Classifications

• • 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
  • H02K3/18—Windings for salient poles
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
  • H02K1/12—Stationary parts of the magnetic circuit
  • H02K1/14—Stator cores with salient poles
  • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
• • 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
  • H02K3/28—Layout of windings or of connections between windings
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
  • H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information

Definitions

• the invention relates to a rotating electric machine stator with improved magnetic performance.
• the invention finds a particularly advantageous, but not exclusive, application with electric motor vehicle compressors.
• the rotating electrical machines comprise a stator and a rotor secured to a shaft.
• the rotor may be integral with a driving shaft and / or driven and may belong to a rotating electrical machine in the form of an alternator, an electric motor, or a reversible machine that can operate in both modes.
• the rotor comprises a body formed by a stack of sheets of sheet metal held in pack form by means of a suitable fastening system.
• the rotor has poles formed by permanent magnets housed in cavities in the rotor body.
• the stator is mounted in a housing configured to rotate the shaft for example by means of bearings.
• the stator comprises a body consisting of a stack of thin sheets forming a crown-shaped yoke whose inner face is provided with notches open towards the inside to receive phase windings.
• the windings are obtained for example from a continuous wire coated with enamel or from conductive elements in the form of pins connected together by welding.
• the phase windings are constituted by closed coils on themselves which are wound around the stator teeth. These windings are polyphase windings connected in star or delta whose outputs are connected to a control electronics.
• Rotating electrical machines are known that are coupled to a shaft of an electric compressor.
• This electric compressor makes it possible to compensate at least in part for the power loss of the heat engines of reduced capacity used on many motor vehicles to reduce the consumption and emissions of particulate pollutants (so-called principle of "downsizing" in English).
• the electric compressor comprises a turbine disposed on the inlet duct upstream or downstream of the heat engine to allow compression of air to optimize the filling of the cylinders of the engine.
• the electric machine is activated to drive the turbine in order to minimize the torque response time, in particular during the transient phases during acceleration, or in the automatic restart phase of the engine after a standby ("stop and start" operation in English).
• the present invention aims in particular to remedy this difficulty by proposing a rotating electric machine stator, in particular for an electric compressor for a motor vehicle, the stator comprising a body having:
• a coil comprising a plurality of coils, each coil being formed by a wire wound around a tooth
• a ratio between a diameter of a conductive portion of said unglazed wire, expressed in mm, and a number of turns of each coil is between 5% and 25%, especially between 10% and 20%.
• the teeth come from material with the yoke, the yoke forming an outer annular portion and continuous body and extending between the bottom of the notches and the outer periphery of the stator.
• the yoke forms a ring having continuity of material along its circumference and radially on at least a portion of its thickness.
• the invention thus makes it possible to optimize the magnetic performance of the electrical machine while facilitating the insertion of the winding needle into the notches to produce the coils around the stator teeth in the context of a winding of concentric type.
• said wire comprises a conductive portion with a diameter of between 1 and 2 mm.
• each coil is formed by a number of turns between 5 and 20.
• each coil is formed by nine turns.
• the choice of the number of wire and the coupling of the coils is very restrictive, insofar as with a turn close it can become impossible to achieve the required performance in terms of acceleration of the machine in particular.
• each coil is formed by eighteen turns and the diameter of the copper section of the wire is equal to 1.06mm.
• said stator comprises six coils.
• said winding is of the three-phase type, each phase being formed in particular by two diametrically opposed coils.
• said coils are electrically connected in pairs in parallel.
• said coils are coupled in a triangle. Such a coupling makes it possible to minimize the number of connections to be made.
• the number of turns located on the side of the yoke is greater than the number of turns located on the side of an axis of the stator.
• a portion of the coil filling said notch is formed by three layers of turns. Alternatively, one could make two layers of turns only.
• each notch has a zone extending over an entire length of said stator.
• a ratio between a diameter of a conductive portion of said wire and an internal diameter of said stator is between 3 and 10%, especially 5 and 10%, especially between 5 and 7%, for example between 5.2 % and 6.3%.
• a plurality of notches being each defined by two adjacent teeth, a ratio between a smaller notch opening measured between two adjacent tooth legs, and an outer diameter of said stator is between 5% and 25% , especially between 5% and 15%. This thus optimizes the magnetic performance of the electric machine while facilitating the insertion of the winding needle inside the slots to make the coils around the teeth of the stator.
• said stator body is composed of a plurality of sheets of sheet metal superimposed axially on each other.
• At least one sheet has on its surface a stud intended to cooperate with a hollow of an adjacent sheet, and in that a ratio between a larger diameter of said pad and an outer diameter said stator is between 5% and 15%, especially between 2% and 10%.
