite Leiterelement miteinander zu fixieren, sodass das Wicklungssegment zerstö¬ rungsfrei in die entsprechende Blechpaketpolnut eingefügt und entsprechend dem Wickelschritt des Wicklungsträgers im The independent mechanical stability of the insulating member of ranges to fix the first and second circuit members together so that the winding segment inserted destruc ¬ approximately freely in the corresponding Blechpaketpolnut and in accordance with the winding pitch of the winding support in
Spreizschritt verschränkt und mit anderen entsprechend dem Wickelschritt beabstandet im Blechpaket angeordneten Wick¬ lungssegmenten elektrisch verbunden werden kann, ohne dabei die beiden Leiterelemente des Wicklungsträgers auseinanderfallen. Damit dient das Isolierelement auch als mechanischer Träger der beiden Leiterelemente. Spreizschritt entangled and with other according to the winding step spaced in the laminated core arranged Wick ¬ ment segments can be electrically connected, without falling apart the two conductor elements of the winding support. Thus, the insulating member also serves as a mechanical support of the two conductor elements.
Gemäß einer bevorzugten Ausgestaltung des Wicklungssegments ist das Isolierelement ebenfalls formschlüssig, kraftschlüssig oder stoffschlüssig an dem zweiten Leiterelement befestigt. Vor¬ zugsweise ist das Isolierelement als ein um das erste und das zweite Leiterelement umspritztes Spritzgußteil ausgebildet. In einer alternativen bevorzugten Ausgestaltung ist das Isolierelement mittels einer Klebeverbindung einfach an dem ersten und dem zweiten Leiterelement befestigt. Gemäß noch einer bevorzugen Ausgestaltung umschließt dasAccording to a preferred embodiment of the winding segment, the insulating member is also positively, positively or materially secured to the second conductor element. Before ¬ preferably the insulating element is formed as an over-molded around the first and the second conductor element injection-molded part. In an alternative preferred embodiment, the insulating element is simply attached by means of an adhesive connection to the first and the second conductor element. According to another preferred embodiment, this encloses
Isolierelement das zweite Leiterelement ebenfalls mit Ausnahme von einem dritten und einem vierten Endbereich des ersten Leiterelements umfangsmäßig vollständig, wobei der dritte und der vierte Endbereich ebenfalls zur Bildung von elektrischen Verbindungen zu den Leiterelementen anderer Wicklungssegmenten dienen . Insulating element, the second conductor element also with the exception of a third and a fourth end region of the first conductor element circumferentially completely, wherein the third and the fourth end region also serve to form electrical connections to the conductor elements of other winding segments.
Gemäß einem weiteren Aspekt der vorliegenden Erfindung wird ein Wicklungsträger, sprich ein Stator oder ein Rotor, für eine elektrische Maschine bereitgestellt, der zumindest eine Wicklung aufweist, welche aus zumindest einem zuvor beschriebenen Wicklungssegment ausgebildet ist. According to a further aspect of the present invention, a winding carrier, that is to say a stator or a rotor, is provided for an electrical machine which has at least one winding which is formed from at least one winding segment described above.
Gemäß noch einem weiteren Aspekt der Erfindung wird eine elektrische Maschine bereitgestellt, die einen Wicklungsträger mit zumindest einer Wicklung aufweist, wobei die zumindest eine Wicklung aus zumindest einem zuvor beschriebenen Wicklungssegment ausgebildet ist. Gemäß noch einem weiteren Aspekt der vorliegenden Erfindung wird ein Verfahren zur Herstellung einer Wicklung für einen Wicklungsträger, sprich einen Stator oder einen Rotor, einer elektrischen Maschine bereitgestellt. Dabei umfasst das Ver¬ fahren folgende Verfahrensschritte: According to yet another aspect of the invention, an electrical machine is provided which has a winding support with at least one winding, wherein the at least one winding is formed from at least one winding segment described above. According to still another aspect of the present invention, there is provided a method of manufacturing a winding for a coil carrier, that is, a stator or a rotor, an electric machine. The method comprises the following method steps :
- Bereitstellen eines ersten, elektrisch leitenden stab- förmigen Leiterelements zur Bildung der Wicklung, Providing a first electrically conductive rod-shaped conductor element for forming the winding,
- Befestigen eines eigenständig mechanisch stabilen Isolierelements zur elektrischen Isolierung und zur Stärkung der mechanischen Stabilität des ersten Leiterelements an dem ersten Leiterelement zur Bildung eines Wicklungssegments, wobei das Isolierelement das das erste Leiterelement um- fangsmäßig umschließt, und - Attaching a self-mechanically stable insulating for electrical insulation and strengthening the mechanical stability of the first conductor element on the first conductor element to form a winding segment, the insulation element surrounding the first conductor element in a peripheral manner, and
- Einfügen des Wicklungssegments, das das erste Leiterelement und das Isolierelement umfasst, nach dem Schritt des Be¬ festigens in ein Blechpaket zur Bildung der Wicklung. - Inserting the winding segment comprising the first conductor element and the insulating element, after the step of Be ¬ consolidate in a laminated core to form the winding.
