WO2016062813A1

WO2016062813A1 - Stator for an electric motor and use of same

Info

Publication number: WO2016062813A1
Application number: PCT/EP2015/074502
Authority: WO
Inventors: Stefan Losch; Wolfgang Meyer; Sebastian METZLER
Original assignee: Ebm-Papst St. Georgen Gmbh & Co. Kg
Priority date: 2014-10-22
Filing date: 2015-10-22
Publication date: 2016-04-28
Also published as: DE112015004844A5; DE102014115379A1

Abstract

The invention relates to a stator device for an electric motor, comprising (20) a plurality of windings (1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12) provided on a winding support, for electromotive interaction with a rotor that is rotatably mounted relative to the winding support about a central axis (26), said windings extending parallel to one another and to the central axis and preferably being arranged along a circular segment course. The windings have winding connections, in particular free wire ends of a winding wire, which ends are designed to be individually electrically contactable. According to the invention, at least two discoid and/or annular electrically conductive connection assemblies (26i; 36i) are associated with the windings, such that said assemblies are provided in or on the winding support in the axial direction of the central axis and are insulated from one another in such a way that respective winding connections of the plurality of windings with the same electrical connection polarity (U; V; W) can be connected, preferably on the radial inner side or outer side and/or permanently, to one of the connection assemblies associated with the connection polarity for external common contacting, thus forming a contact.

Description

Stator device for an electric motor and

Use of such The present invention relates to a stator device for an electric motor according to the preamble of the main claim. Furthermore, the present invention relates to a use of such a stator device.

From the prior art, generic stator devices are well known; these have an angle carrier on or on which a plurality of stator windings wound with suitable angle wire are seated. Depending on the realization principle of the electric motor realized with such a stator device, these windings are appropriately connected or connected; Thus, it is known as a typical use of such a generic stator device, the stator device with the windings provided thereon for generating a rotating electrical field set up and beschalte, which in turn with a suitable rotatably mounted around the central axis rotor (as external rotor or inner rotor) cooperates.

A typical implementation of a stator device for producing a three-phase rotating field for correspondingly realizing a three-phase motor requires, for example, the connection of the windings in star connection (Y-circuit), alternatively in a triangular circuit, again alternatively in mixed forms of these generic circuit topologies, wherein in particular also several, typically Periodically staggered in the circumferential direction of the windings in a typical three-phase system can be connected in parallel to each other in the circumferential direction. As is known from the prior art, it is the case that the free wire ends (typically realized with the winding connections) are led out separately and interconnectable windings via connection or connection arrangements in order to achieve a desired topology and, for example, parallel connections ensure correct operating power supply to the entire arrangement. Especially with stator devices having a larger number of individual windings, approximately twelve or more individually contactable windings on a winding support are not uncommon, but then an electrotechnically and mechanically complex connection structure is formed, which is not only used for purposes such as mechanized or automated production. consuming, but also space-related disadvantages and disadvantages in terms of failure and failure-prone operating environments: So, first, suitable (possibly also soldered or welded to connect to the free wire ends trained) connection or support body bulky, difficult in the automated handling, especially in the actual (non-detachable) producing an electrical contact as well as not problematic in the fixation in the context of a respective motor associated housing structure; This would, for example in the described plurality of windings and the associated connection and Verschaltungsproblematik first, especially in a front-axial direction relative to the winding support, considerable additional space required for the arrangement, which ultimately adversely affect the range of applications and applications such device. In addition, there is the fact that contacting of suitable contact means or nodes is usually not possible without the emergence of intersections or crossovers of the wire ends to the respective windings, with the possible disadvantage that about in thermally or vibration loaded use environments the Risk of chafing or other defects with which Effect of unwanted short circuits, arises; Other defects that can lead to such defects in overlapping wires or wire ends are about (especially in confined spaces) unavoidable housing contacts, so there is a risk of friction or shaking caused damage of the kind described.

Since in addition, especially in complex interconnections of the described plurality of windings, automation is virtually impossible, not only consuming handwork in the assembly is necessary, this leads, for example over fully automated manufacturing processes, more often incorrect assembly and thus to rejects or inefficiency in the Production.