• a ratio between a larger diameter of said pad and an outer diameter said stator is between 5% and 15%, especially between 2% and 10%.
• said stator body comprises at least one through-fixing hole opening on the side of each axial end face of said stator body, and in that a ratio between a first distance between an axis of said stator and an axis.
• said fixing hole and half of an outer diameter of said stator is between 80% and 97%, in particular between 85% and 95%. This thus makes it possible to obtain an optimum between a good mechanical strength and the magnetic performance of the electrical machine in which the stator is mounted.
• the subject of the invention is also a stator of a rotating electrical machine, in particular intended for an electric compressor for a motor vehicle, said stator comprising a body having:
• a coil comprising a plurality of coils, each coil being formed by a wire wound around a tooth
• each coil having a number of turns equal to nine or eighteen, and in that said coils are coupled in a triangle.
• said machine comprises a rotor provided with buried permanent magnets for example four in number.
• said rotor body has an outer periphery delimited by a cylindrical face of external diameter between 20 mm and 50 mm, in particular between 24 mm and 34 mm, and preferably of the order of 28 mm.
• said machine has a response time of between 100 ms and 600 ms, in particular between 200 ms and 400 ms, for example being of the order of 250 ms to go from 0 or 5000 to 70,000 revolutions / min.
• plating elements are interposed between the rotor body and each permanent magnet.
• the invention finally relates to a rotating electrical machine comprising a stator as described above and a rotor with buried permanent magnets.
• Figure 1 is a sectional view of an electric compressor comprising a rotary electric machine according to the present invention
• Figure 2 shows a perspective view of the stator of the rotating electrical machine according to the present invention
• Figure 3 is a top view of the single stator of the rotating electrical machine according to the present invention.
• Figure 4 is a top view of the stator according to the invention provided with turns for the formation of a coil portion occupying a half-notch;
• Fig. 5 shows a partial sectional view illustrating the configuration of a stator tooth according to the present invention
• Figure 6 is a sectional view of a wire used for producing a coil belonging to the stator winding according to the present invention.
• FIG. 7 shows an evolution of the filling ratio (O1) in percentages as well as the inverse of the inertia of the machine (O2) as a function of the ratio between the diameter of a conductive portion of the winding wire and the internal diameter of the stator;
• Figure 8 is a sectional view illustrating an interlocking between the sheet metal sheets of the stator in the case of a button assembly;
• Fig. 9 shows a perspective view of the rotor of the rotating electrical machine according to the present invention.
• Fig. 10 is a cross-sectional view of the rotor of the rotating electrical machine according to the present invention.
• FIG. 11 shows an evolution of the filling ratio (07) in percentages as well as the power of the machine (O8) proportional to the inverse of the number of turns as a function of the ratio between the diameter of a conductive portion of the wire of winding and the number of turns of each coil.
• FIG. 1 shows an electric compressor 1, comprising a turbine 2 equipped with fins 3 able to suck, via an inlet 4, uncompressed air coming from an air source (not represented) and to repress the compressed air via the outlet 5 after passing through a volute referenced 6.
• the output 5 may be connected to an intake manifold (not shown) located upstream of the engine to optimize the filling of the cylinders of the engine.
• the suction of the air is performed in an axial direction, that is to say along the axis X1 of the turbine 2, and the discharge is carried out in a radial direction perpendicular to the axis X1 of the turbine 2.
• the suction is radial while the discharge is axial.
• the suction and the discharge are made in the same direction relative to the axis of the turbine (axial or radial).
• the turbine 2 is driven by an electric machine 7 mounted inside the housing 8.
• This electric machine 7 comprises a stator 9, which may be polyphase, surrounding a rotor 10 with the presence of a gap 1 1.
• This stator 9 is mounted in the housing 8 configured to rotate a shaft 12 by means of bearings 13.
• the shaft 12 is rotatably connected. with the turbine 2 as well as with the rotor 10.
• the stator 9 is preferably mounted in the housing 8 by hooping.
• the electric machine 7 has a short response time of between 100 ms and 600 ms, in particular between 200 ms and 400 ms. , for example being of the order of 250ms to go from 0 or 5000 to 70000 revolutions / min.
• the operating voltage is 12V.
• the electric machine 7 is able to provide a current peak, that is to say a current delivered over a continuous period of less than 3 seconds, between 150 A and 300 A, in particular between 180 A and 250 A .
• the electric machine 7 is able to operate in alternator mode, or is a reversible type electric machine.
• the stator 9 comprises a body 16 and a coil 17.