Zur Bildung der Wicklung wird somit ein erstes, elektrisch leitendes stabförmiges Leiterelement bereitgestellt. An dem ersten Leiterelement wird ein eigenständig mechanisch stabiles Isolierelement befestigt, das zugleich zur Stärkung der me¬ chanischen Stabilität des ersten Leiterelements dient und das erste Leiterelement umfangmäßig umschließt und somit elektrisch isoliert. Nach dem Befestigen des Isolierelements an dem ersten Leiterelement wird das erste Leiterelement und das Isolier¬ element umfassende Wicklungssegment zur Bildung der Wicklung in ein Blechpaket eingefügt. Gemäß einer bevorzugten Ausgestaltung des Verfahrens wird das Isolierelement durch Spritzgießen einer Gießmasse um das erste Leiterelement geformt und zugleich an dem ersten Leiterelement befestigt . Gemäß einer weiteren bevorzugten Ausgestaltung des Verfahrens wird gemäß dem Verfahrensschritt des Bereitstellens vorgesehen, dass neben dem ersten Leiterelement ein zweites elektrisch leitendes stabförmiges Leitelement zur Bildung der Wicklung bereitgestellt wird. Gemäß dem Verfahrensschritt des Befestigens wird ferner vorgesehen, dass das Isolierelement zur Bildung des Wicklungssegments an dem ersten Leiterelement und an dem zweiten Leiterelement befestigt wird, wobei das Isolierelement das erste und das zweite Leiterelement umfangsmäßig umschließt. Dabei dient das Isolierelement zur elektrischen Isolierung des ersten und des zweiten Leiterelements voneinander und von dem Blechpaket sowie zur Stärkung der mechanischen Stabilität bei dem ersten und dem zweiten Leiterelement. Gemäß dem Verfahrensschritt des Einfügens wird ferner vorgesehen, dass das Wicklungssegment umfassend das erste und das zweite Leiterelement sowie das Isolierelement nach dem Befestigen des Isolierelement an dem ersten und dem zweiten Leiterelement zur Bildung der Wicklung in das Blechpaket eingefügt wird. In order to form the winding, a first electrically conductive rod-shaped conductor element is thus provided. Independently a mechanically stable insulating element is fixed to the first conductor element, which also serves to strengthen the me chanical stability of the ¬ first conductor member and circumferentially encloses said first conductor element and thus electrically isolated. After attaching the insulating element to the first conductor element, the first conductor element and the insulating ¬ comprehensive element winding segment is inserted to form the winding in a laminated core. According to a preferred embodiment of the method, the insulating element is formed by injection molding a casting compound around the first conductor element and at the same time attached to the first conductor element. According to a further preferred embodiment of the method is provided according to the method step of providing that, in addition to the first conductor element, a second electrically conductive rod-shaped guide element for forming the winding is provided. According to the method step of fastening, it is further provided that the insulating element is attached to the first conductor element and to the second conductor element for forming the winding segment, wherein the insulating element surrounds the first and the second conductor element circumferentially. there The insulating member is used for electrical insulation of the first and second conductor element from each other and from the laminated core and to strengthen the mechanical stability in the first and the second conductor element. According to the inserting step, it is further provided that the winding segment comprising the first and second conductor element and the insulating element is inserted into the laminated core after the insulating element has been secured to the first and second conductor elements to form the winding.
Gemäß noch einer bevorzugten Ausgestaltung wird das Isolierelement durch Spritzgießen der Gießmasse um das erste und das zweite Leiterelement geformt. Vorteilhafte Ausgestaltungen des oben beschriebenen Wicklungssegments sind, soweit im Übrigen auf den oben genannten Wicklungsträger, die oben genannte elektrische Maschine bzw. das oben beschriebene Verfahren übertragbar, auch als vorteilhafte Ausgestaltungen des Wicklungsträgers, der elektrischen Maschine bzw. des Verfahrens anzusehen. According to yet a preferred embodiment, the insulating element is formed by injection molding of the casting compound around the first and the second conductor element. Advantageous embodiments of the winding segment described above, as far as applicable to the above-mentioned winding support, the above-mentioned electric machine or the method described above, also be regarded as advantageous embodiments of the winding support, the electric machine or the method.
Im Folgenden werden beispielhafte Ausführungsformen der Erfindung bezugnehmend auf die beiliegenden Zeichnungen näher erläutert. Es zeigen: In the following, exemplary embodiments of the invention are explained in more detail with reference to the accompanying drawings. Show it:
Figur 1 eine elektrische Maschine gemäß einer Ausführungsform der Erfindung in einer schematischen Querschnittdarstellung; Figur 2 einen Stator der in Figur 1 dargestellten elektrischen Figure 1 shows an electrical machine according to an embodiment of the invention in a schematic cross-sectional view; FIG. 2 shows a stator of the electrical illustrated in FIG
Maschine in einer schematischen Vogelperspektivdarstellung; Figur 3 ein Wicklungssegment einer Wicklung des in Figur 3 dargestellten Stators in einer schematischen Vogelperspektivdarstellung; und Figur 4 ein Verfahren zur Herstellung des in Figur 3 dargestellten Wicklungssegments in einem schematischen Diagramm. Machine in a schematic bird's-eye view; FIG. 3 shows a winding segment of a winding of the stator illustrated in FIG. 3 in a schematic bird's-eye view; and FIG. 4 shows a method for producing the winding segment shown in FIG. 3 in a schematic diagram.