Finally, the disadvantage of known technologies resides in the fact that, based on a respective one of the windings, effective wire lengths for a supply line are generally inhomogeneous, in other words, due to the complex interconnection and optionally distributed connection nodes, there are unequal ones to the respective windings Ratios in terms of line lengths, which may result in differences in effective line resistances, inductances, and other effects in certain engine technologies, which in turn may be detrimental to the operation of a motor implemented therewith in the form of vibration or fluctuations in torque. The object of the present invention is therefore to improve a superordinate stator device for an electric motor, both with regard to its mounting and manufacturability, ie also with regard to the operating characteristics of an electric motor to be realized thereby, in particular to facilitate automated manufacturability, a lower required Space for the contacting of windings, especially in a plurality of windings to realize and the prerequisites tions for a low-vibration or low-fluctuation engine operation in that an effective connection length, that is about a wire length between a connection for power supply to the actual winding, for all windings largely homogenous (or symmetrical) is gleichmäßigt.

The object is achieved by the stator device having the features of the main claim; advantageous developments of the invention are described in the subclaims. Independent protection in the context of the invention is also claimed for the use of the stator device according to the invention for the realization of an internal or external rotor three-phase and / or polyphase motor, which recognizable or disclosed process characteristics as equally claiming a method invention should apply in the context of the invention.

In accordance with the invention advantageously at least two disc or annular electrically conductive terminal groups are assigned to the windings so that these - are provided electrically insulated from each other along an axial direction of the central axis or on the winding support, such as in the manner of a layering or a stacking. In this case, these connection assemblies (formed in the practical realization as metal rings) are designed in such a way that they, in particular radially on the inside, in the case of a realization as a ring, ie then on a respective circumferential inner circumference, of respective one of the winding connections (ie approximately the Wire ends) can be contacted, wherein usually and preferably the terminal assemblies (ie about the rings) then realize each pole or phase of a realized motor principle and contact according to the invention is preferably insoluble, such as by (otherwise known) welding with conventional welding tongs od. like. Automatisierungsmit- Alternatively, a contact-forming connection by soldering or crimping or the like. can be done.

In this way, the provision of a number of (planar) connection assemblies according to the necessary phase or number of poles is then required, first in (axially) space-saving manner, and then in the preferred contacting of these connection assemblies on the radially inner side Geometric conditions for respective wire extensions of the winding terminals (free wire edges) are given so that they extend parallel to each other and parallel to the central axis, then find no crossovers or the like. mechanical contacts instead of, which, as described above, in the prior art to the discussed problems of defects or bare spots and associated short circuits or the like. to lead. Rather, connects in this way, the present invention high-grade contact and reliability with simple, contact-safe finish and contactability, since about again the radially inside contacts can be easily achieved with the automation tools, such as a welding gun. Analogously, when the stator device for an external rotor rotor is realized, preferably the rings (to be axially centered) should be contacted radially on the outside.

A further advantage of this principle according to the invention lies in increased flexibility in adaptation and manufacturability: the number of contacts and thus of the contact connections to be produced is merely determined by the number of windings which, in the preferred application, are simply configurable on the winding support and, Either by suitable design of a respective winding carrier, alternatively by only partial or suitable winding of a winding carrier with the desired number of windings, can be suitably adapted to a particular intended use. In each In this case, the winding connections (wire ends) would advantageously be guided parallel to the respective connection assemblies without crossovers and contacted there, so that the contact reliability is ensured in every configuration with the simplest manufacturability. Corresponding to the number of connection nodes, respective connection modules must be provided.

