WO2020104701A1

WO2020104701A1 - Connection component for connecting electrical conductors of a hairpin winding of a stator of an electric machine, and method for producing said connection

Info

Publication number: WO2020104701A1
Application number: PCT/EP2019/082457
Authority: WO
Inventors: Richard A. Rasp; Norman Kroll-Gast
Original assignee: Gehring E-Tech Gmbh
Priority date: 2018-11-23
Filing date: 2019-11-25
Publication date: 2020-05-28
Also published as: DE102018009206B3

Abstract

The invention relates to an electrically conductive connection component (20, 30, 40) which, in a stator of an electric machine having at least one hairpin winding (3), electrically connects free ends (4) of mutually associated hairpin conductor bars (6) to one another. The connection component (20, 30, 40) comprises a cap-like connection region (8) having a receiving space (9), in which free ends (4) of at least two mutually associated conductor bars (6) can be received. In order to enable automated and reliable establishing of the electrical connection, according to the invention, the receiving space (9) of the at least one cap-like connection region (8) of the connection component (20, 30, 40) is defined by three side walls (10, 11, 12) and one cover wall (13), and the cover wall (13) has at least one through-hole (14), which leads into the receiving space (9). The side walls (10, 11, 12) engage around the hairpin conductor bars (6) in a form-fitting manner, and a laser beam (33) is can be guided through the through-hole (14) and thermally produces an electrically conductive connection of the hairpin conductor bars (6) to one another and to the connection component (20, 30, 40). The invention also relates to a method for using said connection components (20, 30, 40).

Description

Title: Connection component for connecting electrical conductors of a hairpin winding of a stator of an electrical machine and

Process for the preparation of this compound

Description

The invention relates to an electrically conductive

Connecting component for connecting electrical conductors of a hairpin winding of a stator of an electric machine according to the preamble of claim 1 and a

Process for producing this connection according to the independent process claim. In addition, the invention relates to a stator of an electric machine, which is equipped with such electrical connection components. For example, DE 103 21 702 A1 discloses a so-called hairpin-wound stator, in which the stator has a hollow cylindrical stator core, in the inner lateral surface of which laterally extending slots are formed. In each of these slots, four electrical conductors which are approximately rectangular in cross section are used, which are bent in the shape of a U in the middle and are therefore also referred to as hairpin conductors or hairpin conductor bars. in the

In the area of the slots, the legs of the hairpin conductor bars are insulated in order to prevent electrical contact with other hairpin conductor bars arranged in the same stator slot and with the stator core.

Only at their free ends is there no insulation material in order to make electrical contact with other hairpin conductor bars. The free ends of the hairpin conductor bars protrude axially from the stator core, while their bent section forms the winding head of the stator. To make the stator winding, the two free ends of each

U-shaped hairpin conductor bar bent in the circumferential direction of the stator core. Then the two free ends of each hairpin conductor bar are connected in an electrically conductive manner to further hairpin conductor bars arranged more or less far away.

There are different connecting components and for the electrical connection of the hairpin conductor bars

Connection methods known. The hairpin conductor bars can be contacted by soldering, welding or crimping. Welding or soldering the free ends of hairpin conductor bars of a stator winding can lead to a very complicated and labor-intensive manufacturing process given the large number of connection points on a stator. As such, it is advantageous to weld the free ends of the hairpin conductor bars to the free Eden of associated other hairpin conductor bars. If, however, only one welded connection is made incorrectly, all hairpin conductor bars have to be pulled out of the stator core in order to subsequently refill it with other hairpin conductor bars and to carry out the welding again. A stator, in which hairpin conductor bars are welded during a manufacturing process, is known, for example, from DE 601 29 902 T2. EP 3 088 124 B1 and US 2003/0 159 269 A1 disclose manufacturing processes in which adjacent hairpin conductor bars are connected to one another by means of a laser beam or electron beam.