Zunächst wird auf Figur 1 verwiesen, in der eine elektrische Maschine EM gemäß einer Ausführungsform der Erfindung in einer schematischen Querschnittdarstellung abgebildet ist. Die elektrische Maschine EM umfasst ein Gehäuse GH, in dem ein als Stator ausgebildeter Wicklungsträger ST gegenüber dem Gehäuse GH drehfest in dem Gehäuse GH angeordnet ist. Die elektrische Maschine EM umfasst ferner einen Rotor RT mit einer Rotorwelle RW, der über zwei Wellenlager WL gegenüber dem Stator ST drehbar in dem Gehäuse GH gelagert ist. Reference is first made to FIG. 1, in which an electrical machine EM according to an embodiment of the invention is depicted in a schematic cross-sectional representation. The electric machine EM comprises a housing GH, in which a winding support ST designed as a stator is arranged in a rotationally fixed manner in the housing GH with respect to the housing GH. The electric machine EM further comprises a rotor RT with a rotor shaft RW, which is rotatably mounted in the housing GH via two shaft bearings WL relative to the stator ST.
Eine detaillierte Darstellung eines Abschnitts des Stators ST ist in Figur 2 abgebildet. A detailed representation of a portion of the stator ST is shown in FIG.
Dabei umfasst der Stator ST ein Blechpaket BP, das hohlzy- linderförmig ausgebildet ist. Das Blechpaket BP weist eine Anzahl von Blechpaketpolnuten NT auf, die auf einer der Zylinderachse AS zugewandten Innenseite des Blechpakets BP gleichmäßig verteilt sich in Richtung der Zylinderachse AS von einem axialen Ende des Blechpakets BP zu einem anderen axialen Ende des Blechpakets BP erstreckend geformt sind. In den Blechpaket¬ polnuten NT weist der Stator ST Wicklungen WL auf, die aus einer Anzahl von Wicklungssegmenten WS in nachfolgend zu beschreibender Weise ausgebildet sind. Die Anzahl von Wicklungssegmenten WS entspricht der Anzahl der Blechpaketpolnuten NT bzw. der Anzahl der Pole also einem Zweifachen der Polpaarzahl des Stators ST. Eins der Wicklungssegmente WS ist in Figur 3 detailliert dargestellt, wobei in der linken Figurhälfte A das Wick¬ lungssegment WS in dessen ursprünglicher Form und in der rechten Figurhälfte das Wicklungssegment WS in einem Zustand einer fertig ausgebildeten Wicklung WL schematisch abgebildet ist. In this case, the stator ST comprises a laminated core BP, which is designed in the manner of a hollow cylinder. The laminated core BP has a number of Blechpaketpolnuten NT, which are uniformly distributed in the direction of the cylinder axis AS on one of the cylinder axis AS facing inside of the laminated core BP from one axial end of the laminated core BP to another axial end of the laminated core BP extending. In the laminated core ¬ polnuten NT, the stator ST windings WL, which are formed from a number of winding segments WS in the manner to be described below. The number of winding segments WS corresponds to the number of Blechpaketpolnuten NT or the number of poles so a two times the number of pole pairs of the stator ST. One of the winding segments WS is shown in detail in Figure 3, wherein in the left half of the figure A Wick ¬ ment segment WS in its original form and in the right half of the figure, the winding segment WS is shown schematically in a state of a finished winding WL.
So wie in der linken Figurhälfte A dargestellt ist, umfasst das Wicklungssegment WS in dessen ursprünglicher Form ein erstes Leiterelement LI und ein zweites Leiterelement L2 sowie einAs shown in the left half of the figure A, the winding segment WS in its original form comprises a first conductor element LI and a second conductor element L2 and a
Isolierelement IS, das das erste und das zweite Leiterelement LI, L2 umfangsmäßig umschließt und miteinander mechanisch verbindet . Insulating element IS, which encloses the first and the second conductor element LI, L2 circumferentially and mechanically interconnects.
Dabei sind die beiden Leiterelemente LI, L2 stabförmig aus¬ gebildet und weisen eine gleiche Länge auf. Je nach Bedarf können die beiden Leiterelemente LI, L2 auch unterschiedlich lang ausgeführt sein. Zudem sind die beiden Leiterelemente LI, L2 räumlich nebeneinander jedoch voneinander beabstandet angeordnet . The two conductor elements LI, L2 are rod-shaped and formed from ¬ have a same length. Depending on requirements, the two conductor elements LI, L2 can also be designed differently long. In addition, the two conductor elements LI, L2 spatially next to each other, however, are spaced from each other.