In accordance with the invention advantageously, the arrangement is associated with an at least partially hollow cylindrical housing, so that an axis or radially symmetrical arrangement is formed. The housing is then suitably opened at least at one end or provided with supply lines, so that the (ring-shaped or disc-shaped) connection assemblies can be suitably externally contacted. In the practical realization and further developing according to the invention, it is also preferred to form the housing for interacting with the terminal assemblies or for holding these assemblies such that a plastic material of the housing (which keeps the terminal assemblies spaced from each other and thus isolated from each other) suitable openings, grooves or Has recesses on which then (eg radially inside an internal rotor) in turn the contact portions can be achieved on the terminal assemblies for connection to the wire ends. These contact portions, which are further preferably formed approximately in the form of forked or web-shaped projections and further preferably integrally radially on the inside of the disk or ring-shaped terminal assemblies, can in turn simply be punched parts or the like. Assemblies are mass produced and reliably produced, in addition to suitable steel material in particular copper or the like. Metal materials, more preferably coated suitable for improved electrical conduction or contactability, may advantageously be provided. In particular, in the case of multi-phase arrangements, for example three connection rings provided parallel to one another in the case of a three-phase stator, it is also preferable to design the contact sections of these connection assemblies in such a way that along the circumferential direction these contact sections are offset from each other; this in turn, especially when used with a plurality of, for example, twelve or more windings, the risk of unintentional touches or the like. of respective winding wire ends and further facilitate automated contacting, such as by the intervention of welding tongs.

In the constructional-mechanical realization of the housing, it is also preferred that this multi-shell-like design so that (typically along the axial direction) cooperating with each other, more preferably interlocking, each other snapping or latching housing shells are formed, which further preferably in the described way between themselves, and in turn, for example, suitable by insulating disks or the like. isolated holding the (flat, annular) terminal assemblies, which in turn then suitable projections or the like. mechanical portions of the Anschlußbau- groups (but possibly also already the above-discussed contact portions) prevent unintentional twisting and correspondingly angularly mutually aligned and correspondingly safe contactable sections are present. In the structural design of the (in the discussed manner preferably as stamped parts, integrally formed with contact portions for connecting to wire ends trained) subassemblies, it is further development possible to provide a typically elongated, pin-like portion, which, for example after a suitable bending or Anwinkein , then as (central) contact for this assembly for connection to an external plug or the like. contact distances can serve cut; In this way, constructive simplicity (it then remains in a one-piece, can be produced by punching device for the realization of the connection assembly) connect with high contact reliability, since a renewed contact is then no longer required by the one-piece.

The result of the present invention is a stator device which, although suitable for any use, phase and pole numbers and number of turns, but in particular with more than six, preferably more than nine or even more than twelve windings considerable advantages in the problem context described above. Thus, for example, the present invention is suitable for applications in automotive or manufacturing technology, where often with mechanical or thermal stress environment is expected, but the invention is not limited to this application context and application. The present invention is in principle independent of a realization of the stator device according to the invention for a rotor realization as an internal or external rotor. Further advantages, features and details of the invention will become apparent from the following description of preferred embodiments and from the drawings; these show in:

1 is a perspective view of the stator device according to a first preferred embodiment of the present invention

Invention in 12-pole configuration for an internal rotor;

2 shows a circuit diagram for clarifying the interconnection of the windings in the embodiment of Figure 1 as a triangular circuit with four parallel windings. 3 shows a connection and winding diagram for the windings according to FIGS. 1, 2; a plan view of the embodiment of FIG. 1

to illustrate the relative arrangement of contact portions to the individual windings along the axial direction;

Fig. 5,

6 are perspective views (FIG. 6 thereof cut away) for illustrating the structure and the layered arrangement of the terminal assemblies associated with the respective terminal polarities; FIG. 7 is an exploded view, exploded along the axial direction, of the embodiment of FIG. 1 with the sequence of individual assemblies prior to assembly thereof; FIG. 7a is a detailed view of a one-piece connection ring as a connection assembly for the realization of a connection polarity associated contacts in the embodiment of FIG. 7; Fig. 8 is a perspective view similar to Figure 7 with almost completely assembled assemblies with only shown removed cover portion of the housing.

9 is a perspective view of the stator device according to a second embodiment of the present invention for an external rotor; FIG. 10: an exploded view of the second exemplary embodiment with the sequence of the rings or individual assemblies prior to their mounting in the stator body according to FIG. 9; FIG. and an exploded view similar to FIG. 10, again to clarify the order of the assemblies in the second embodiment.