DE 10 2012 219 668 A1 also discloses a method in which the free ends of two hairpin conductor bars to be connected are connected mechanically by a

cap-shaped, electrically conductive connecting component are connected. In conclusion, this is

Connection component covered with a cap formed from an insulator. Accordingly, the hairpin windings of the stator should be able to be produced without a welding process. A similar welding-free manufacturing process using cap-shaped, electrically conductive

Connecting components is known from US 9,847,683 B2. In addition, DE 103 21 702 A1

Known connecting device with which the

Scope of work for making the electrical connections between hairpin conductor bars of a hairpin-wound stator should be small. In this connection device, a component is used which has to be placed on the stator and soldered, welded or crimped there. The connection device comprises an insulating plate with a plurality of slots arranged therein. Everyone who

Slots are arranged and set up for this

Pick up the leg end of a hairpin ladder. There are several electrical connection elements on the plate

Arranged, by means of which leg ends of the hairpin conductor bars assigned to one another can be electrically connected to one another. These fasteners can be used for

Example as straight connecting elements, C-shaped

Connecting elements, Z-shaped connecting elements or S-shaped connecting elements can be formed.

The known thermally or purely mechanical methods and devices for electrically connecting ends of hairpin conductor bars assigned to one another have all the advantages and disadvantages. The invention was therefore based on the object of presenting a new device for connecting the hairpin conductor bars mentioned, which has the advantages of purely mechanical electrical

Connects components with the advantages of thermal connection processes. In addition, a

Manufacturing processes are presented, by means of which these new connecting components quickly and safely with the free Ends of mutually assigned hairpin conductor bars are mechanically and thermally connectable.

The solution to these tasks is first with a

Connection component achieved which the characteristics of

Claim 1 has. An independent procedural claim defines the procedure, like these new ones

Connection components quickly and reliably with free ends of assigned hairpin conductor bars

regarding good electrical conductivity

are to be connected mechanically and thermally. A

Usage claim states where and how this

Connection components can be used particularly advantageously. Associated dependent claims define advantageous developments of the invention.

Accordingly, the invention is based on an electrical

conductive connecting component which electrically connects free ends of mutually assigned hairpin conductor bars to one another in a stator of an electrical machine with at least one hairpin winding, the

Connecting component has a cap-shaped connecting area with a receiving space in which free ends of at least two mutually assigned conductor bars

are recordable.

To solve the device related task is

provided that the receiving space of the at least one cap-shaped connection area of the connection component is delimited by three side walls and a cover wall, and that the cover wall has at least one through hole which opens into the receiving space.

The invention was based on the finding that the free ends of hairpin conductor bars assigned to one another can be connected to one another in the most process-reliable manner by a mechanical and additionally by a thermal connection in an electrically conductive manner. The mechanical and electrical connection of the hairpin conductor bars concerned, which is to be carried out first in terms of time, is carried out by positive locking by means of the cap-shaped connecting components, which ensure that the respective hairpin conductor bars abut one another as well as on the respective cap-shaped connecting component. This creates a first electrical contact of the hairpin conductor bars, which is the starting point for the thermal connection that then follows. To the thermal contacting of the

To enable mutually assigned hairpin conductor bars, the cap-shaped ones used are used

Connecting components an opening in their respective

Top wall of the receiving spaces through which a laser beam can reach the front surface of the paired hairpin conductor bars. The laser beam then welds the respective cap-shaped

Connecting component with the assigned hairpin conductor bars as well as these hairpin conductor bars with one another.

By combining the purely mechanical contacting of the free ends of hairpin assigned to one another Conductor rods with the described thermal contacting of the hairpin conductor rods by means of a laser beam can be ensured with an extremely high degree of certainty that even with a fully automatic production of the described rod winding of a stator, the electrical connection between the two

assigned ends of hairpin ladder bars will be successful. Such a fully automatic manufacture of the stator winding is necessary for electric motors

to be able to manufacture more cheaply than before, which is an important prerequisite for ensuring that these

Individual vehicles can be used successfully.

The fact that the respective recording space of

Connection components according to the invention of only three

Side walls and a top wall is bounded, at least two of the three side walls have a good elastic deformability, which a game-less positive and mechanically stable electrical connection of the

Connection components with the assigned hairpin conductor bars guaranteed.

According to a first advantageous development of the

The invention provides that the connecting components are a J-shaped, an S-shaped, a Z-shaped or a

Have a C-shaped geometry. This makes them

Connection components suitable for different tasks, for example as connection flags for individual

Stator windings or electrical phases function, or for this purpose, to more or less distant but assigned hairpin conductor bars

electrically connect with each other. So much for connection components with an S-shaped geometry

is spoken, it also means a Z-shaped geometry.