• the stator body 16 has an annular cylindrical shape of axis X and consists of an axial stack of flat sheets. More precisely, the stator body 16 is delimited radially by an inner cylindrical face 21 and by an outer cylindrical face 22. The body 16 is moreover defined axially by end faces 23 and 24.
• the body 16 has teeth 27 distributed angularly in a regular manner on an inner circumference of a yoke 28. These teeth 27 delimit notches 29, so that each notch 29 is delimited by two successive teeth 27.
• the yoke 28 thus corresponds to the solid outer annular portion of the body 16 which extends between the bottom of the notches 29 and the outer periphery of the stator 9.
• the notches 29 open axially into the axial end faces 23, 24 of the body 16
• the notches 29 are also radially open in the internal cylindrical face of the body 16.
• the teeth 27 of the stator 9 are preferably with parallel edges, so that the inner faces facing each other of the notches 29 are inclined. one with respect to the other.
• the notches 29 are angularly distributed regularly around the X axis.
• the stator 9 is provided with tooth roots 34 on the free end side of the teeth 27 (see FIG. Each tooth root 34 extends circumferentially on either side of a corresponding tooth 27.
• the stator 9 is an unsegmented piece made of laminated sheets of magnetic material.
• the teeth 27 are made of material with the yoke 28.
• the stator 9 may however be segmented, that is to say that it is made from several angular segments assembled together.
• the cylinder head 28 radially has a continuity of material along its circumference and radially throughout its thickness.
• the teeth 27 may be reported relative to the yoke 28 and fixed to the inner periphery of the yoke by a tenon-mortise type system.
• a ratio between a radial thickness L1 of the gap 1 1 and an external diameter L 2 of the stator 9 is between 0.1% and 2%, especially between 0.2% and 1%.
• This ratio makes it possible to maximize the torque developed by this type of machine provided with a stator 9 of small dimensions.
• the gap 1 1 is chosen according to a thickness L13 of permanent magnets 62 of the rotor 10 (see FIG.
• a second ratio between a thickness of the gap 1 1 and a thickness of magnets L13 is between 0.9 and 0.15.
• a ratio between a thickness L3 of the yoke 28 measured radially and an internal diameter L4 of the stator 9 measured between two teeth 27 diametrically Opposite is between 9% and 20%, for example between 10% and 20%, especially between 12% and 15%, and is preferably about 9% or 13%.
• a ratio between the internal diameter L4 and an external diameter L2 of the stator 9 is between 40% and 60%, and is preferably of the order of 51.5%. This optimizes the coil space of the notches 29 and the inertia of the rotor 10.
• the stator body 16 is preferably formed by an axial stack of sheet metal sheets 37 each extending in a radial plane perpendicular to the axis X. This stator body 16 is formed in ferromagnetic material.
• the sheets 37 are held by fixing means 41 for forming a manipulable and transportable assembly.
• a plurality of fixing holes 40 are made in the stator body 16 to allow each passage of a fastening means 41 of the sheets of the stator body 16.
• the fixing holes 40 are preferably through, that is to say that they open axially on each of the axial ends 23, 24 of the stator body 16, so that it is possible to pass inside each fixing hole 40 a rod 41 provided with a head or not 42 at one of its ends and whose other end or both will be (are) deformed (s) for example by a method of pegging to ensure the axial retention of the package of sheets.
• a ratio between a distance L5 between the axis X of the stator 9 and a Z axis of a fixing hole 40 (see FIG. 3) and half of the external diameter L2 of the stator 9 is between 80% and 97%. %, especially between 85% and 95%.
• each fixing hole 40 is included in a plane of symmetry P d. a corresponding tooth 27.
• the Z axes of the fixing holes 40 are also preferably positioned on the same circle C (see FIG.
• the stator 9 has a number of fixing holes 40 between three and the number of teeth 27, here equal to six.
• the fixing holes 40 pass through the yoke 28, in particular by passing only the yoke 28, that is to say without encroaching on the corresponding tooth 27.
• a ratio between the maximum diameter L6 of each fixing hole 40 and the external diameter L2 of the stator 9 is between 2% and 10%.
• the rod 41 has no head 42 and the two ends are then deformed by a method of pegging.
• the fixing holes 40 may have a section of square, rectangular shape, or any other shape adapted to the passage of the fixing means 41.
• the sheets may be held together by buttoning, or bonding, or laser welding.
• each sheet 37 has on its surface a stud 45 intended to cooperate with a recess 46 of an adjacent sheet. The last leaf is pierced.