Fig. 1 shows a perspective view of the (fully assembled) stator device for an internal rotor electric motor according to a first embodiment of the present invention. On a shell-side see cylindrical coil support 20 twelve single windings, referred to in the diagram representations of Figures 2 and 3 with the numbers 1 to 12, are arranged in a circular shape for the realization of the illustrated 12-pole stator device, wherein the windings each on a (not in Detail shown to be generally known) stator and Joch- blechanordnung are provided and in particular the perspective view of Figure 1 then each winding associated, inner pole pieces 30 for cooperation with a (not shown) inside running rotor is formed; This rotor is to be mounted rotatably about an axis of rotation which corresponds to the center or symmetry axis of the device according to FIG.

Figures 2 and 3 illustrate in the diagram that the windings 1 to 12 with a three-phase rotating field applied to terminals U, V and W, respectively, are applied, wherein in the manner shown in Fig. 2 and Fig. 3, four of the Single windings in parallel circuit form a branch of the delta connection shown and, along the Umfangsrich- tion of the bobbin 20 in Fig. 1, the respective parallel-connected windings are nested according to their numbering in the circumferential direction. The present invention according to the embodiment shown now allows the individual contacting of each of the windings 1 to 12, (more precisely, the contacting of a respective end wire end of the winding wire of the respective windings), so that first 24 wire ends are contacted. At the same time, in the exemplary embodiment shown, the design and arrangement of the connection assemblies in the form of connection rings (in the form of connection assemblies) held in the housing 22 aligned with the coil support 20 ensure that in addition to the reliable, contact-proof and, in particular, cross-over-avoiding, individual contacting, the contactors shown in FIG 2 or Fig. 3 shown nested parallel circuit can be effected. This is illustrated initially by the plan view of FIG. 4, which shows in the (axial) projection that each winding is assigned 1 (at least) a pair of contact sections 24 which are fork-like (with a direction towards the axis center 26). Fig. 4 - directed opening) for axially approaching and preferably non-detachable contacting with one of the winding wire ends of a respective associated winding are formed. Specifically, in an otherwise known manner, a wire section inserted or projecting into the open region of a contact section 24 would be electrically contacted by welding inwardly by electrodes engaging on the inside of a contact section and connected inseparably.

While the projection representation in the axial direction of FIG. 4 assigns at least one pair of contact portions 24 in the manner described, FIGS. 5, 6 show a first variant on the one hand and FIGS. 7, 8 show a different variant on the other hand - Possibilities to realize these contact portions 24 by means of the mentioned contact rings as connection assemblies. For example, it is clear from the perspective illustration of FIGS. 5, 6 that the respective, fork-shaped projecting contact sections 24 are projections of radially encircling metallic rings 26, wherein the marking with the letters U, V, W in conjunction with the respective terminal assembly rings 26 the assignment to the polarity shown clarifies. More specifically, and preferably realized as a stamped ring formed integrally from a steel material (or copper) (see also Fig. 7a), each of these three rings 26U, 26V and 26W is provided with a number of inwardly projecting contact portions, so that one of a respective one of the windings hochgeführter (ie, in sections parallel to the axial direction of the central axis) guided lead wire in the associated contact section opens and there in the manner described by welding (alternatively, for example, by crimping, soldering or the like.) Can be contacted electrically and mechanically , The three rings 26i (U, V, W) are for this purpose, as shown in the sectional view of Fig. 6, in these partially enclosing and thus against each other electrically insulating plastic rings 28 mounted, said plastic rings radially innwärtig toward the central center axis Have breakthroughs or openings, so far as the respective contact portions 26 protrude into the interior for contacting. Associated with this mechanical solution is the fact that in this way the respective rings 26i are fixed in a circumferential direction, thus can not inadvertently twist or otherwise move from their relative position to the associated windings.