Furthermore, it is preferably provided that the cap-shaped connection area of the J-shaped connection component is designed such that its side wall-less

Receiving space side in the installed state on the stator pointing radially inward that the two cap-shaped

Connection areas of the C-shaped connection components are designed such that their two

Side wallless receiving space sides in the installed state on the stator point radially inwards, and that the two cap-shaped connecting areas of the S-shaped or Z-shaped connecting components are designed in such a way that the two of them are each without side walls

Recording room sides when installed in

have opposite circumferential directions of the stator.

The J-shaped connecting component has one

Embodiment a long leg and a short leg, which has a connecting section

are interconnected, and in the short

At the end of the leg, a cap-shaped connection region is formed with a receiving space for receiving the free end of hairpin conductor bars to be electrically connected, and at the end of the long leg there is one Contact plate is formed with a through hole for performing a connecting element.

According to a development, the cap-shaped

Connection area of the

J-shaped connecting component has such a receiving space, the wall-less side of which forms the free end of the short leg and the wall of the cover

opposite side of the cover is wallless.

The long leg of the J-shaped connecting component can also be designed to be flexible and, for this purpose, can consist, for example, of a copper wire mesh. At all

Embodiments of the J-shaped connecting component, however, provide that the effective cross-sectional area of the long leg, the connecting section and the short leg of the J-shaped connecting component

are at least as large as the cross-sectional area of the free end of the at least one hairpin conductor bar to be accommodated in its receiving space. This is sufficient conductivity for an electric current from one end to the other end of the J-shaped

Connection component guaranteed.

This J-shaped serving as a connecting drive

Connection component, the basic characteristic of which is that it has only one receiving space for at least one hairpin conductor bar, can therefore also have any other geometry, provided that it fulfills its intended function. The design of this is crucial cap-shaped connecting area, which delimits the receiving space for receiving the free end of preferably two directly adjacent conductor bars and is provided with a hole through which a laser beam can be conducted for welding the connecting component to the said conductor bars.

The connection component, which is S-shaped or Z-shaped with regard to its geometric wall profile, has a cap-shaped one at each of its two ends

Connection area each with a receiving space for receiving the free end of hairpin conductor bars to be electrically connected. In this case, it is considered to be advantageous with regard to simple and secure assembly if it is provided that the cap-shaped connection areas of the S-shaped or

Z-shaped connecting component each have a receiving space, the wall-free end faces of which are oriented in opposite directions, and that their to

Face the opposite lidless sides of the cover wall in the same direction.

Another advantageous development of the S-shaped or Z-shaped connecting component provides that its cap-shaped connecting areas are connected to one another via a web section, the cross-sectional area of which is at least as large as the cross-sectional area of the respective free end of the hairpin conductor bars to be connected. This is sufficient

Conductivity for an electrical current of one Guaranteed end to the other end of the connecting component and good mechanical stability of the

Connection component reached.

The C-shaped connecting component, on the other hand, has a C-shaped leg, at the two ends of which a cap-shaped connecting area, each with one

Recording space for receiving the free end of electrically connectable hairpin conductor bars is formed.

With regard to simple and safe installation, it is advantageous if it is provided that the

cap-shaped connection areas of the C-shaped

Connecting component each have a receiving space, the wall-less end faces not in opposite

Show directions, and their towards the top wall

opposite sides of the cover are wallless. The C-shaped leg has a cross-sectional area which is at least as large as the cross-sectional area of the respective free end of the hairpin conductor bars to be connected. This also provides sufficient conductivity for an electrical current from one end to the other end of this connecting component

guaranteed and achieved good mechanical stability.

In addition, it is preferably provided that the C-shaped

Connecting component from a central section has inwardly bent sections, at the respective ends of the two cap-shaped

Connection areas are formed. The aforementioned through hole in the top wall of the

each connection area is preferably arranged and designed such that it covers the area in which the free ends of the hairpin conductor bars to be connected touch within the receiving space. This ensures that a

Through hole on the hairpin conductor rods guided laser beam can connect them with the connecting component and also directly with each other.

It is further preferably provided that the thickness of the

Cover wall of the connecting component is selected so that welding of the cover wall with the in the receiving space

arranged hairpin conductor bars by means of a laser beam is possible. So it is sufficient

fusible material of the connecting component

available to the thermally generated electrical

Realize connection.