Das Isolierelement IS ist durch Spritzgießen einer Gießmasse um die beiden Leiterelemente LI, L2 ausgebildet. Die verwendete Gießmasse besteht aus einem elektrisch isolierenden Material, sodass das Isolierelement IS nach dem Erhärten die beiden Leiterelemente LI und L2 voneinander und von der Umgebung elektrisch isoliert. The insulating element IS is formed by injection molding a casting compound around the two conductor elements LI, L2. The casting compound used consists of an electrically insulating material, so that the insulating element IS after hardening the two conductor elements LI and L2 from each other and electrically isolated from the environment.
Nach dem Erhärten bildet die Gießmasse zudem das Isolierelement IS, das einen H-förmigen Isolierkörper mit einem zentralen Hauptabschnitt HA als „Rumpf" und je zwei sich von dem After hardening, the casting compound also forms the insulating element IS, which forms an H-shaped insulating body with a central main section HA as a "fuselage" and two each from the
Hauptabschnitt HA entlang der beiden Leiterelement LI, L2 erstreckenden Teilabschnitten TAI, TA3 und TA2, TA4 als „Gliedmaßen" (das heißt, als von dem Hauptabschnitt HA abgehende Abschnitte) auf je einer der beiden Seiten des Hauptabschnitts HA aufweist. Dabei weist das Isolierelement IS vorzugsweise in dem Hauptabschnitt HA eine höhere Materialstärke bzw. -dicke als in den vier Teilabschnitten TAI, TA3, TA2 und TA4 auf. Dadurch weist das Isolierelement IS in dem Hauptabschnitt HA eine höhere eigenständige mechanische Stabilität als in den vier Teilab¬ schnitten TAI, TA3, TA2 und TA4 auf, wodurch die beiden Leiterelemente LI, L2 von diesem Hauptabschnitt HA mit einer ausreichenden mechanischen Kräfte zusammengehalten werden können. Umgekehrt weist das Isolierelement IS eine gewisse Elastizität in den vier Teilabschnitten TAI, TA3, TA2 und TA4 auf, sodass die vier Teilabschnitte TAI, TA3, TA2 und TA4 beim Biegen bzw. beim Verschränken der Leiterelemente LI, L2 auch mit gebogen werden können, ohne dabei auseinanderzubrechen. Die beiden Leiterelemente LI, L2 sind von der Gießmasse derart Übergossen, dass ein erster Endbereich EB1 und ein zweiter Endbereich EB2 des ersten Leiterelements LI und ein dritter Endbereich EB3 und ein vierter Endbereich EB4 des zweiten Leiterelements L2 nicht von der Gießmasse bzw. dem Isolierelement IS abgedeckt sind. Diese vier Endbereiche EB1, EB2, EB3 und EB4 dienen zur elektrischen Verbindung mit anderen Wicklungssegmenten zur Bildung der Wicklung WL . Main section HA along the two conductor element LI, L2 extending portions TAI, TA3 and TA2, TA4 as "limbs" (that is, as outgoing from the main portion HA sections) on either one of the two sides of the main section HA. In this case, the insulating element IS preferably has a higher material thickness or thickness in the main section HA than in the four sections TAI, TA3, TA2 and TA4. As a result, the insulating element IS in the main section HA higher independent mechanical stability than in the four Teilab ¬ sections TAI, TA3, TA2 and TA4, whereby the two conductor elements LI, L2 can be held together by this main section HA with sufficient mechanical forces. Conversely, the insulating element IS has a certain elasticity in the four sections TAI, TA3, TA2 and TA4, so that the four sections TAI, TA3, TA2 and TA4 can also be bent during bending or when interleaving the conductor elements LI, L2, without to break apart. The two conductor elements LI, L2 are cast in such a way by the casting compound that a first end region EB1 and a second end region EB2 of the first conductor element L1 and a third end region EB3 and a fourth end region EB4 of the second conductor element L2 are not separated from the casting compound or the insulating element IS are covered. These four end regions EB1, EB2, EB3 and EB4 are used for electrical connection with other winding segments to form the winding WL.
In einem fertig gebauten Zustand des Stators ST sind das Wicklungssegment WS bzw. dessen beide Leiterelemente LI, L2 samt dem Isolierelement IS in eine dafür vorgesehene Polnut NT eingesteckt . In a ready-built state of the stator ST, the winding segment WS or its two conductor elements LI, L2 together with the insulating element IS are inserted into a designated Polnut NT.
Dabei liegen die beiden Leiterelemente LI, L2 jeweils in einer inneren, der Zylinderachse AS des Blechpakets BP zugewandten Lage einer Polnut NT und in einer äußeren, der Zylinderachse AS des Blechpakets BP abgewandten Lage der Polnut NT. Aus der Zylinderachse AS betrachtet liegen die beiden Leiterelemente LI und L2 somit radial hintereinander. Der Hauptabschnitt HA des Isolierelements IS ist dabei samt den entsprechenden von diesem Hauptabschnitt HA umhüllten Abschnitten der beiden Leiterelemente LI, L2 in die Polnut NT des Blechpakets BP hineingedrückt bzw. hinein gesenkt. In this case, the two conductor elements LI, L2 are respectively in an inner, the cylinder axis AS of the laminated core BP facing position of a pole groove NT and in an outer, the cylinder axis AS of the laminated core BP remote from the position of the pole groove NT. Viewed from the cylinder axis AS, the two conductor elements LI and L2 thus lie radially one behind the other. The main section HA of the insulating element IS is pressed together with the corresponding portions of the two conductor elements LI, L2 enveloped by this main section HA into the pole slot NT of the laminated core BP or lowered into it.