Axially enclosed at both ends is the layer arrangement of (plastic) insulator rings and the metallic contact rings 26i according to the invention, which are realized by housing shell elements 30, 32, which limit the layering of the rings at both ends, insofar Form housing and secured in the manner shown in Fig. 6 by a snap-in portion 34 (in which projecting lugs on end portions of an upper ring 32 in associated annular groove portions of a lower ring 30) for an easily mounted, solid, secured against accidental opening and easy to make connectable connectivity. This mechanical functionality is also clearly recognizable in the comparison of FIG. 7 (with an exploded view) and FIG. 8 (with all mounted rings and upper housing ring 32 still removed); The embodiment of FIGS. 7, 7a and 8 is analogous to the embodiment of FIGS. 5, 6, with the exception that the three metal rings used there 36U, 36V, 36W (insofar as the detail of FIG 24 individual contact portions 24 integrally formed ansitzend, but the rings of Figure 7a are each mounted against each other by a distance of two adjacent contact portions (along the circumferential direction) twisted; Here, too, in the projection of the axial direction, the assignment of the contact sections 24 to the respective windings recognizable in FIG. 4 would then arise. The detailed representation of FIG. 7a (to that extent analog transferable to the embodiment of FIGS. 5, 6) discloses in the form of a like the contact portions 24 integrally molded central contact portion 38 an efficient way to contact central terminal contacts for the individual phases U, V, W. and lead out; Concretely, such a central contact portion 38 is umknick- or bendable in a direction parallel to the axial direction in the manner of an extended web or finger-shaped configuration (yes, Fig. 7a represents the radial view) so far so the section 38 vertically to the plane of the figure would be bent, so that the vertical contact portions 38 shown in Figures 5, 6 and 7, 8 arise in the assembled state. As seen in this respect approximately the perspective view of FIG. 6 well Also, these sections protrude through a respective opening or space of the insulator assembly (consisting of housing shells 32, 30 and the intermediate insulator rings 28), wherein the central contact portion 38, insofar as the functionality of the contact portions 24 realizing, even a fork portion 40 has to to attach an associated winding wire end here; At the same time, the outer free end of the section 38 can be connected to plug contacts 42, 44 or 46 (cf., Fig. 1 and Fig. 4), so far as to enable the external contacting of the assembled assembly by suitable upstream control electronics.

For the assembly 36i shown in FIG. 7a (where i should always stand for the three poles U, V and W in the context of the present connection disclosure), analogously also for the rings 26i, the assemblies 42, 44, 46 can be referred to as be realized simple punched parts, which are then connected by suitable welding methods with the contact portions 38 contact-safe.

FIGS. 9 to 11 illustrate a second exemplary embodiment of the present invention, wherein here a stator body (stator main body) 50, again designed as a 12-pole and to be wound in polyphase, is designed to cooperate with a rotor designed as an external rotor. Accordingly, the assembly 50 in the inner (hub side) area, bounded by a cylindrical wall 60, a receiving space for to be coated, annular assemblies 52-58, which, again analogous to the inventive concept and illustrated in the first embodiment about the Fig. 7, the Contacting optimized. Specifically, as the exploded perspective views of FIGS. 10 and 11 illustrate, contact rings for different phases of the winding with insulating intermediate rings 56 change, wherein in the second exemplary embodiment and according to FIG. 10, FIG - on the side a first contact ring 52S is inserted into the body 50, thereon a first plastic ring 56 formed approximately from a plastic material, axially followed again by a metallic ring 52U, a further insulation ring 56, on which in turn another contact ring 52W, an insulation ring 56 , a contact ring 52V and an overhead cover ring 58. This layer assembly fills the area enclosed by the wall 60, and the respective metallic contact rings 52S, 52U, 52W and 52V are respectively provided with contact portions 54 which are staggered in respective lengths , are dimensioned so that a front, approximately suitable for wire bonding end of such a contact portion with a suitably formed in the wall 60 groove 62 is aligned. The identifiers "U", "V", "W" and "S", in turn, are assigned to a respective polarity or phasing of the total winding distributed on individual windings analogously to the previously described exemplary embodiment; "S" would be here a center of a possible star connection.

This embodiment realized in structurally simple, manufacturing elegant and highly reliable manner advantages of the present invention, namely a simple and reliable contact wiring, the avoidance of crossovers and a potentially automatable manufacturability of the individual annular conductor sections, which in turn in the embodiment shown by the respective Slices 56 are electrically isolated from each other. Also in this embodiment, the number of poles, number of slots, interconnection of the windings, etc. is purely exemplary, corresponding to the selected number of (conductive) rings.