In order to prevent molten material of the hairpin conductor bars and / or the connecting component from spraying out, it is further preferably provided that the thickness of the cover wall is selected so that, during laser welding, highly spraying metal comes into contact with the wall of the through hole and does not come out the through hole

squirts out. This can be favored by the fact that an annular wall extending away from the receiving space is formed on the edge of the hole. The object relating to a production method is one by a method for electrically connecting the free ends of two hairpin conductor bars assigned to one another

Solved stator of an electric machine, which has the following process steps:

a) inserting the free ends of two mutually assigned hairpin conductor bars of the stator into the at least one receiving space of the cap-shaped

Connection area of a connection component with the features of at least one of the previous ones

Device claims,

b) pressing the top wall of the receiving space onto the free ends of the hairpin conductor rods assigned to one another,

c) generating a laser beam and directing it through a through hole in the top wall of the receiving space onto the front end of the hairpin conductor bars assigned to one another in such a way,

that the metallic material of the top wall and the metallic material of the hairpin conductor bars assigned to one another partially melt and the top wall is thereby welded to the hairpin conductor bars.

It can be provided here that the laser beam is directed at the area where the through hole in the cover wall on the end face of the other

assigned hairpin conductor bars ends. As a result, the metal of the cover wall is welded to the metal of the hairpin conductor bars. However, it can also be provided that the laser beam is directed onto that end region of the other

assigned hairpin conductor bars is directed at which they lie side by side. As a result, the hairpin conductor bars assigned to one another become direct

welded together.

Furthermore, it can be provided that the laser beam is aligned at such an angle that one, possibly partially, generated by the laser beam

highly spraying metallic melt does not leave the through hole, but adheres to the wall of the through hole. This ensures that no welding material is caused by the welding process to get onto or into the windings of the stator.

Finally, the invention relates to the use of

Connecting components, which have the features of at least one of the device claims, on a stator of an electric machine designed as an electric motor and / or generator, the windings of the stator being formed by a plurality of hairpin conductor bars, and in which the free ends of the hairpin conductor bars by means of S-shaped or Z-shaped and C-shaped

Connection components are electrically connected to each other in phase, and in the case of the J-shaped connection components serving as electrical connection elements, each winding of the stator is electrically connected to at least one hairpin conductor bar. To further clarify the invention, the

Description attached a drawing in which several

Embodiments are shown. This drawing shows

1 is a perspective top view of a stator core with hairpin conductor bars arranged thereon, which are in phase on a connection and connection side of the stator core via connecting components according to the invention

electrically with each other or with connection elements

are connected,

2 the stator core according to FIG. 1 with a view of its connection and connection side,

3a to 3d perspective views of a J-shaped connecting component which is designed as an electrical connection element,

4a to 4e are perspective views of an S-shaped or Z-shaped connecting component which is designed for the electrical connection of hairpin conductor bars,

5a to 5d are perspective views of a C-shaped connecting component which is designed for the electrical connection of hairpin conductor bars,

Fig. 6 is a schematic sectional view through a connection area of an inventive

Connecting component with two hairpin conductor bars accommodated therein during a welding process on the edge with a laser beam, and

Fig. 7 is a schematic sectional view through a connection area of an inventive Connection component with two hairpin conductor bars accommodated therein during a central welding process with a laser beam.

In the figures now to be described, the same components are provided with the same reference symbols

Accordingly, Figures 1 and 2 show a hollow cylindrical stator core 2 of a stator

Electric machine. This electric machine can be a

Electric motor, a generator or a starter / generator. The inside of the stator core 2 has grooves 51 aligned parallel to its longitudinal center axis. In these grooves 51 are arranged in their starting geometry U-shaped hairpin conductor rods 6 which are largely rectangular in cross section. It can be seen that four hairpin conductor bars 6 are inserted in each of the grooves 51, so that the hairpin conductor bars 6 are arranged in four mutually concentric rings of different diameters. The legs overlap

end of the respective U-shaped hairpin conductor rods 6 each have a plurality of grooves 51. In addition, the

U-shaped arches of the hairpin conductor bars 6 at one end of the stator core 2 a winding head 52 and

opposite end of the stator core 2 a connection and connection side of the stator windings 3 of here

three-phase electric machine.

In order to be able to produce the stator windings 3, the free ends of the respective hairpin conductor bars 6 in Circumferential direction of the stator core 2 each bent.