Die vier Teilabschnitte TAI, TA3, TA2 und TA4 des Isolierelements IS sind samt den von diesen Teilabschnitten TAI, TA3, TA2 und TA4 umhüllten Abschnitten der beiden Leiterelemente LI, L2 und den vier Endbereichen EBl, EB2, EB3 und EB4 der beiden Leiterelemente LI, L2 ragen aus der Polnut NT und somit aus dem Blechpaket BP hervor . The four subsections TAI, TA3, TA2 and TA4 of the insulating element IS are, together with the sections of the two conductor elements LI, L2 enveloped by these subsections TAI, TA3, TA2 and TA4 and the four end regions EB1, EB2, EB3 and EB4 of the two conductor elements LI, L2 protrude from the pole groove NT and thus from the laminated core BP.
Die beiden von den Teilabschnitten TAI, TA3 des Isolierelements IS umhüllten Abschnitte der beiden Leiterelemente LI, L2 sind samt den beiden Teilabschnitten TAI, TA3 mit einem Spreizschritt entsprechend dem Wickelschritt des Stators ST verschränkt, so wie es in der rechten Figurhälfte B abgebildet ist. Analog sind die beiden von den Teilabschnitten TA2, TA4 des Isolierelements IS umhüllten Abschnitte der beiden Leiter¬ elemente LI, L2 samt den beiden Teilabschnitten TA2, TA4 mit einem Spreizschritt entsprechend dem Wickelschritt des Stators ST verschränkt. Dabei sind die beiden von den Teilabschnitten TAI, TA2 umhüllten Abschnitte des ersten Leiterelements LI samt den beiden Teilabschnitten TAI, TA2 in zwei voneinander entgegengesetzte Richtungen verschränkt. Analog sind die beiden von den Teilabschnitten TA3, TA4 umhüllten Abschnitte des zweiten Leiterelements L2 samt den beiden Teilabschnitten TA3, TA4 in zwei voneinander entgegengesetzte Richtungen verschränkt. The two sections of the two conductor elements LI, L2 enveloped by the sections TAI, TA3 of the insulating element IS are, together with the two sections TAI, TA3, entangled with a spreading step corresponding to the winding step of the stator ST, as illustrated in the right half of FIG. Likewise, the two enclosed by the sections TA2, TA4 of the insulating sections IS of the two conductor elements ¬ LI, L2, together with the two sections TA2, TA4 crossed with a spreading step according to the winding pitch of the stator ST. In this case, the two sections of the first conductor element LI enveloped by the subsections TAI, TA2, together with the two subsections TAI, TA2, are entangled in two mutually opposite directions. Analogously, the two sections of the second conductor element L2 enveloped by the sections TA3, TA4, together with the two sections TA3, TA4, are entangled in two mutually opposite directions.
Der erste Endbereich EBl des ersten Leiterelements LI ist mit einem dritten Endbereich EB3 λ eines zweiten Leiterelements L2 λ eines anderen, entsprechend dem Wickelschritt des Stators ST von dem Wicklungssegment WS beabstandet in dem Blechpaket BP an¬ geordneten Wicklungssegments WS λ direkt elektrisch verbunden. The first end region EB1 of the first conductor element LI is connected to a third end region EB3 λ of a second conductor element L2 λ of another, corresponding to the winding step of the stator ST of FIG the winding segment WS spaced in the laminated core BP to ¬ ordered winding segment WS λ directly electrically connected.
Analog ist der vierte Endbereich EB4 des zweiten Leiterelements L2 mit einem zweiten Endbereich EB2 λ eines ersten Leiterelements LI λ des anderen Wicklungssegments WS λ direkt elektrisch ver¬ bunden . Analogously, the fourth end portion EB4 of the second conductor element L2 with a second end portion of a first conductor element EB2 λ LI λ of the other winding segment WS λ directly electrically connected ¬ ver.
Der zweite Endbereich EB2 des ersten Leiterelements LI und der dritte Endbereich EB3 des zweiten Leiterelements L2 des The second end region EB2 of the first conductor element LI and the third end region EB3 of the second conductor element L2 of the
Wicklungssegments WS sind jeweils mit einem Endbereich eines weiteren, entsprechend dem Wickelschritt des Stators ST von dem Wicklungssegment WS beabstandet in dem Blechpaket BP ange¬ ordneten, in der Figur nicht dargestellten Wicklungssegments direkt elektrisch verbunden. Winding segments WS are in each case directly electrically connected to an end region of a further winding segment , not shown, corresponding to the winding step of the stator ST, spaced apart from the winding segment WS in the laminated core BP.