In the manners shown, a stator device can thus be realized which, in a very compact and space-saving manner, rests axially on a winding carrier, in the simplest case is flush with the latter on the casing side and thus does not protrude radially. On the other hand, the If the terminal assemblies designed as preferred metal rings in the context of a multi-part, layered housing assembly not only a mechanically stable (and thus favorable for vibration-prone and other polluted environments) attachment and embedding allows, the arrangement allows a simple, automatable production with the greatest possible electrical Contact security, since according to the underlying object by the axially aligned assignment of the respective contact portions to a respective winding a potentially disadvantageous branching, overlapping, touching or the like. Effective structurally prevented.

The present invention is not limited to the illustrated embodiments of a stator for internal rotor or for an external rotor, but can both the number of windings, as on their interconnection (such as star-shaped, with other parallel circuits or with a completely different, even individually externally controlled assignment) be realized.

Claims

claims

1 . Stator device for an electric motor with (20)

a plurality of provided on a winding support, for electromotive cooperation with a relative to the winding support about a central axis (26) rotatably mounted rotor, to each other and to the central axis extending parallel and preferably along a circular arc-shaped course arranged windings (1, 2, 3 4, 5, 6, 7, 8, 9, 10, 1 1, 12) which are preferably electrically contactable individually with winding connections, in particular free wire ends of a winding wire,

characterized in that

the windings at least two disc and / or annular, electrically conductive connection assemblies (26i, 36i) are assigned so that these, electrically isolated from each other, are provided along an axial direction of the central axis on or on the winding support so

in that respective ones of the winding terminals of the plurality of windings with the same electrical terminal polarity (U; V; W) can be connected to one of the terminal polarities for external common contacting of the terminal assemblies in a contact-forming, preferably radially inside or outside and / or insoluble manner.

2. Apparatus according to claim 1, characterized in that the connection assemblies are held in a preferably hollow cylindrical housing (30, 32, 28) stacked so that the at least partially parallel to the central axis and / or guided without crossover winding connections of a winding in each case a preferred zugt radially on the inside of two of the terminal assemblies formed contact portion (24) reach.

Apparatus according to claim 2, characterized in that in a circumferential direction preferably aligned with the winding contact portion (24) is formed for preferably automatable welding, soldering and / or crimping with a wire end of the winding terminal.

Apparatus according to claim 2 or 3, characterized in that the housing radially inwardly grooves and / or recesses for contactable exposure of the contact portions is formed.

Device according to one of claims 2 to 4, characterized in that the integrally attached to the terminal assemblies contact portions axially adjacent the terminal assemblies are arranged along a circumferential direction offset or exposed and / or projecting staggered.

Device according to one of claims 2 to 5, characterized in that the housing is on the shell side formed so that it at least partially aligned along a circumferential direction with an outer shell portion of the winding support (20) and / or the winding support is at least partially integrated into the housing.

Device according to one of claims 2 to 6, characterized in that the housing of two along the axial direction with each other, in particular by latching, gluing or welding, connectable, preferably annular Schalenabschnit th (30, 32) is realized, which keep the terminal assemblies stacked between them.

8. Device according to one of claims 2 to 7, characterized in that the housing has axially end and preferably frontally a portion (42, 44, 46) for taking out a plug contact for external electrical contacting of each of the terminal assemblies.

9. Device according to one of claims 1 to 8, characterized in that each preferably formed as a stamped part of a metal material of the terminal assemblies (26i, 36i) einstückig ansitzenden, for bending in an extension direction parallel to the central axis bendable, in particular pin-shaped Zentralkontaktab- cut ( 38).

10. Use of the stator device according to one of claims 1 to 9 for at least six, preferably at least nine, more preferably at least twelve stator windings as windings in an internal or external rotor motor.

1 1. Use according to Claim 10, characterized in that the stator windings connected in a delta connection with three terminal polarities are connected to three circumferential metal rings as terminal assemblies such that the stator windings associated with one branch of the delta connection are connected in parallel to one another by the action of the metal rings.