Subsequently, the free ends of hairpin conductor rods 6 assigned to one another in phase were connected by means of

Connecting components 20, 30, 40 according to the invention

electrically connected. In doing so, they connect

Connecting components 20, 30, 40 can be seen in each case two radially immediately adjacent hairpin conductor bars 6 with one another. The C-shaped connector 40

overlap other connecting components 20, 30, 40 axially and in the circumferential direction of the stator core 2. Die

According to the invention, connection components 20, 30, 40 each have at least one connection area 8 at the end, but are otherwise formed in three different geometries, which will be discussed first.

The connecting components 20, 30, 40 are shown in different views in FIGS. 3a to 3d, 4a to 4e, 5a to 5d and FIGS. 6 and 7. It can be seen from FIGS. 3a to 3d that a first embodiment of the connecting components 20 is essentially J-shaped

Has geometry. Here one of them

Connecting component 20 has a long leg 21 and a short leg 22 oriented bent therefrom and a leg 20, 21 connecting these legs

Connection section on. On the short leg 22 there is a cap-shaped connection area 8 at the end, each with a receiving space 9 for receiving the free end of two hairpin conductor bars 6 to be electrically connected

educated. On the long leg 21 there is a contact plate 23 with a through hole 24 at the end formed by which a connecting element, for example in the form of a machine screw,

can be passed through. An electrical line is usually connected to this contact plate 23, which leads to the outside of the housing of the electric machine. The cap-shaped connecting area 8 of the J-shaped connecting component 20 has a receiving space 9 with three side walls 10, 11, 12 and a cover wall 13, a wallless end face forming the free end of the short leg 22 and the side opposite the cover wall 13 being wallless.

As FIGS. 1 and 2 illustrate, three egg-shaped connecting components 20 are arranged on the stator core 2 in such a way that the cover-free side of the respective one

Recording spaces 9 axially inwards and the wallless

Face the front of each short leg 22 radially inward. The long leg 21, the short leg 22 and the connecting these two legs 21, 22

Connection areas each have a cross-sectional area which is at least as large as that

Cross-sectional area of the in the cap-shaped

Connection area 8 of the free end 4 of the associated conductor bar 6 to be received.

The shown in Figures 4a to 4e and in terms of its wall geometry

S-shaped or Z-shaped connecting component 30 has a cap-shaped at its two ends

Connection area 8, each with a receiving space 9, which also for receiving the free end of two electrically connected hairpin conductor bars 6

are trained. The cap-shaped connecting regions 8 of the S-shaped or Z-shaped connecting component 30 each have a receiving space 9 with three side walls 10, 11, 12 and a cover wall 13, the wallless end faces being oriented in opposite directions in relation to one another. The wallless sides lying opposite the respective cover wall 13 each point in the same direction.

4c clearly shows, the two cap-shaped connecting areas 8 of the S-shaped or Z-shaped connecting component 30 are connected to one another via a web section 31, the cross-sectional area QF

is at least as large as the cross-sectional area of the respective free end 4 of the hairpin conductor bars 6 to be connected. As a result, the connecting component 30 has a comparatively high mechanical stability and sufficient conductivity for an electrical current from one end to the other

Connection component on.

FIGS. 5a to 5d show a third embodiment in which the connecting component 40 has an essentially C-shaped geometry. For this purpose, this connecting component 40 has a C-shaped leg 41, at the two ends of which a cap-shaped connecting region 8 is formed, each with a receiving space 9, into which the free ends 4 of two hairpin connectors to be electrically connected Ladder bars 6 can be used. The receiving spaces 9 are each by three side walls 10, 11, 12 and one

Covered wall 13. The wallless end face of the two receiving spaces 9 of the C-shaped connecting component 40 do not point in opposite directions. The wallless sides of the two receiving spaces 9 lying opposite the respective cover wall 13 are each open in the same direction. In the installed state, therefore, the wall-free end faces of the two receiving spaces 9 of the C-shaped

Connecting component 40 on the stator radially inward and the wallless sides of the two receiving spaces 9 lying opposite the respective cover wall 13 axially inward.

The C-shaped leg 41 of the connecting component 40 has a cross-sectional area which is at least as large as the cross-sectional area of the respective free end 4 of the hairpin conductor bars 6 to be connected. This achieves good mechanical stability and sufficient conductivity for an electrical current .