Derartige Anordnung und derartige elektrische Verbindungen der Wicklungssegmente WS setzen sich über das gesamte Blechpaket BP fort und bilden so eine Wicklung WL aus. Such an arrangement and such electrical connections of the winding segments WS continue over the entire laminated core BP and thus form a winding WL.
Es können auch Wicklungssegmente mit drei oder mehr Leiter¬ elementen und mit einem Isolierelement vorgesehen sein, wobei das Isolierelement dann die drei oder mehr Leiterelemente in der zuvor beschrieben Weise umfangsmäßig umschließt, miteinander mechanisch zusammenhält und voneinander und von der Umgebung elektrisch isoliert. It is also possible winding segments having three or more conductor ¬ elements and be provided with an insulating member, said insulating element then encloses the three or more conductor elements in the previously described manner circumferentially together mechanically holds together and apart and electrically insulated from the environment.
Ein Verfahren zur Herstellung eines in Figur 3 dargestellten Wicklungssegments WS wird nachfolgend anhand Figur 4 näher erläutert. A method for producing a winding segment WS shown in FIG. 3 is explained in more detail below with reference to FIG.
Zunächst wird gemäß einem Verfahrensschritt S100 ein erstes und ein zweites elektrisch leitendes stabförmiges Leiterelement LI, L2 bereitgestellt. Dabei sind die beiden Leiterelemente LI, L2 aus einer Metalldraht oder Metallschiene auf gleiche oder unterschiedliche vorbestimmte endgültige Länge geschnitten oder gestanzt . Anschließend wird gemäß einem Verfahrensschritt S200 einFirst, according to a method step S100, a first and a second electrically conductive rod-shaped conductor element LI, L2 are provided. The two conductor elements LI, L2 cut or punched from a metal wire or metal bar to the same or different predetermined final length. Subsequently, according to a method step S200
Isolierelement IS an dem ersten und dem zweiten Leiterelement L I , L2 befestigt. Hierzu wird in einem Spritzgießvorgang eine Gießmasse aus einem elektrisch isolierenden Material auf die beiden Leiterelemente L I , L2 gegossen. Nach dem Erhärten bildet die Gießmasse das Isolierelement IS mit einer eigenständigen mechanischen Stabilität, das die beiden Leiterelemente L I , L2 voneinander und von der Umgebung elektrisch isoliert und mechanisch zusammenhält. Dabei werden die beiden Leiterelemente L I , L2 bis auf jeweilige beide Endbereiche EBl, EB2, EB3 und EB4 mit der Gießmasse Übergossen, sodass die Endbereiche EBl, EB2, EB3 und EB4 nicht von dem Isolierelement IS abgedeckt und elektrisch isoliert sind. Das Isolierelement IS bildet somit mit dem ersten und dem zweiten Leiterelement L I , L2 ein einstückiges und mechanisch stabiles Wicklungssegment WS zur Bildung einer Wicklung WL . Insulating element IS attached to the first and the second conductor element L I, L2. For this purpose, a casting compound of an electrically insulating material is poured onto the two conductor elements L I, L2 in an injection molding process. After hardening, the casting compound forms the insulating element IS with an independent mechanical stability, which electrically isolates and mechanically holds the two conductor elements L I, L2 apart from one another and from the environment. In this case, the two conductor elements L I, L2 to the respective two end portions EBL, EB2, EB3 and EB4 with the casting compound poured over, so that the end portions EBL, EB2, EB3 and EB4 are not covered by the insulating element IS and electrically insulated. The insulating element IS thus forms with the first and the second conductor element L I, L2 a one-piece and mechanically stable winding segment WS for forming a winding WL.
Alternativ zu den oben beschriebenen Verfahrensschritten S100, S200 können zwei „endlosen" Metalldrähte oder Metallschienen zuerst mit der Gießmasse gegossen und nach dem Erhärten der Gießmasse in Leiterelementen L I , L2 geschnitten oder gestanzt werden. Anschließend kann die Gießmasse an den vier Endbereichen EBl, EB2, EB3 und EB4 der beiden Leiterelemente L I , L2 wieder entfernt werden, sodass diese vier Endbereiche EBl, EB2, EB3 und EB4 nicht von der Gießmasse bzw. dem Isolierelement IS abgedeckt sind. As an alternative to the method steps S100, S200 described above, two "endless" metal wires or metal rails can first be cast with the casting compound and cut or punched in the conductor elements LI, L2 after hardening of the casting compound. EB3 and EB4 of the two conductor elements LI, L2 are removed again, so that these four end regions EBL, EB2, EB3 and EB4 are not covered by the casting compound or the insulating element IS.
In einer alternativen Ausführungsform kann das Isolierelement IS auch durch Extrusion einer dickflüssigen härtbaren Masse aus einem elektrisch isolierenden Material hergestellt werden. Dabei kann die Masse in einem Strangpressvorgang auf die beiden Leiterelemente LI, L2 bis auf jeweilige beide Endbereiche EB1, EB2, EB3 und EB4 aufgetragen werden. Nach dem Erhärten bildet die Masse dann das Isolierelement IS aus. In an alternative embodiment, the insulating element IS can also be produced by extrusion of a viscous curable composition of an electrically insulating material. there the mass can be applied in an extrusion process to the two conductor elements LI, L2 except for respective two end regions EB1, EB2, EB3 and EB4. After hardening, the mass then forms the insulating element IS.