• a ratio between the largest diameter L7 of the stud 45 and an external diameter L2 of the stator 9 is between 5% and 15%, especially between 2% and 10%. Such a ratio allows a good mechanical strength of the sheet package of such a stator type 9 of reduced dimensions, while limiting the magnetic disturbances related to the presence of the pads 45. In addition, such a ratio makes it easier to manufacture the sheets 37 while ensuring a precise positioning of a sheet 37 relative to the other.
• Each sheet of sheet 37 has at least one face directly in contact with a single face of another sheet 37.
• the number of pads 45 per sheet 37 is between 2 and the number of teeth of the stator 9.
• the pads 45 are arranged on a first face and the recesses 46 are arranged on a second face opposite to the first face.
• each recess 46 is axially aligned with a stud 45 corresponding to an axis referenced A1 in Figure 8.
• the pads 45 on the sheet are positioned in the middle of each tooth 27, and on the same diameter for example of the order of 47mm.
• the yoke 28 is solid and radially has a continuity of material along its circumference and radially throughout its thickness.
• FIG. 7 shows a change in the filling ratio (curve C1) as well as the inverse of the inertia of the machine (curve C2) as a function of the ratio between the diameter L8 of a conductive portion of said wire 51 and the internal diameter L4 of the stator 9.
• the ratio is between 5 and 10%, especially between 5 and 7%, for example between 5.2% and 6.3%.
• the ratio is substantially equal to 5.4%, which corresponds to the intersection between the two curves C1 and C2.
• the diameter L8 of the conductive portion of the wire 51 is of the order of 1 .5 mm in the case where the stator comprises 9 turns. With the enamel layer, the wire diameter is 1.602mm. Alternatively, the diameter L8 of the conductive portion of the wire 51 is of the order of 1 .06mm in the case where the stator has 18 turns.
• the choice of the diameter of the wire 51 is an important choice to ensure the feasibility of a concentric winding type. Furthermore, the choice of the stator inner diameter L4 is guided by the minimization of the inertia (or the maximization of 1 / inertia which is optimal when this ratio is close to 1), as well as by the feasibility of the winding. Indeed, the greater the inner diameter of the stator 9 increases, the greater the outer rotor diameter increases, the more the inertia increases.
• the stator can thus have a slot filling rate of the order of:
• a ratio between a smaller slot opening L9 measured between two adjacent tooth legs 34 (see FIG. 4), and the external diameter L 2 of the stator 9 is between 5% and 25%, in particular between 5% and 15%. This facilitates insertion of the winding needle into the notch 29.
• the number of turns 54 located on the side of the yoke 28 is greater than or equal to the number of turns 54 located on the X axis side of the stator 9. It is recalled here that a turn 54 corresponds to a turn of the wire around the tooth 27.
• the portion of the coil 50 filling the notch 29 is formed for example of three layers of turns 54. In each layer, the turns 54 are positioned side by side .
• Each coil 50 is preferably formed by nine turns 54.
• the winding 17 is of the three-phase type, each phase being in particular made by two diametrically opposed coils 50.
• the diametrically opposed coils 50 are electrically connected in pairs in parallel.
• the phases each formed by two coils 50 in parallel are preferably connected in a triangle.
• This type of winding minimizes the number of connections to be made.
• the choice of the number of wire and the coupling of the coils 50 is very restrictive, since at a turn 54 it can become impossible to achieve the required performance especially in terms of acceleration of the machine.
• the coupling could be made in a triangle, coils in series, or star with coils either in series or in parallel.
• the ratio is of the order of 16.7%.
• FIG. 11 thus shows that the curve representing a fill rate C8 in percent and the curve representing the power of the machine C7 proportional to the inverse of the number of turns have optimal values for the aforementioned ratios.
• the other fixed stator and rotor parameters for obtaining the curves are included in the ranges provided in the embodiment example indicated below.
• the protection between the sheet package 16 and the winding wire 51 is provided by an overmolded insulation 57 on the internal faces of the notches 29. To facilitate readability of the figure, the overmolded insulation 57 has been shown only on a portion of the stator body 13.
• the face of the tooth root 34 turned towards the X axis of the stator 9, that is to say the face of the foot tooth 34 in contact with the gap 1 1 extending along a portion of the cylinder, is devoid of insulation 57. This avoids disturbing the passage of the flow in the gap 1 1.
• the overmolded insulation 57 covers the axial end faces of the teeth 27, and / or the axial end faces of the yoke 28.
• the overmolded insulation 57 may also cover the axial end faces. 23, 24 of the stator body 16. With respect to the use of insulating paper as is the case in FIG. 2, such a configuration makes it easier to place the notch insulation, particularly for stators. 9 of small diameter.
• the gap L1 is of the order of 0.3mm.