In addition, it can be seen in FIGS. 5a to 5d that the C-shaped connecting component 40 has cranked sections 42, 43, starting from a central section, at their respective ends the two cap-shaped sections

Connection areas 8 are formed. This makes it easier to attach the C-shaped connecting components 40 to the radially aligned hairpin conductor bars 6, which are rectangular in cross section. All of these connecting components 20, 30, 40 have a special feature according to the invention. Accordingly, it is provided that the receiving spaces 9 of the cap-shaped

Connection areas 8 of the connection components are delimited by three side walls 10, 11, 12 and a cover wall 13, the cover wall 13 having at least one through hole 14 which opens into the receiving space 9. As FIGS. 6 and 7 illustrate particularly well, it is provided here that the through hole 14 is arranged and designed in such a way that it covers that area in which the free ends 4 of the hairpin conductor bars 6 to be connected are laterally located within the receiving space 9 touch.

The thickness D of the top wall 13 of the cap-shaped

Connection areas 8 are selected such that welding the cover wall 13 to the hairpin conductor bars 6 arranged in the receiving space 9 is possible by means of a laser beam 33. For this purpose, the cover wall 13 has, for example, a thickness D of 1 mm to 3 mm, so that there is sufficient cover wall material,

Welding process melted and in its

molten phase can still maintain contact with the remaining lid wall material.

The thickness D of the cover wall 13 is also preferably selected such that metal 36 which is highly spraying does not emerge from the surface during welding with a laser 32

Through hole 14 splashes out, but comes to rest against the wall 34 of the through hole 14 and there stiffens. This avoids that

Welding process generated metal particles into impermissible

Areas of the stator. The described structure of the invention

Connecting elements 20, 30, 40

enables a combined mechanical and thermal connection of at least two mutually assigned hairpin conductor bars 6 in a particularly process-reliable and fully automatic manner. These

Connecting elements 20, 30, 40 are therefore particularly suitable for fast and inexpensive manufacture of stators in an electrical machine. The use of these connecting elements 20, 30, 40 also in the manufacture of rotors of an electric machine is possible and equally advantageous.

The invention also relates to a method for electrically connecting the free ends 4 of two hairpin conductor bars 6 of a stator of an electric machine that are assigned to one another, which comprises the following steps:

a) attaching at least one cap-shaped

Connection area 8 of a connection component 20, 30, 40 with the features of at least one of the previous ones

Device claims on the free end 4 of at least two mutually associated hairpin conductor bars 6 of the stator, the free ends 4 in one

assigned receiving space 9 of the cap-shaped

Connection area 8 are arranged b) pressing the cover wall 13 of the receiving space 9 onto the free ends of the hairpin conductor bars 6 which are assigned to one another,

c) Generating a laser beam 33 and directing it through a through hole 14 in the top wall 13 of the

Recording space 9 on the front end of the

mutually assigned hairpin conductor bars 6 such

that metallic material of the top wall 13 as well

metallic material of the

mutually associated hairpin conductor bars 6 partially melt and form a common melt 35, as a result of which the top wall 13 with the hairpin conductor bars 6

is welded.

Because the connecting components 20, 30, 40 grip the hairpin conductor bars 6 to be fastened in a form-fitting manner in the respective insulator-free receiving space 9, there is a first mechanical and electrical connection between the hairpin conductor bars 6 and the

Connecting component 20, 30, 40 have been generated. By means of the subsequent welding using the laser beam 33, a second mechanical and electrical connection between the hairpin conductor bars 6 and the

Connecting component 20, 30, 40 generated. This double electrical and mechanical connection ensures that the described hairpin winding 3 of an electric machine can be produced quickly, safely and also inexpensively.

In a further embodiment of the described

Manufacturing process can be provided that the laser Beam 33 is aimed specifically at that area where the through hole 14 in the cover wall 13 on the

Front of the mutually assigned hairpin conductor bars 6 ends. As a result, a radial welding of the two hairpin conductor bars 6 with the connecting component 30 shown there is achieved in FIG. 6, the volume-related formation of the melt 35 being comparatively small. Depending on the energy coupled in by the laser beam 33, however, a comparatively large amount of melt 35 can also form, which completely covers the through-hole-side regions of the two hairpin conductor bars 6 (FIG. 7). As a result, the two hairpin conductor bars 6 are particularly well electrically connected to one another.