Danach wird das Wicklungssegment WS gemäß einem Verfahrens¬ schritt S300 in eine entsprechende Polnut NT eines Blechpakets BP eingefügt und anschließend in einer dem Fachmann bekannten Weise entsprechend dem Wickelschritt des Stators ST mit Thereafter, the winding segment WS is inserted according to a method ¬ step S300 in a corresponding Polnut NT of a laminated core BP and then in a manner known to those skilled in accordance with the winding step of the stator ST with
Spreizschritt verschränkt und zur Bildung der Wicklung WL mit weiteren entsprechend dem Wickelschritt beabstandet angeord¬ neten Wicklungssegmenten wie zuvor beschrieben elektrisch verbunden . Spreizschritt entangled and to form the winding WL with further according to the winding step spaced angeord ¬ Neten winding segments as previously described electrically connected.
Mit dem zuvor beschriebenen Verfahren können durch geringfügige und für einen Fachmann ohne Weiteres ausführbare Anpassungen auch Wicklungssegmente mit drei oder mehr Leiterelementen hergestellt werden . With the method described above, it is also possible to produce winding segments with three or more conductor elements by means of slight adjustments that can be readily carried out by a person skilled in the art.

Claims

Wicklungssegment (WS) zur Bildung einer Wicklung (WL) einer elektrischen Maschine (EM), das folgende Merkmale aufweist:Winding segment (WS) for forming a winding (WL) of an electric machine (EM), which has the following features:
- ein erstes elektrisch leitendes stabförmiges Leiter¬ element (LI) zur Bildung der Wicklung (WL) , und - A first electrically conductive rod-shaped conductor ¬ element (LI) to form the winding (WL), and
- ein elektrisch isolierendes und eigenständig mechanisch stabiles Isolierelement (IS), das das erste Leiter¬ element (LI) umfangsmäßig umschließt und elektrisch isoliert, - An electrically insulating and independently mechanically stable insulating element (IS), which surrounds the first conductor ¬ element (LI) circumferentially and electrically isolated,
- wobei das Isolierelement (IS) an dem ersten Leiter¬ element (LI) befestigt ist. - Wherein the insulating element (IS) is attached to the first conductor ¬ element (LI).
Wicklungssegment (WS) nach Anspruch 1, wobei das Iso¬ lierelement (IS) formschlüssig, kraftschlüssig oder stoffschlüssig an dem ersten Leiterelement (LI) befestigt ist . Winding segment (WS) according to claim 1, wherein the Iso ¬ lier element (IS) is positively, positively or materially secured to the first conductor element (LI).
Wicklungssegment (WS) nach Anspruch 1 oder 2, wobei das Isolierelement (IS) als ein um das erste Leiterelement (LI) umspritztes Spitzgußteil ausgebildet ist. Winding segment (WS) according to claim 1 or 2, wherein the insulating element (IS) is formed as a molded around the first conductor element (LI) Spitzgußteil.
Wicklungssegment (WS) nach Anspruch 1 oder 2, wobei das Isolierelement (IS) mittels einer Klebeverbindung an dem ersten Leiterelement (LI) befestigt ist. Winding segment (WS) according to claim 1 or 2, wherein the insulating element (IS) by means of an adhesive connection to the first conductor element (LI) is attached.
Wicklungssegment (WS) nach einem der vorangehenden Ansprüche , wobei das Isolierelement (IS) das erste Leiterelement (LI) mit Ausnahme von einem ersten (EB1) und einem zweiten (EB2) Endbereich des ersten Leiterelements (LI) umfangsmäßig umschließt . A winding segment (WS) according to one of the preceding claims, wherein the insulating element (IS) surrounds the first conductor element (LI) with the exception of a first (EB1) and a second (EB2) end region of the first conductor element (LI).
6. Wicklungssegment (WS) nach einem der vorangehenden Ansprüche, das ferner folgende Merkmale aufweist: 6. winding segment (WS) according to one of the preceding claims, further comprising the following features:
- ein zweites elektrisch leitendes stabförmiges Lei¬ terelement (L2) zur Bildung der Wicklung (WL) ,- a second electrically conductive bar-shaped Lei ¬ terelement (L2) to form the coil (WL),
- wobei das Isolierelement (IS) das zweite Leiterelement (L2) umfangsmäßig umschließt, und das erste Leiter¬ element ( L I ) und das zweite Leiterelement (L2) mit¬ einander mechanisch verbindet und voneinander elektrisch isoliert. - Wherein the insulating element (IS) surrounds the second conductor element (L2) circumferentially, and the first conductor ¬ element (LI) and the second conductor element (L2) with ¬ mechanically interconnects and electrically insulated from each other.