• the external diameter L2 of the stator 9 is between 40 mm and 60 mm, and is preferably 52 mm.
• the internal diameter L4 of the stator 9 is between 15mm and 35mm, in particular between 20mm and 30mm, for example of the order of 26.8mm.
• the wire 51 comprises a conductive portion 52 of diameter L8 between 1 mm and 2 mm and is preferably 1 .5 mm as indicated above; while each coil 50 has a number of turns 54 between 5 and 20, in particular equal to 9.
• the thickness L3 of the yoke 28 may advantageously be between 2mm and 5mm, and is preferably 3.5mm.
• a radial length L10 of each tooth 27 is between 5mm and 15mm.
• the smallest notch opening L9 measured between two adjacent tooth roots 34 is of the order of 4 mm.
• the fixing holes 40 may have a diameter L6 of between 0.6 mm and 3 mm, and being for example 3 mm; while the distance L5 between the axis X of the stator 9 and a center of a fixing hole 40 is of the order of 47mm.
• the rotational axis rotor Y shown in detail in FIGS. 9 and 10 is permanent magnets.
• the rotor body 60 comprises a sheet package consisting of an axial stack of sheets.
• the rotor body 60 can be rotatably connected to the shaft 12 in various ways, for example by force-fitting the splined shaft 12 inside the central opening 65 of the rotor 10, or by means of a key device.
• the ratio between the external diameter L2 of the stator 9 and an axial length L1 1 of the rotor 10 is between 3 and 4, and is preferably 3.25.
• This ratio makes it possible to reduce the inertia of the rotor 10 and therefore to reduce the time required to reach a high rotational speed corresponding, for example, to an operating speed of an electric compressor.
• the ratio between the external diameter L12 of the rotor 10 and the length L1 1 of the rotor 10 is between 1 .1 and 1 .8, and is for example about 1 .6.
• the rotor 10 has, for example, an axial length L1 1 of between 10 mm and 20 mm and is preferably 16 mm, an external diameter L 12 of between 20 mm and 50 mm, in particular between 24 mm and 34 mm, and preferably of the order of 26mm, and an internal diameter L13 of the order of 10mm.
• the rotor 10 of the buried magnet type 62 comprises a plurality of cavities 61 in each of which is housed at least one permanent magnet 62.
• the magnets 62 are radially magnetized, that is to say that the two parallel faces 63, 64 each other having an orthoradial orientation are magnetized so as to be able to generate a magnetic flux in a radial orientation with respect to the Y axis.
• the magnets 62 located in two consecutive cavities 61 are of alternating polarity.
• the permanent magnets 62 have a rectangular parallelepiped shape whose angles are slightly beveled.
• the inner and outer faces 63, 64 of each magnet 62 are in this case planar.
• the outer face 64 of each magnet 62 is curved, while the inner face 63 of the magnet 62 is flat, or vice versa.
• the two faces 63, 64 are bent in the same direction, so that each magnet 62 generally has a tile shape.
• the magnets 62 do not completely fill the cavities 61, so that there are two voids 67 on either side of a given magnet 62 in a orthoradial direction.
• the volume of air delimited by all the spaces 67 of the rotor makes it possible to reduce the inertia of the rotor 10 and to optimize the magnetic flux.
• the magnets 62 are preferably made of rare earth in order to maximize the magnetic power of the machine 7. Alternatively, however, they can be made of ferrite according to the applications and the desired power of the electric machine 7. Alternatively, the magnets 62 can be of different shades to reduce costs.
• plating elements 70 are interposed between the rotor body 60 and each magnet 62, to ensure the maintenance of each permanent magnet 62 inside the corresponding cavity 61.
• the plating elements 70 are positioned on the side of the Y axis of the rotor 10. In a variant, the plating elements 70 could be positioned on the side of the gap 1 1 of the electric machine.
• Each plating element 70 is constituted by an elastically deformable curved spring blade.
• the plating member 70 is constituted by a pin, a spiral spring, or a spring mounted compressed by crushing along its height between the rotor body 60 and the permanent magnets 62.
• the foregoing description has been given by way of example only and does not limit the scope of the invention which would not be overcome by replacing the different elements by any other equivalent.

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• 2015
  • 2015-09-11 FR FR1558476A patent/FR3041188A1/fr active Pending
• 2016
  • 2016-09-07 EP EP16767338.3A patent/EP3347974A1/fr not_active Withdrawn
  • 2016-09-07 CN CN201680052669.2A patent/CN108141085B/zh active Active
  • 2016-09-07 WO PCT/FR2016/052231 patent/WO2017042489A1/fr unknown

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