According to the method it can further be provided that the

Laser beam 33 is oriented at such an angle that a laser beam 33 generates a

if necessary partially highly spraying metallic

Melt 36 does not leave the through hole 14, but at most on the wall 34 of the through hole 14 for

Clinging.

The described connection components 20, 30, 40 are particularly advantageous for producing a winding 3 of a stator of an electrical machine in a hairpin design

used. The electric machine can be designed as an electric motor and / or generator. Here is the

Winding 3 of the stator by a plurality of

for example U-shaped hairpin conductor bars, the free ends of the hairpin conductor bars 6 being electrically connected to one another in phase in accordance with the described S-shaped or Z-shaped and C-shaped connecting components 30, 40. The J-shaped connecting components 20 serve as electrical

Connection elements which are electrically connected to at least one hairpin conductor bar 6, each having a winding 3 of the stator.

Reference symbol list

2 stator core

3 stator windings

4 Free end of a ladder bar

6 ladder bar, hairpin ladder bar

8 Connection area of a connection component

9 Recording room in the connection area

10 First side wall of the recording room

11 Second side wall of the recording room

12 Third side wall of the recording room

13 top wall of the receiving space

14 through hole in the top wall

15 Side of a connecting component remote from the receiving space

20 J-shaped connecting component

21 Long leg of the J-shaped connecting component

22 Short leg of the J-shaped connecting component

23 Contact plate of the J-shaped connection component

24 through hole in the J-shaped connecting component

30 S-shaped or z-shaped connecting component

31 web section of an S-shaped connecting component

32 lasers

33 laser beam

34 wall of the through hole

35 melt

36 Sprayed metal

40 C-shaped connecting component

41 C-shaped leg of the C-shaped connecting component

42 First bent section of the C-shaped leg 43 Second bent section of the C-shaped leg

51 slots in the stator core

52 winding head

D Cover plate thickness

QF cross-sectional area of the web section of an S-shaped connecting component

Claims

1. Electrically conductive connecting component (20, 30, 40) which electrically connects free ends (4) of mutually assigned hairpin conductor bars (6) to one another in a stator of an electrical machine with at least one hairpin winding (3), the

Connecting component (20, 30, 40) has a cap-shaped connecting area (8) with a receiving space (9), in which free ends (4) of at least two mutually assigned conductor bars (6) can be received, characterized in that the receiving space (9) of the at least one cap-shaped

Connection area (8) of the connecting component (20, 30, 40) is delimited by three side walls (10, 11, 12) and a cover wall (13), and that the cover wall (13) has at least one through hole (14), which in the Recording room (9) opens.

2. Connecting component according to claim 1 thereby

featured this as a J-shaped

electrical connecting component (20), as an S-shaped or Z-shaped electrical

Connecting component (30), or as a C-shaped

electrical connecting component (40) is formed.

3. Connecting component according to claim 2, characterized

characterized that the cap-shaped

Connection area (8) of the J-shaped Connection component (20) is designed such that its side wall-free receiving space side in the installed state on the stator points radially inwards, that the two cap-shaped connecting regions (8) of the C-shaped connecting components (40) are designed such that their two side wall-free receiving space sides in the installed state point radially inward on the stator, and that the two

cap-shaped connection areas (8) of the S-shaped or Z-shaped connection components (30) are designed such that the two of them

have side wallless receiving space sides in the installed state in opposite circumferential directions of the stator.

4. Connecting component according to claim 2 or 3, characterized

characterized in that the J-shaped connecting member (20) has a long leg (21) and a short one

Has leg (22) which over a

Connection section are connected to each other that on the short leg (22) at the end

cap-shaped connection area (8) with a

Recording space (9) for receiving free ends of

hairpin conductor bars (6) to be electrically connected, and that on the long leg (21) at the end a contact plate (23) with a

Through hole (24) for performing a

Connection element is formed.

5. Connecting component according to one of claims 2 to 4, characterized in that the cap-shaped

Connection area (8) of the J-shaped

Connecting component (20) has a receiving space (9), the wall-free receiving space side forms the free end of the short leg (22) and the opposite side of the cover wall (13) remote from the cover is wallless.

6. Connecting component according to claim 2 or 3, characterized

characterized in that the S-shaped connecting component (30) has one at each of its two ends

Has cap-shaped connecting area (8), each with a receiving space (9) for receiving free ends of electrically connectable hairpin conductor bars (6).