7. Wicklungsträger (ST) für eine elektrische Maschine (EM), der zumindest eine Wicklung (WL) aufweist, wobei die zumindest eine Wicklung (WL) aus zumindest einem Wicklungssegment (WS) nach einem der vorangehenden Ansprüche ausgebildet ist. 7. winding support (ST) for an electrical machine (EM) having at least one winding (WL), wherein the at least one winding (WL) is formed from at least one winding segment (WS) according to one of the preceding claims.
8. Elektrische Maschine (EM), die einen Wicklungsträger (ST) mit zumindest einer Wicklung (WL) aufweist, wobei die zumindest eine Wicklung (WL) aus zumindest einem Wick¬ lungssegment (WS) nach einem der vorangehenden Ansprüche 1 bis 6 ausgebildet ist. 8. Electrical machine (EM), which has a winding support (ST) with at least one winding (WL), wherein the at least one winding (WL) from at least one Wick ¬ ment segment (WS) according to one of the preceding claims 1 to 6 is formed ,
9. Verfahren zur Herstellung einer Wicklung (WL) einer 9. A method for producing a winding (WL) of a
elektrischen Maschine (EM) , wobei das Verfahren folgende Verfahrensschritte aufweist:  electric machine (EM), the method comprising the following steps:
- Bereitstellen (S100) eines ersten, elektrisch leitenden stabförmigen Leiterelements ( L I ) zur Bildung der Wicklung (WL) ,  Providing (S100) a first, electrically conductive rod-shaped conductor element (L I) for forming the winding (WL),
- Befestigen (S200) eines eigenständig mechanisch  - Fixing (S200) an independent mechanically
stabilen Isolierelements (IS) an dem ersten Leiterelement ( L I ) zur Bildung eines Wicklungssegments (WS), sodass das Isolierelement (IS) das erste Leiterelement ( L I ) umfangsmäßig umschließt und elektrisch isoliert, - Einfügen (S300) des Wicklungssegments (WS) nach dem Schritt des Befestigens (S200) in ein Blechpaket (BP) zur Bildung der Wicklung (WL) . stable insulating element (IS) on the first conductor element (LI) to form a winding segment (WS), so that the insulating element (IS) surrounds the first conductor element (LI) circumferentially and electrically insulated, - Inserting (S300) of the winding segment (WS) after the step of fastening (S200) in a laminated core (BP) to form the winding (WL).
Verfahren nach Anspruch 9, wobei der Schritt des Befestigen (S200) ferner vorsieht, dass das Isolierelement (IS) durch Spritzgießen einer Gießmasse um das erste Leiterelement (LI) geformt wird. 11. Verfahren nach Anspruch 9 oder 10, The method according to claim 9, wherein the step of fixing (S200) further provides that the insulating member (IS) is molded by injection molding a molding compound around the first conductor member (LI). 11. The method according to claim 9 or 10,
- wobei der Schritt des Bereitstellens (S100) ferner  - wherein the step of providing (S100) further
vorsieht, dass ein zweites elektrisch leitendes stabförmiges Leiterelement (L2) zur Bildung der Wicklung (WL) bereitgestellt wird, und  provides that a second electrically conductive rod-shaped conductor element (L2) is provided for forming the winding (WL), and
- der Schritt des Befestigens (S200) ferner vorsieht, dass das Isolierelement (IS) zur Bildung des Wicklungs¬ segments (WS) an dem ersten Leiterelement (LI) und dem zweiten Leiterelement (L2) derart befestigt wird, dass das Isolierelement (IS) das erste (LI) und das zweite (L2) Leiterelement umfangsmäßig umschließt, miteinander mechanisch verbindet und voneinander elektrisch isoliert, und - said step of attaching (S200) further provides that the insulating element (IS) to form the winding ¬ segments (WS) to the first conductor element (LI) and the second conductor element (L2) is attached such that the insulation (IS) enclosing the first (LI) and second (L2) conductor elements circumferentially, mechanically interconnecting and electrically isolated from each other, and
- der Schritt des Einfügens (S300) ferner vorsieht, dass das Wicklungssegment (WS) aus dem ersten (LI) und dem zweiten (L2) Leiterelement sowie dem Isolierelement (IS) nach dem Schritt des Befestigens (S200) zur Bildung der Wicklung (WL) in das Blechpaket (BP) eingefügt wird.  - the step of inserting (S300) further provides that the winding segment (WS) of the first (LI) and the second (L2) conductor element and the insulating element (IS) after the step of fastening (S200) to form the winding (WL ) is inserted into the laminated core (BP).
Verfahren nach Anspruch 11, Method according to claim 11,
- wobei der Schritt des Befestigen (S200) ferner vorsieht, dass das Isolierelement (IS) durch Spritzgießen der Gießmasse um das erste Leiterelement (LI) und das zweite Leiterelement (L2) geformt wird.  - wherein the step of fastening (S200) further provides that the insulating element (IS) is formed by injection molding the molding compound around the first conductor element (LI) and the second conductor element (L2).
PCT/EP2014/075630 2013-12-06 2014-11-26 Winding segment for forming a winding of an electrical machine, method for producing a winding segment WO2015082270A2 (en)

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