7. Connecting component according to claim 6, characterized

characterized that the cap-shaped

Connection areas (8) of the S-shaped or Z-shaped connection component (30) each have a receiving space (9), the wall-free end faces in

opposite directions are aligned, and that their lidless sides opposite the lid wall (13) each point in the same direction.

8. Connecting component according to claim 6 or 7, characterized in that the cap-shaped

Connection areas (8) of the S-shaped or Z-shaped connection component (30) are connected to one another via a web section (31), the cross-sectional area (QF) of which is at least as large as that

Cross-sectional area of the respective free end (4) of the hairpin conductor bars (6) to be connected.

9. Connecting component according to claim 2 or 3, characterized

characterized in that the C-shaped connecting component (40) has one at each of its two ends

Has cap-shaped connection area (8), each with a receiving space (9) for receiving free ends of electrically connectable hairpin conductor bars (6), and that one between the two

Connection areas (8) formed C-shaped leg (41) has a cross-sectional area (QF) which is at least as large as that

10. Connecting component according to claim 9, characterized

characterized that the cap-shaped

Connection areas (8) of the C-shaped

Connecting component (40) each have a receiving space (9), the wall-less end faces do not point in opposite directions, and the Lid wall opposite sides remote from the lid are wallless.

11. The connecting component according to claim 9 or 10, characterized in that the C-shaped connecting component (40) has sections (42, 43) bent inwards from a central section, at their respective ends the two cap-shaped sections

Connection areas (8) are formed.

12. Connection component according to one of the previous ones

Claims, characterized in that the

Through hole (14) formed and

is arranged so that it covers the area in which the free ends of the hairpin conductor bars (6) to be connected touch within the receiving space (9).

13. Connection component according to one of the previous ones

Claims, characterized in that the thickness (D) of the cover wall (13) is selected so that a

Weld the lid wall (13) to the in

Recording space (9) arranged hairpin conductor bars (6) by means of a laser beam (33) is possible.

14. Connecting component according to claim 13, characterized

characterized in that the thickness (D) of the cover wall (13) is selected such that metal (36) spraying highly with a laser (32) comes into contact with the wall (34) of the through hole (14) during welding and solidifies there.

15. A method for electrically connecting the free ends of mutually assigned hairpin conductor bars (6) of a stator of an electric machine, characterized by the following method steps:

a) plugging on at least one cap-shaped connection area (8) of a connection component (20, 30, 40) with the features of at least one of the device claims onto the free end of at least two mutually associated hairpin conductor bars (6) of the stator,

with the free ends mapped into one

Recording space (9) of the cap-shaped

Connection area (8) are arranged

b) pressing the cover wall (13) of the receiving space (9) onto the free ends of the hairpin conductor bars (6) assigned to one another,

c) generating a laser beam (33) and directing it through a through hole (14) in the

Top wall (13) of the receiving space (9) on the

the front end of the mutually assigned hairpin conductor bars (6) in such a way

that metallic material of the cover wall (13) and metallic material of the mutually associated hairpin conductor bars (6) partially melt and form a common melt (35), as a result of which the top wall (13) is welded to the hairpin conductor bars (6).

16. The method according to claim 15, characterized in that the laser beam (33) is directed to that area where the through hole (14) in the cover wall (13) on the end face of each other

assigned hairpin conductor bars (6) ends.

17. The method according to claim 15 or 16, characterized

characterized that the laser beam (33) on

the frontal area of each other

assigned hairpin conductor bars (6) is directed, on which they lie side by side.

18. The method according to any one of claims 15 to 17, characterized in that the laser beam (33) is oriented at an angle such that a metallic melt (35) generated by the laser beam (33), possibly partially highly spraying, is used

Through hole (14) does not leave, but at most adheres to the wall (34) of the through hole (14).

19. Use of connecting components (20, 30, 40) according to at least one of the preceding claims Stator of an electric machine designed as an electric motor and / or generator, the windings (3) of the stator being formed by a plurality of hairpin conductor bars (6), and in which the free ends of the hairpin conductor bars (6) are S-shaped or Z-shaped and C-shaped

Connecting components (30, 40) are electrically connected to one another in phase, and in the case of the J-shaped connecting components (20) as electrical

Serving connection elements are each electrically connected to at least one hairpin conductor bar (6) of a winding of the stator.